Note: Descriptions are shown in the official language in which they were submitted.
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WO 96/13360 PCT/US95/13713
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SKIN ENG~rGING MEMBER
This invention relates to an improved
skin engaging member for use in razor blade
cartridge assemblies and shaving systems of the
wet shave type. The present invention resides
broadly in providing the skin engaging cap
and/or guard surfaces with configurations which
deliver a shaving aid as the razor is dragged
across the skin. Suitable shaving aids include
lubricants, whisker softeners, razor cleaners,
medicinal agents, cosmetic agents or
combinations thereof. This invention also
relates to a novel method of manufacturing the
skin engaging member of the present invention.
In shaving systems of the wet shave
type. factors such as the frictional drag of the
razor across the skin, the force needed to sever
hairs, and irritation of pre-existing skin
damage can create a degree.of shaving
discomfort. Discomfort, and other problems
accompanying wet shaving systems, can be
alleviated by the application of shaving aids to
the skin. Shaving aids may be applied prior to,
during, or after shaving. A number of problems
accompany the use of pre- and post-applied
shaving aids. Pre-applied-shaving aids can
evaporate or can be carried away from the site
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of application by repeated strokes of the razor.
Post-applied-shaving aids are not present on the
skin during shaving and thus their application
may be too late to prevent an unwanted affect.
Both pre-applied and post-applied shaving aids
add additional steps to the shaving process.
Proposals have bees made to
incorporate a shaving aid, e.g. lubricant,
whisker softener, razor cleanser, medicinal
agent, cosmetic agent or combination thereof,
into a razor, e.g. by depositing a shaving aid
in a recess on the razor, by incorporating a
shaving aid directly into one or more molded
polymeric components of the razor, by adhesively
securing a shaving aid composite to the razor,
and by use of a mechanical connection between a
shaving aid composite and the razor. A water-
soluble shaving aid, e.g. polyethylene oxide,
has been mixed with Water insoluble matrix
material, e.g.. a polystyrene polymer, to form
an insoluble polymer/soluble shaving aid
composite as in U.S. Patent Nos. 4,170,821 to
Booth and 5,113,585 to Ropers: The composite
has been mounted on razor and shaving cartridge
structures, adjacent the shaving edge or edges,
of single or multiple blade shaving systems.
Upon exposure to water, the water-soluble
shaving aid leaches from the composite onto the
skin. These composites tend to release large
amounts of shaving aid is the first few shaves
and dramatically less shaving aid in subsequent
shaves. Furthermore, extruded composites with
relatively large amounts of shaving aid (up to
80% by weight) and relatively low amounts of
water insoluble matrix material (as little as
20% by weight) are relatively weak and have a
tendency towards mechanical failure,
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both in assembly and in use. Increased
mechanical strength can be obtaiaed with
increased amounts of the insoluble matrix
material. However, such increase reduces the
releasability of the shaving aid material.
Coamnercial lubricating strips,
especially those with high levels of
polyethylene oxide lubricant like those
described in U.S. Patent Nos. 4,170,821 to Booth
and 5,113,585 to Rogers, tend to deteriorate
after use. Leach rate varies during the course
of shaving and typically about 50% of the
polyethylene oxide is trapped in the strip. The
selection of the polyethylene oxide carrier
(i.e.. the non-water soluble matrix material) is
limited to a carrier that has a low melting or
softening temperature and is at least partially
miscible with polyethyleneoxide. In addition,
because the strip is made at a high temperature
of approximately 180°C.. additives such as.
fragrances and plasticizers are difficult to
incorporate in the strips.
U.S. Patent No. 4,872,263 to
Etheredge. III. issued October 10, 1989,
discloses a lubricating device comprised of a
porous matrix impregnated with a particular acid
soap. The impregnated matrix is covered With a
water insoluble perforated sheet material in an
effort to prevent the lubricant from eroding too
quickly and to provide a smooth "massaging"
effect on the skin. These lubricating devices
have not met with commercial success. These
lubricating devices are expensive to manufacture
due to the additional assembly required of the
' 35 sheet-over-matrix design. They also tend to
swell and delaminate when affixed to the razor
cartridge with glue. Furthermore, the soft
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porous matrix does not lend itself to economical
mechanical means of affixing the strip to the
razor cartridge.
