US3911579A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Cutting instruments and methods of making same
Assignee: Warner Lambert Co LLC
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Filing: 1973-04-18
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Granted: 1975-10-14
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Expires: 1993-04-18
Abstract
Abstract The specific disclosure is directed to razor blades and methods of making the same wherein the cutting edge formed by two intersecting surfaces is sputter deposited with a refractory material which is subsequently overlaid with a sputter deposited coating of material displaying adhesion to a final lubricious coating.
Inventors
- 👤 George C Lane
- 👤 Phyllis M Curtis
- 👤 Arthur E Michael
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-22 23:01
CPC Classifications
C; C23; C23C; C23C14/00; C23C14/22; C23C14/34; C23C14/3435; C23C14/345; B; B26; B26B; B26B21/00; B26B21/54; C23C14/02; C23C14/021; C23C14/022; C23C14/56; Y; Y10; Y10S; Y10S76/00; Y10S76/08
Claims Analysis
Total Claims: 69
Claim 1
Independent Claim
69 words
A method of making a razor blade comprising the steps of: forming a blade from a suitable material, the blade having an elongate edge comprising two intersecting surfaces; sputter depositing on the edge a first coating of refractory material; coating the edge with a second material displaying adhesion to a subsequent coating of lubricious material and to the refractory material; and then coating the edge with the lubricious material.
Claim 2
Independent Claim
69 words
A method of making a razor blade comprising the steps of: forming a blade from a suitable material, the blade having an elongate edge comprising two intersecting surfaces; sputter depositing on the edge a first coating of refractory material; coating the edge with a second material displaying adhesion to a subsequent coating of lubricious material and to the refractory material; and then coating the edge with the lubricious material.
Claim 3
Dependent Claim
20 words
The method of claim 1 wherein the first coating is RF sputter deposited and the second material is sputter deposited.
Claim 4
Dependent Claim
11 words
The method of claim 2 wherein the refractory material is corundum.
Claim 5
Dependent Claim
28 words
The method of claim 2 wherein the refractory material is selected from the group consisting of glass, corundum, quartz, alumina, beryllia, silicon carbide, boron nitride, and tungsten carbide.
Claim 6
Dependent Claim
19 words
The method of claim 4 wherein the refractory material comprises alloys and mixtures of materials selected from the group.
Claim 7
Dependent Claim
12 words
The method of claim 2 wherein the refractory material is synthetic sapphire.
Claim 8
Dependent Claim
31 words
The method of claim 1 wherein the total thickness of the deposited refractory material and the second material is limited to that necessary to maintain a desired degree of edge sharpness.
Claim 9
Dependent Claim
14 words
The method of claim 7 wherein the total thickness is approximately 500 Angstrom units.
Claim 10
Dependent Claim
29 words
The method of claim 7 wherein the thickness of the refractory material is approximately 300 Angstrom units and the thickness of the second material is approximately 25 Angstrom units.
Claim 11
Dependent Claim
84 words
The method of claim 2 wherein the RF sputter depositing comprises the steps of: disposing the blade in an evacuated chamber having an electrode on which is mounted a target of refractory material; introducing into the chamber an ionizable gas and establishing a plasma by imposing an RF potential between the electrode and the blade; depositing on the edge particles dislodged from the target by impingement of gas ions formed in the plasma upon collision of RF excited electrons and the ionizable gas molecules.
Claim 12
Dependent Claim
33 words
The method of claim 10 wherein the chamber is evacuated to approximately 10 6 Torr and the ionizable gas is introduced to a pressure of approximately between 5 and 8 (10) 3 Torr.
Claim 13
Dependent Claim
65 words
The method of claim 11 wherein the refractory material is synthetic sapphire, the ionizable gas is Argon and the blade is positioned approximately 2 inches from the target, the edge apex being diSposed substantially in a plane parallel to the target and the refractory material is deposited at a rate of approximately 30 Angstroms per minute for a period between approximately 5 and 10 minutes.
Claim 14
Dependent Claim
42 words
The method of claim 12 wherein the frequency is 13.56 MC and wherein the blade is sputter etched prior to deposition of the refractory material and a shutter is interposed between the target and the blade during the step of sputter etching.
Claim 15
Dependent Claim
53 words
The method of claim 13 wherein capacitor means is serially connected between the blade and the RF potential and the shutter is connected to ground during sputter etching and wherein when the shutter is removed, the RF potential is connected to the electrode and the blade is connected to ground for sputter deposition.
Claim 16
Dependent Claim
36 words
The method of claim 14 wherein the target is pre-cleaned prior to sputter etching and wherein during pre-cleaning the shutter is interposed, the RF potential connected to the electrode and the shutter is connected to ground.
