This invention relates to shaving systems including a razor handle and a disposable cartridge which is adapted for releasable attachment to the handle.

In its preferred embodiments, the invention is directed in particular to a shaving system comprising a cartridge having a plurality of sharpened cutting edges arranged in a shaving plane. Such cartridges typically provide a smoother and closer shave than the single blade used in earlier razors, but require specific mounting arrangements so as to expose the shaving plane (typically the largest, flat side of the cartridge) for use.

The cutting edges are commonly provided by a plurality of blades arranged between a guard and a cap. The guard and cap are arranged respectively in front of and behind the cutting edges when considered in the direction of shaving, and together with the end portions of the blade housing comprise skin-engaging surfaces serving to determine the position of the cutting edges relative to the user's skin in use. The cutting edges, the guard and the cap lie substantially in alignment within the shaving plane, which is defined as that plane containing the guard and cap or corresponding skin-engaging surfaces in use. The exposure of each cutting edge is defined as the positive or negative distance of the cutting edge above or below the shaving plane, usually measured in tens of microns.

The cartridge may comprise a plastics housing containing an assembly of two, three, four or more blades, each having a cutting edge. The cap, guard and blades may be fixedly or moveably mounted (e.g. on springs) in the housing, or the cap and guard may be integral parts of the housing. Alternatively the cartridge may comprise an assembly or even a unitary element having a plurality of cutting edges made for example from a single piece of steel, ceramic or silicon material.

Typically, a shaving system also includes a dispenser for holding new cartridges, which is preferably adapted also to receive the used cartridges so as to retain them safely prior to disposal. Preferably, the cartridges are removed from and returned to the dispenser by means of the razor handle, so that the user's fingers are not exposed to the cutting edges.

Many razor handles now available in the market provide a pivoting mechanism in which the pivot axis is arranged on the opposite side of the cartridge from the shaving plane and in-between the guard and the cap, allowing the user to apply force to the cutting edges directly in line with the pivot axis. Such pivot mechanisms help the cartridge to follow the contours of the body area being shaved, but do not effectively limit the force applied to the skin.

Some users may find difficulty in manipulating a cartridge release button. Moreover, the cartridge structure when retained in the dispenser presents a confusing array of surfaces and apertures into which the user may attempt to insert the connection structure of the handle, so care is required when changing the cartridge. The pressure exerted against the user's skin by the cutting edges and by the cap and guard or other skin-engaging surfaces is an important factor in determining the closeness of the shave. If too much pressure is exerted, the shave may be overly aggressive so that the blades irritate or cut the user's skin. If too little pressure is exerted, the shave quality may be poor. It is therefore desirable to provide some means for limiting the pressure of the blades against the skin. At the same time, the user should be able to exercise precise control over the position of the cartridge and to obtain tactile feedback giving a "feel" for the interaction between the cartridge and the skin via the handle during shaving.

A pivoting connection between the cartridge and the handle helps the shaving plane to remain in correct relation to the skin as it passes over the changing contours of the user's body. However, in practice it can often fail to limit the force applied to the user's skin, since the user may apply force to the cutting edges directly in line with the pivot axis while moving the cartridge in the direction of shaving. At the same time, the pivot mechanism can also make it difficult for the user to control the shaving process and to "feel" the

engagement between the cutting edges and the skin through the razor handle, because the rotational position of the handle relative to the cartridge has little or no effect on the pressure of the cartridge against the skin. GB 2 408 01 0 A discloses a one-piece razor handle formed as a unitary, two- shot moulding. The handle is bifurcated to form a pair of arms, the cartridge being releasably mounted in fixed relation to the distal ends of the arms by squeezing the arms together and then releasing them so as to engage a hook structure on the end of each arm in a cooperating aperture in the cartridge. Each arm is provided with a living hinge surrounded by an elastomeric material, providing a hinge axis which lies just in front of the guard in the direction of shaving. Pressure applied to the cartridge during shaving causes the cartridge to pivot about the hinge axis with respect to the handgrip against the restoring force of the elastomer, so that the cartridge follows the contours of the user's skin. The position and structure of the hinge effectively limits the pressure applied to the cutting edges while providing the user with tactile feedback that enables precise control of the shaving operation.