We have demonstrated that it is
feasible to produce a two-component, controlled-
release shaving device consisting of an outer
surface layer with openings and an internal
shaving aid-containing layer. The potential
advantages of using the device are to 1)
maintain a uniform surface appearance, 2)
achieve near zero-order release profile of the
shaving aid after 1-4 shaves. 3) minimize
material degradation. 4) minimize shaving aid
material trapped in the device. 5) provide a
shaving aid device which is easy to manufacture
and/or 6) to provide a shaving aid device which
is easily integrated with a razor cartridge
system. These and other objects of the present
invention will be evident from the following.
In accordance with one aspect of the
invention, there is provided a two-component,
controlled-release skin engaging member consist-
ing of (a) a sheath made from thermoplastic
resins with openings therein. and (b) a core
containing shaving aids. The skin engaging
member can be in the form of a strip. a razor
guard, a razor cap. a razor platform or a razor
housing made (1) by coextrusion or two-color
(i.e. two component) molding, or (2) by extrud-
ing or molding the surface layer and shaving
aids separately and then assembly later. Poten-
tially, the device can maintain surface appear-
rance, control-release the shaving aid, minimize
the degradation of the shaving aid, and prevent
the shaving aid from being trapped in the skin
engaging member. Furthermore, the addition of
low-melt additives to the shaving aid becomes
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feasible and the compatibility between the
shaving aid and the shaving aid carrier, such as
polystyrene in the lubricating strip composite
becomes less critical.
FIG. 1 is a perspective view of a
razor unit in accordance With the invention;
FIG. 2 is a sectional view taken along
the line 2-2 of FIG. 1;
FIG. 3 is a sectional view of another
razor unit in accordance with the present
invention;
FIG. 4 is as enlarged perspective view
of a skin engaging member of the present
invention;
FIG. 5 is sectional view taken along
the lice 5-5 of FIG. 4;
FIG. 6 is a sectional view of the skin
engaging member 42 found is FIG. 2;
FIG. 7 is a schematic cross-section
diagram of an extrusion die suitable for
manufacturing the skin engaging member of
FIG. 3;
FIGS. 8-11 are enlarged perspective
views of alternate skis engaging members
according to the present invention;
FIG. 12 is a plot of shaving aid
release versus the number of theoretical shaves
comparing a conventional lubricating strip with
a lubricating strip according to the present
invention.
Referring to the drawings. the shaving
unit 10 shown is FIGS. 1 and 2 includes base or
platform member 12 molded of high impact
polystyrene that includes integral coupling
groove structure 14 gor attachment to a razor
handle and guard structure 16 that defines a
transversely extending anterior skin engaging
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surface 18. On the upper surface of platform 12 are disposed
steel leading blade 20 having a sharpened edge 22, steel
following blade 24 having sharpened edge 26, and aluminum spacer
member 28 that maintains blades 20 and 24 in spaced relation.
Cap member 30 is molded of high impact polystyrene and has body
portion 32 that defines the posterior skin engaging surface 34
that extends transversely between forwardly projecting end walls
36 and has a front edge 38 that is disposed rearwardly of blade
edge 26. Integral rivet portions 40 extend downwardly from
transversely extending body portion 32 and pass through holes in
blades 20 and 24, spacer 28, and platform 12 to secure cap 30,
blades 20, 24 and spacer 28 on platform 12. Adhesively affixed
to skin engaging surface 34 is skin engaging member 42.
The shaving unit 50 shown in FIG. 3 is of the type shown in
Jacobson U.S. Patent 4,586,255, and includes body 52 with front
portion 54 and rear portion 56. Resiliently secured in body 52
are guard member 58, leading blade unit 60 and trailing blade
unit 62. A shaving aid composite in the form of elongated
insert member 64 is frictionally locked in opening 66 of rear
portion 56.