Claim 17
Dependent Claim
19 words
The method of claim 15 wherein the following parameters are maintained during pre-cleaning, sputter etching and sputter deposition, respectively:
Claim 18
Dependent Claim
20 words
The method of claim 10 wherein the second material is RF sputtered in accordance with the steps of claim 10.
Claim 19
Dependent Claim
23 words
The method of claim 17 wherein the second material is deposited to a thickness sufficient to provide adhesion of the subsequent lubricious material.
Claim 20
Dependent Claim
28 words
The method of claim 18 wherein the second material is deposited to a thickness of approximately 25 Angstrom units and the second material is a metal containing material.
Claim 21
Dependent Claim
22 words
The method of claim 19 wherein the second material is selected from the group consisting of chromium, platinum, aluminum, titanium and iron.
Claim 22
Dependent Claim
27 words
The method of claim 19 wherein the second material comprises mixtures and alloys of metals selected from the group consisting of chromium, platinum, aluminum, titanium and iron.
Claim 23
Dependent Claim
11 words
The method of claim 19 wherein the second material is chromium.
Claim 24
Dependent Claim
13 words
The method of claim 19 wherein the lubricious material is a polymer material.
Claim 25
Dependent Claim
21 words
The method of claim 23 wherein the polymer is selected from the group consisting of polytetrafluoroethylene, polypropylene, polyhexafluoropropylene, polychlorotrifluoroethylene and polyethylene.
Claim 26
Dependent Claim
27 words
The method of claim 23 wherein the lubricious material comprises copolymers and telomers of polymers selected from the group consisting of polytetrafluoroethylene, polypropylene, polyhexafluoropropylene, polychlorotrifluoroethylene and polyethylene.
Claim 27
Dependent Claim
10 words
The method of claim 23 wherein the polymer is polytetrafluoroethylene.
Claim 28
Dependent Claim
15 words
The method of claim 6 wherein the lubricious material is sputter deposited onto the edge.
Claim 29
Dependent Claim
20 words
The method of claim 27 wherein the lubricious material is deposited to a thickness of at least 1,000 Angstrom units.
Claim 30
Dependent Claim
100 words
The method of claim 17 wherein the edge is sputter etched in a first vacuum chamber, the blade is moved through a vacuum interlock to a second vacuum chamber in which the edge is sputter deposited with the refractory material, the blade is then moved through a second vacuum interlock to a third vacuum chamber in which the edge is sputter deposited with the second material, and finally the blade is moved through a third vacuum interlock to a fourth vacuum chamber which is then vented to the atmosphere to permit blade removal for subsequent coating with the lubricious material.
Claim 31
Dependent Claim
14 words
The method of claim 29 wherein blades are continuously sequentially passes through the chambers.
Claim 32
Dependent Claim
33 words
The method of claim 1 wherein the refractory material comprises an aluminum oxide compound formed on the elongate edge when material sputtered from an aluminum target combines with oxygen present in The environment.
Claim 33
Dependent Claim
18 words
The method of claim 10 wherein the sputtering rate is increased by the presence of a reactive gas.
Claim 34
Dependent Claim
47 words
A cutting instrument comprising: an elongate edge of narrow included angle formed by two intersecting surfaces of a refractory material, an overlay coating of material over the edge for providing adhesion to the refractory material and a lubricious material, and a final coating of the lubricious material.
Claim 35
Dependent Claim
47 words
A cutting instrument comprising: an elongate edge of narrow included angle formed by two intersecting surfaces of a refractory material, an overlay coating of material over the edge for providing adhesion to the refractory material and a lubricious material, and a final coating of the lubricious material.
Claim 36
Dependent Claim
19 words
The cutting instrument of claim 33 wherein the refractory material and the coating are sputter deposited on the edge.
Claim 37
Dependent Claim
13 words
The cutting instrument of claim 33 wherein the refractory material is synthetic sapphire.
Claim 38
Dependent Claim
29 words
The cutting instrument of claim 34 wherein the refractory material is selected from the group consisting of corundum, alumina, glass, quartz, beryllia, silicon carbide, tungsten carbide and boron nitride.
Claim 39
Dependent Claim
17 words
The cutting instrument of claim 35 wherein the refractory material is RF sputter deposited on the edge.
Claim 40
Dependent Claim
14 words
The cutting instrument of claim 37 wherein the overlay coating is RF sputter deposited.
Claim 41
Dependent Claim
14 words
The cutting instrument of claim 38 wherein the lubricious material is RF sputter deposited.
Claim 42
Dependent Claim
25 words
The cutting instrument of claim 37 wherein the total thickness of the refractory material and the overlay coating does not exceed approximately 500 Angstrom units.
Claim 43
Dependent Claim
30 words
The cutting instrument of claim 40 wherein the thickness of the refractory material is approximately 300 Angstrom units and the thickness of the overlay coating is approximately 25 Angstrom units.
