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

Abstract

A functional polymeric cutting edge structure and methods for the manufacturing of cutting edge structures comprised of polymeric materials are provided. The cutting edge structures may be produced on a substrate having a blade body or blade support type. The polymeric material is produced by curing a precursor material activated by electromagnetic radiation wherein a wavelength of said radiation is about double a wavelength required to activate the precursor material. A razor blade for use in a razor cartridge or a blade box may be formed using the present invention.

What is claimed is: 
     
         1 . A method for manufacturing at least one cutting edge structure from a polymeric material comprising the steps of:
 (a) providing a computer model of a cutting edge structure;   (b) providing a precursor material;   (c) activating portions of said precursor material in a focal point of electromagnetic radiation while at least one substrate is disposed in said precursor material, wherein a wavelength of said radiation is about double a wavelength required to activate said precursor material;   (d) moving the focal point of said radiation within said precursor material to form at least one cutting edge structure on said substrate based on said model; and   (e) curing portions of said activated precursor material to produce said cutting edge structure comprised of a polymeric material.   
     
     
         2 . The method of  claim 1 , wherein said precursor material in step (b) is a solid precursor material. 
     
     
         3 . The method of  claim 1 , wherein said precursor material is a liquid precursor disposed in a container in step (b) and prior to step (c), a step of converting said liquid precursor material to a solid precursor material. 
     
     
         4 . The method of  claim 1 , wherein said at least one cutting edge structure is comprised of a plurality of voxels. 
     
     
         5 . The method of  claim 1 , wherein said at least one substrate comprises a blade body or blade support for said at least one cutting edge structure. 
     
     
         6 . The method of  claim 1 , wherein an extended cutting edge is formed of closely spaced cutting edge elements. 
     
     
         7 . The method of  claim 1 , wherein said precursor material is comprised of an epoxy based material. 
     
     
         8 . The method of  claim 3 , wherein said moving of said focal point in step (d) further includes movement of a lens in any direction, or movement of said container in any direction, or any combination thereof. 
     
     
         9 . The method of  claim 1 , wherein said precursor material is comprised of a monomer material, an oligomer material, or any combination thereof. 
     
     
         10 . The method of  claim 1 , wherein said at least one cutting edge structure comprises a gothic arch, a roman arch, or one or more undercuts. 
     
     
         11 . The method of  claim 1 , wherein a tip radius of said at least one cutting edge structure is less than 1 micrometer. 
     
     
         12 . The method of  claim 1 , wherein said precursor material is transparent to electro-magnetic radiation at a wavelength in the range of 250 to 1500 nanometers. 
     
     
         13 . The method of  claim 1  wherein said step (e) of curing comprises cross-linking or polymerization. 
     
     
         14 . The method of  claim 1 , further comprising a step (g) for physical or chemical removal of said substrate from said cured polymeric material cutting edge structure. 
     
     
         15 . The method of  claim 1 , wherein said at least one cutting edge structure is a razor blade or a portion of a blade box. 
     
     
         16 . The method of  claim 15 , further comprising a step (h) of assembling said razor blade or said blade box into a razor cartridge housing or frame. 
     
     
         17 . A cutting edge structure comprising a polymeric material, said polymeric material being produced from a solid precursor material activated by electromagnetic radiation, wherein a wavelength of said radiation is about double a wavelength required to activate said precursor material, said activated precursor material being cured to produce said cutting edge structure. 
     
     
         18 . A cutting edge structure of  claim 17 , wherein said cutting edge structure is produced on at least one substrate comprising a blade body or blade support. 
     
     
         19 . A cutting edge structure of  claim 17 , wherein said cutting edge structure comprises an extended cutting edge formed of closely spaced cutting edge elements. 
     
     
         20 . The cutting edge structure of  claim 17 , wherein said precursor material is comprised of an epoxy based material. 
     
     
         21 . The cutting edge structure of  claim 17 , wherein said electromagnetic radiation activates said precursor material in a plurality of voxels by moving a focal point in any direction. 
     
     
         22 . The cutting edge structure of  claim 17 , wherein said precursor material is comprised of a monomer material, an oligomer material, or any combination thereof. 
     
     
         23 . The cutting edge structure of  claim 17 , wherein said at least one cutting edge structure comprises a gothic arch, a roman arch, or one or more undercuts. 
     
     
         24 . The cutting edge structure of  claim 17 , wherein a tip radius of said at least one cutting edge structure is less than 1 micrometer. 
     
     
         25 . The cutting edge structure of  claim 17 , wherein said precursor material is transparent to electro-magnetic radiation at a wavelength in the range of 250 to 1500 nanometers. 
     
     
         26 . The cutting edge structure of  claim 17  wherein said activated precursor material is cured by cross-linking or polymerization. 
     
     
         27 . The cutting edge structure of  claim 17  is a razor blade. 
     
     
         28 . A blade box comprising:
 at least one cutting edge structure;   at least one non-cutting edge structure coupled to said at least one cutting edge structure, both said cutting and non-cutting edge structures comprised of polymeric material, said polymeric material being produced from a solid precursor material activated by electromagnetic radiation, wherein a wavelength of said radiation is about double a wavelength required to activate said precursor material, said activated precursor material being cured to produce said cutting edge structure.   
     
     
         29 . The blade box of  claim 28 , wherein said precursor material is comprised of an epoxy based material. 
     
     
         30 . The blade box of  claim 28 , wherein said electromagnetic radiation activates said precursor material in a plurality of voxels by moving a focal point in any direction.