FIGS. 4-6 and 8-11 generally depict variations on the
present invention. As used herein, the term "core" refers to an
internal portion of a skin engaging member as examined at the
cross-section. The core typically runs throughout the skin
engaging member along an axis. The axis need not be the central
axis. The FIGS. designate the core as 70. Embodiments of the
present invention have at least one core.
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As used herein the term "sheath" refers to as
outer coating layers) over the core 70. The
FIGS. designate the sheath as 72.
The two-component. controlled-release
skin engaging member of the present invention
consists of an outer sheath which surrounds an
internal core. Wherein said core contains
shaving aid such as water soluble polymers and
additives. The skin engaging surface ?4 can be
an insoluble layer with built-in openiags~ or a
soft layer such as a commercial strip
(polyethylene oxide/polystyreae) Which will
become porous during use.
Referring again to the drawings. and
is particular to FIGS. 3-5~ there is shown an
elongated skin engaging member 64. The member
64 has a skin engaging surface 74 and an
elongated insert member 76. The insert member
76 is designed to frictionally lock is as
opening 66 as shown is FIG. 3. The skin
engaging member further comprises a shaving
aid-containing core 70 which is surrounded by a
sheath 72. The sheath includes at least one
opening to release shaving aid to. the skin.
Preferably. the sheath includes from about 3 to
about 30 holes, most preferably 10-15 holes,
evenly distributed along the skin engaging
surface 74. Hole diameters vary depending an
the particular shaving aid selected: however.
we have observed best results with hole
diameters of from about 0.020 to about 0.040
inches. Preferably. the hole diameter is about
0.035 inches. It should be noted that the
holes need not be circular is shape and that
nay shape hole would suffice. See for
example FIGS. 7-11~ The hole area along
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the skin engaging surface is important.
Preferably. the hole area is from about 0.0005
to about 0.0250 square inches. When a high
level of polyethylene oxide lubricant is
utilized in the core, a hole area of about
0.0125 square inches is preferred. Many shaving
aids tend to swell upon contact with water. BY
binding these swelling shaving aids Within an
insoluble matrix material. the degree of swell
can be modified to prevent aesthetically
unpleasant results. The most preferred hole
patters is found in FIGS. 4-5.
The shaving aid is selected from the
group consisting of polyethylene oxide,
polyvinyl pyrrolidone, polyacrylamide,
hydroxypropyl cellulose: polyvinyl imidazoline,
polyethylene glycol, poly vinyl alcohol,
polyhydroxyethylmethacrylate, silicone
copolymers, sucrose stearate, vitamin E, soaps,
surfactants, panthenol, aloe, plasticizers. such
as polyethylene glycol beard softeners:
additional lubricants, such as silicone oil,
Tefloae polytetrafluoroethylene powders
(manufactured by DuPont), and waxes; essential
oils such as menthol, camphor, eugenol,
eucalyptol, safrol and methyl salicylate~
tackifiers such as Hercules Regalrez 1094 and
1126 non-volatile cooling agents, inclusion
complexes of skin-soothing agents with
cyclodextrins; fragrances:
antipruritic/counterirritant materials:
antimicrobial/keratolytic materials such as
Resorciaol~ anti-inflaa~atory agents such as
Candilla wax and glycyrrhetinic acid
astringeints such as zinc sulfate: surfactants
such as pluronic and iconol materials;
compatibilizers such as styrene-b-EO copolymers;
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and combinations thereof. These shaving aids
may release from the surface to provide improved
shaving. These components can be dispersed
throughout the core and, additionally, the outer
sheath may also contain small amounts of these
shaving aids.
Preferably, said shaving aid is a
water soluble or water miscible material;
however, non-water soluble additives can also be
incorporated as long as they aria be carried out
with a water soluble core component.
The preferred shaving aid will
comprise a lubricious water-soluble polymer.
Such water-soluble polymer will preferably
comprise at least 50%, more preferably at least
60%. by weight of the core. The more preferred
water-soluble polymers are the polyethylene
oxides generally known as POLYOX (available from
Union Carbide Corporation) or ALROX (available
from Meisei Chemical Works, Ryoto, Japan).