Claim 44
Dependent Claim
23 words
The cutting instrument of claim 41 wherein the intersecting surfaces are honed surfaces and the narrow included angle is less than approximately 30*.
Claim 45
Dependent Claim
14 words
The cutting instrument of claim 42 wherein the narrow included angle is approximately 20*.
Claim 46
Dependent Claim
14 words
The cutting instrument of claim 43 wherein the cutting instrument material is stainless steel.
Claim 47
Dependent Claim
31 words
The cutting instrument of claim 43 wherein the cutting instrument material is selected from the group consisting of stainless steel, carbon steel, chromium steel, tungsten steel, molybdenum steel, and chrome-nickel steel.
Claim 48
Dependent Claim
35 words
The cutting instrument of claim 43 wherein the cutting instrument material is an alloy containing material selected from the group consisting of stainless steel, carbon steel, chromium steel, tungsten steel, molybdenum steel, and chrome-nickel steel.
Claim 49
Independent Claim
57 words
A method for applying a lubricious material to a cutting instrument having an edge formed by two intersecting surfaces of a refractory material having limited adhesion to the lubricious material comprising the steps of: sputter depositing on the edge an overlay coating displaying adhesion to the lubricious material; and then coating the edge with the lubricious material.
Claim 50
Independent Claim
57 words
A method for applying a lubricious material to a cutting instrument having an edge formed by two intersecting surfaces of a refractory material having limited adhesion to the lubricious material comprising the steps of: sputter depositing on the edge an overlay coating displaying adhesion to the lubricious material; and then coating the edge with the lubricious material.
Claim 51
Dependent Claim
27 words
The method of claim 47 wherein both the refractory material and the overlay coating material are sputtered on the edge and the refractory material is synthetic sapphire.
Claim 52
Dependent Claim
20 words
The method of claim 48 wherein both the refractory material and the overlay material are RF sputtered on the edge.
Claim 53
Dependent Claim
28 words
The method of claim 49 wherein the refractory material is selected from the group consisting of glass, quartz, corundum, alumina, beryllia, silicon carbide, tungsten carbide and boron nitride.
Claim 54
Dependent Claim
23 words
The method of claim 49 wherein the refractory material is an aluminum oxide compound formed by sputter depositing aluminum in an oxygen atmosphere.
Claim 55
Dependent Claim
22 words
The method of claim 49 wherein the lubricious material is selected from the group consisting of polytetrafluoroethylene, polypropylene, polyhexafluoropropylene, polychlorotrifluoroethylene and polyethylene.
Claim 56
Dependent Claim
16 words
The method of claim 52 wherein the lubricious material is sputter deposited on the overlay coating.
Claim 57
Dependent Claim
14 words
The method of claim 49 wherein the overlay coating is a metal containing material.
Claim 58
Dependent Claim
21 words
The method of claim 54 wherein the metal is selected from the group consisting of chromium, platinum, titanium, aluminum anD iron.
Claim 59
Dependent Claim
26 words
The method of claim 54 wherein the overlay coating is an alloy containing metal selected from the group consisting of chromium, platinum, titanium, aluminum and iron.
Claim 60
Dependent Claim
12 words
The method of claim 54 wherein the overlay coating material is chromium.
Claim 61
Dependent Claim
41 words
The method of claim 54 wherein the overlay coating thickness is approximately 25 Angstrom units and the total thickness of both the refractory material and the overlay coating is limited to that necessary to maintain a desired degree of edge sharpness.
Claim 62
Dependent Claim
17 words
The method of claim 58 wherein the refractory material coating is approximately 300 Angstrom units in thickness.
Claim 63
Dependent Claim
11 words
The method of claim 32 wherein said reactive gas is oxygen.
Claim 64
Dependent Claim
14 words
The cutting instrument of claim 33 wherein the cutting instrument is a razor blade.
Claim 65
Dependent Claim
14 words
The cutting instrument of claim 35 wherein the cutting instrument is a razor blade.
Claim 66
Dependent Claim
14 words
The cutting instrument of claim 36 wherein the cutting instrument is a razor blade.
Claim 67
Dependent Claim
14 words
The cutting instrument of claim 37 wherein the cutting instrument is a razor blade.
Claim 68
Dependent Claim
14 words
The cutting instrument of claim 38 wherein the cutting instrument is a razor blade.
Claim 69
Dependent Claim
14 words
The cutting instrument of claim 40 wherein the cutting instrument is a razor blade.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-10-13 | 1979-04-14 | 1979-10-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-10-13 | 1983-04-14 | 1983-10-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-10-13 | 1987-04-14 | 1987-10-14 | $7700.00 | Window Closed / Lapsed |