Polymeric cutting edge structures and method of manufacturing polymeric cutting edge structures

Abstract

A functional polymeric cutting edge structure and methods for the manufacturing cutting edge structures using polymeric materials are provided. A razor blade for use in a razor cartridge or a blade box for assembly in a razor cartridge frame may be formed using the present invention.

What is claimed is: 
     
         1 - 21 . (canceled) 
     
     
         22 . A blade box comprising
 at least one cutting edge structure;   at least one non-cutting edge structure coupled to each of said at least one cutting edge structure, both said cutting and non-cutting edge structures comprised of a polymeric material, said polymeric material produced by a precursor material for said polymeric material.   
     
     
         23 . A razor blade comprising
 at least one cutting edge structure comprised of a polymeric material, said polymeric material produced by a precursor material for said polymeric material.   
     
     
         24 . The razor blade of  claim 23  wherein said precursor material is comprised of a monomer material, an oligomer material, or any combination thereof. 
     
     
         25 . The razor blade of  claim 23  wherein said precursor material is comprised of an acrylic based material or an epoxy based material. 
     
     
         26 . The razor blade of  claim 23  wherein said polymeric material is cured by cross-linking or polymerization. 
     
     
         27 . The razor blade of  claim 23  wherein said polymeric material is cured by heat, light, or a combination thereof. 
     
     
         28 . The razor blade of  claim 23  wherein a viscosity of said precursor material is less than about 10,000 centiPoise. 
     
     
         29 . The razor blade of  claim 23  wherein said at least one cutting edge structure is formed within a cavity. 
     
     
         30 . The razor blade of  claim 29  wherein the cavity is entirely comprised in a single part in a base structure. 
     
     
         31 . The razor blade of  claim 27  wherein at least one of said precursor material, said polymeric material and at least one side of the cavity is transparent to electro-magnetic radiation at a wavelength in the range of 250 to 1500 nanometers. 
     
     
         32 . The razor blade of  claim 23  wherein a photo-initiator of about 1 to about 3% by weight of composition is added to said precursor prior to curing said precursor. 
     
     
         33 . The razor blade of  claim 23  wherein said polymeric material is comprised of Poly (methyl methacrylate) (PMMA) or Polydimethylsiloxane (PDMS). 
     
     
         34 . The razor blade of  claim 23  wherein said at least one cutting edge structure comprises a gothic arch, a roman arch, or one or more undercuts. 
     
     
         35 . The razor blade of  claim 23  wherein a tip radius of said at least one cutting edge structure is less than 1 micrometer. 
     
     
         36 . The razor blade of  claim 23  wherein said at least one cutting edge structure is secured into a blade box or into a razor cartridge housing, or frame. 
     
     
         37 . The razor blade box of  claim 22  wherein said blade box is comprised of different types of cutting edge structures.