These polyethylene oxides will preferably have
molecular weights of about 100,000 to 6 million,
most preferably about 300,000 to 5 million. The
most preferred polyethylene oxide comprises a
blend of about 40 to 80% of polyethylene oxide
having an average molecular weight of about 5
million (e.g. POLYOX COAGULANT) and about 60 to
20% of polyethylene oxide having an average
molecular weight of about 300,000 (e. g. POLYOX
WSR-N-750). The polyethylene oxide blend may
also advantageously contain up to about 10% by
weight of a low molecular weight (i.e.
MW<10,000) polyethylene glycol such as PEG-100.
The shaving aid may also advantageous-
ly comprise a non-volatile cooling agent or an
inclusion complex of a skin-soothing agent with
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a cyclodextrin, preferably in amounts up to
about 25%. most preferably 10 to 20%. by weight
of the core.
By non-volatile cooling agent is meant
an agent which has a physiological cooling
effect on the skin and which is appreciably less
volatile than menthol. Preferably, the non-
volatile cooling agent will be one which when
subjected to thermogravimetric analysis (e~g~
using a 951 Thermogravimetric Analyzer from
Dupont with a 20°C. temperature rise per minute)
will retain at least 50% of its initial weight
at a temperature of 160°C.. more preferably at
least 80% of its initial weight at a temperature
of 160°C.. and most preferably at least 50% of
its initial weight at a temperature of 175°C.
Suitable cooling agents which can be
utilized include non-volatile menthol analogs
such as menthyl lactate, menthyl ethoxyacetate,
menthone glycerinacetal, 3-1-menthoxypropane-1,2-
diol, ethyl 1-menthyl carbonate, (1S.3S,4R)-p-
menth-8-en-3-ol, menthyl pyrrolidone
carboxylate, N-substituted-p-menthane--3-
carboxamides (as described in U.S. 4,136,163,
which is incorporated herein by reference)
including, for example, N-ethyl-p-menthane-3-
carboxamide, acyclic carboxa~ides of the formula
R1
R2 C* CONR'R"
R3
Where R' and R". when taken separately. are each
hydrogen, C1-C5 alkyl or C1-C8 hydroxyalkyl and
provide a total of no more thaa 8 carbon atoms,
with the proviso that when R' is hydrogen R" may
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also be alkylcarboxyalkyl of up to 6 carbon atoms; R' and R~~,
when taken together, represent an alkylene group of up to 6
carbon atoms thereby forming a nitrogen heterocycle, the
alkylene chain being optionally interrupted by oxygen; R' is
hydrogen or C,-CS alkyl; and RZ and R3 are each C,-CS alkyl (such
acyclic carboxamides being described in U.S. 4,153,679),
including, for example, N,2,3-trimethyl-2-isopropylbutanamide,
and ketal coolants (as described in WO 93/23005) , including, for
example, 1-menthon-/d-isomenthon glycerin ketal.
Suitable skin-soothing agents which can be utilized in the
cyclodextrin inclusion complex include menthol, camphor,
eugenol, eucalyptol, safrol, methyl salicylate, and the
aforedescribed menthol analogs. Any suitable cyclodextrin may
be utilized to form the inclusion complex including
alpha-cyclodextrin, beta-cyclodextrin, gamma-cyclodextrin and
modified cyclodextrins such as hydroxypropyl-beta-cyclodextrin,
methyl-beta-cyclodextrin, and acetyl-beta-cyclodextrin. The
preferred cyclodextrins are beta-cyclodextrin and
gamma-cyclodextrin.
When the shaving aid comprises a cyclodextrin inclusion
complex, the core may also advantageously comprise up to about
10%, preferably about 2 to 7%, by weight of a displacing agent
which displaces the skin-soothing agent from the inclusion
complex upon contact with water, thereby enhancing the release
of the skin-soothing agent from the core material during use.
The displacing agent is a material which is capable of forming
a more
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stable complex with the cyclodextria than. the
complex formed with the skin-soothing agent and,
thus. displaces the skin-soothing agent from the
complex when the shaving aid is contacted with
water. Suitable displacing agents include
surfactants, benzoic acids, and certain amines
(e. g, urea).
