US 9,808,944 B2
Methods of manufacturing silicon blades for shaving razors
Graham John Simms, Reading (GB); Peter Johannus Leussink, Enschede (NL); and Neville Sonnenberg, Newton, MA (US)
Assigned to The Gillette Company LLC, Boston, MA (US)
Filed by The Gillette Company, Boston, MA (US)
Filed on Jun. 17, 2014, as Appl. No. 14/306,702.
Prior Publication US 2015/0360376 A1, Dec. 17, 2015
Int. Cl. B26B 21/40 (2006.01); B26B 21/56 (2006.01); B26B 21/60 (2006.01); B26B 21/58 (2006.01); C30B 29/06 (2006.01); C30B 33/08 (2006.01)
CPC B26B 21/4068 (2013.01) [B26B 21/58 (2013.01); B26B 21/60 (2013.01); C30B 29/06 (2013.01); C30B 33/08 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method for manufacturing at least one razor blade comprising:
providing a mono-crystalline silicon wafer comprising a {100} surface;
etching the mono-crystalline silicon wafer at an angle relative to the surface {100} to expose an {111} plane where the {111} plane intersects the {100} surface at an angle and a second plane to provide at least one blade edge having between about a 19.5 degree included blade angle and about a 35.3 degree included blade angle;
applying at least one inner layer on the at least one blade edge;
providing a radius of curvature of the at least one blade edge between about 20 nanometers and about 100 nanometers after deposition of the at least one inner layer;
applying at least one outer layer on the at least one blade edge; and
removing the at least one razor blade from the mono-crystalline silicon wafer.