Further details with respect to the
aforementioned cooling agents, cyclodextrin
inclusion complexes and displacing agents may be
found in the following U.S. patent applications
No. 08/496,860 entitled Shaving Aid Composite
With Aa Inclusion Complex Of A Skin-Soothing
Agent And A Cyclodextrin, filed on June 30,
1995 and No. 08/497,193 entitled Shaving Aid
Composite With A Non-Volatile Cooling Agent,
filed oa June 30, 1995.
The core includes from about 0% to
about 50% by weight, preferably from 0% to about
20%. of a water-insoluble matrix material and
from about 50% to about 100% by weight,
preferably from about 80% to about 100%. of the
shaving aid. Suitable water-insoluble polymers
for the matrix include, for example, nylon,
ethylene vinyl acetate (EVA), polyethylene,
polypropylene, polyurethane, polystyrene,
polystyrene-butadiene, polyacetal,
polypheaol/polystyrene blends (such as NOBEL
brand polymer). and combinations thereof.
The sheath must have sufficient
mechanical strength and rigidity to provide
adequate mechanical strength to the entire skin
engaging member, both as initially produced and
after a significant amount of water soluble
material has 'been leached out of the
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skis engaging member. Preferably the sheath
will comprise at least 35%. most preferably at
least 40%. bY weight of a water-insoluble
polymer, particularly a thermoplastic resin.
Thermoplastic resins suitable for use in the
sheath include polystyrene, high impact
polystyrene (polystyrene-butadiene),
polypropylene, filled polypropylene,
polyethylene. nylon, ethylene vinyl acetate and
blends such as 70% nylon/30% polyethylene oxide,
60% polystyrene/40% polyethylene oxide. The
preferred resins are high impact polystyrene,
polystyrene, ethylene vinyl acetate (EVA) and
combinations thereof. In addition to the water-
insoluble polymer, the sheath may also comprise
some water-soluble polymer, such as polyethylene
oxide, but generally no more than about 65% by
weight, preferably less than 60% by weight, in
order to maintain the structural integrity of
the sheath. Optionally. the sheath can include
additives such as lubricants or plasticizers,
fillers such as CaC03. and colorants such as
Ti02.
Ia one embodiment of the present
invention a wear indicating effect is produced
when the sheath and the core are made of
disparately colored materials (e. g. white
colored sheath and blue colored core). The
core leaches out of the akin engaging member
through use. With sufficient use, a colored
region within the core leaches out. ay
examining the release holes along the skin
engaging surface, the user is provided with as
indication that the shaving unit and/or skin
engaging surface have reached their effective
life. In a preferred embodiment, the core
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consists of polyethylene oxide/polystyrene blend
which is colored with Indigotine, FD&C #2 dye
and the sheath consists of nylon and/or
polystyrene which has been colored white.
According to the present invention,
the skin engaging members may be affixed by
adhesive such as Loctite Super Bonder 499, by
mechanical locking mechanism, by thermal welds
or by a combination thereof.
The akin engaging member can be a
strip made by two-color (two-component) molding
or coextruding, or by extruding or molding the
surface layer and the shaving aids separately
and then assembly later. The skin engaging
member can then be glued or snapped onto a razor
cartridge. The skin engaging member can also be
a razor cap, platform, or housing made by two-
color molding: For example, 1) a surface with
holes can be made by molding or two-color
molding, and 2) a surface with channels can be
made by molding. Extrusion and coextrusion
processes are preferred as they require less
capital and skilled labor. Then the skin
engaging member is coextruded, holes must be
made in the skin engaging surface. The holes
are placed in the sheath by any of the following
processes: drilling, laser, water jet,
embossing or puncturing. The core and the
sheath should be processed at different barrel
temperatures to minimize material degradation.
To easily incorporate functional additives
including liquids and powders into the core, a
twin-screw extruder should be considered as an
alternative to the single-screw extruder used in
the extrusion and coextrusion processes.
Optimally the sheath will have a hard to
moderately hard surface.
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The preferred skin engaging member is
produced by a coextrusion process whereby a sheath
is present on at least the skin engaging surface
~4. The nature nerd relative portions of the
sheath nerd core polymeric materials are such that
the skin engaging member has adequate mechanical
streagth~ both as initially produced and after a
significant amount of water soluble material has
been leached out the quantity of the water-
soluble material being sufficient to provide
effective shaving assistance, such as lubrication,
for the entire expected life of the blade or
blades. The function of the sheath is not only to
provide additional rigidity but to meter the
shaving aid. Ia conventional skin engaging
members, such as those described in U.S. Pat. Nos.
5~063~667~ 5~095e619i and 5,113,585 a significant
amount of shaving aid is trapped within the
insoluble matrix. By increasing the shaving aid
concentration in the core, diffusion is increased
and more efficient delivery is achieved.
Furthermore if an insoluble matrix is added to the
cores it also provides some additional mechanical
strength.
Figure 7 is a schematic cross section
diagram dower the length of a two-component extruder
(or coextruder) suitable for manufacturing the skin
engaging member of the present invention. Core
material 80 is fed into the intrusion die 81 by an
extrusion screw hot malt or other suitable means.
In the core islet port 82 the tight core orifice 83
encounters the sheath material 86, which has been
fed into sheath inlet port 84~ wherein the core
becomes encapsulated by the sheath material when
viewed is a transverse cross section to the flow of
the die material. The encapsulated core they
proceeds to the die outlet 85 wherein the
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continuous skin engaging members can be cured
and/or drawn down to provide the appropriate
dimensions. For general discussion of
coextrusion technology see Levi, Plastics
Extrusion Technoloav Handbook, Industrial Press
Inc.. pages 168-188 (1981). After the continu-
ous skin engaging members are produced, the
strand is sent for further processing where it
is typically drawn down to the correct size and
cut to length suitable for implant into the body
of a razor blade cartridge. This cutting can be
achieved by knife edge cutting, lasers or water
jet. The skin engaging surfaces of the present
invention typically are rectangular in shape
with a width of from about 0.05 inches to about
0.1 inches and a length of about 1.2 inches.
The two-component extruder allows the
core material to be processed at a relatively
low temperature to reduce material degradation.
For example, polyethylene oxide can be processed
at a temperature lower than that required by
conventional strips, i.e. polyethylene oxide in
insoluble matrix lubricating strips. Shaving
aids can be made from water soluble polymers
such as polyethylene oxide, polyethylene glycol,
and polyvinyl alcohol, etc. Additives such as
perfume, moisturizers, Vitamin E, and
plasticizers etc. can easily be added to the
shaving aid. Additives can also be water-
insoluble materials as long as they can be
carried out through the surface openings. The
core containing shaving aid can be molded or
extruded, although the extrusion process is
preferred.
Leach rates of the shaving aids depend
oa the thickness of the surface, the number and
the shape of the openings. and the surface
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CA 02203897 1997-04-28
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structures (porous or non-porous). The surface
layer can also be made to be removable so that
the shaving aids can be added to the device
during use.
Applicant considers equivalent
embodiments to be part of the present invention.
For example non-rectangular skis engaging
surface areas may be utilized (such as ovals)
and non-flat surface patterns could be utilized.
These and other equivalent embodiments are also
contemplated by the present invention. The
present invention and the manger of making and
using the same should be evident from the
following examples.
EXAMPLES 1-8
Core containing shaving aid (inner
layer) such as those found in Table 1 are co-
extruded into a device with a cross-section as
in Figure 7 at approximately the temperatures
found is the table. Typical finished width is
1/g of an inch after a draw dower of less than
2%. These devices require no additional
assembly. The coextrusion line includes two
3/4" 88I Systems 90 extruders (mfg. by Haake).
and a coextrusion die. The sheath or outer
layer of the coextruded skin engaging member was
made from a mixture at barrel temperature as
shows and the core containing shaving aid was
made from the material shown. The hole pattern
is cut with a 0.030 inch diameter drill is the
pattern of FIG 4. The finished strips are cut
1.25 inches long with a knife edge cutter
resulting in 13 holes per strip.
~ENpEp SM~ET
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WO 96/13360 PCT/US95/13713
- 18 -
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