In order for the user to release the blade cartridge when the blades have become dulled it is usally necessary for the user to manipulate either both ends of the cartridge or both ends of each of the forks of the razor. This operation can be difficult to perform when the razor is wet and in particular if the user is not very dextrous or has poor eyesight.

It is the object of the present invention to provide a razor handle for a shaving system which addresses some or all of the above mentioned problems so as to offer improved effectiveness in use and/or manufacture.

In accordance with its various aspects the invention provides a razor handle as defined in the appended claims.

Some illustrative embodiments will now be described, purely by way of example and without limitation to the scope of the claims, and with reference to the accompanying drawings, in which:-

Fig. 1 shows an embodiment of a first razor handle of the invention together with a cartridge, shown unattached, to the razor handle, viewed from the non- shaving side,

Fig. 2 shows the razor handle of Fig 1 viewed from the non-shaving side, with the cartridge attached thereto, Fig. 3 shows a cross section of the razor cartridge and a longitudinal section of the razor handle of Fig 1 , approximately centrally through the razor, Fig. 4 shows the same longitudinal view of the razor cartridge and razor handle as Fig. 3 with the cartridge in a fitted position,

Fig. 5 shows a partial enlarged view of Fig. 1 of the end of the razor handle and the razor cartridge with the blades not shown for clarity and with the cartridge in a fitted position,

Fig. 6 shows the same views of the end of the razor handle as Fig. 5 with the cartridge not present, Fig. 7 shows a razor handle and cartridge according to a further embodiment of the invention,

Fig. 8 shows an enlarged cross section of the razor cartridge and a

longitudinal section of the razor handle of Fig 7, approximately centrally through the razor,

Fig. 9 shows an enlarged cross section as in Fig. 8, but with the cartridge unattached and without the blades shown, Fig. 10 shows a further embodiment of a razor and razor blade cartridge according to the invention, and

Fig. 1 1 shows the same embodiment as fig. 10 with the cartridge removed. Corresponding elements are indicated by the same reference numerals in each of the figures.

Referring to Figs. 1 -6, a shaving system comprises a first, re-usable razor handle 1 , and a replaceable and disposable cartridge 60.

The handle 1 is forked and comprises a handgrip portion 2 and a bifurcated portion comprising a pair of arms 3, each with a hinge portion 4. The arms are arranged between the handgrip portion and a mounting portion 30, which is attached to both hinges so that it may pivot (together with the attached cartridge 60) relative to the handgrip portion 2 about a pivot axis defined by the hinge 4, in response to shaving forces exerted against the cartridge 60.

The forked handle configuration simplifies the cartridge mounting portion, avoids obstruction of the bottom side of the cartridge so as to allow effective wash-through of the blades, and allows the user to observe between the forks (e.g. in a shaving mirror) the area of skin immediately in front of the blades so that he can see where he is about to shave.

It also provides a mechanically stable configuration which gives improved tactile feedback when shaving, and makes it easy for the less dextrous user to apply pressure to the mounting portion while avoiding any risk of overturning the razor during engagement or disengagement of the cartridge.

The position and configuration of the handle with respect to the mounting portion also ensures that the mounting portion always trails behind the handle. This provides a smooth shaving action and makes it very difficult for the cartridge to be inadvertently applied to the skin in a gouging motion as is sometimes possible with prior art razors having a short, straight section which supports the cartridge at a point between the guard and the cap and below the shaving plane (i.e. on the opposite side of the shaving plane from the user's skin). Generally, the smaller the angle between the longitudinal axis of the handle and the shaving plane (or a plane parallel with the shaving plane), down to an optimal angle of about 20 ^° , the smoother and safer the shaving action.

The cartridge 60 comprises a plastics housing 61 containing a plurality of steel blades 62, each blade being permanently mounted in the housing 61 and having a cutting edge. The cutting edges lie in a shaving plane at the top side 64 of the housing and are arranged one behind the other in a shaving direction so as to exert a consecutive cutting action in use when the shaving plane is moved across a user's skin in the shaving direction.

The shaving plane formed by the top side 64 of the cartridge also contains a plurality of skin engaging surfaces defined by permanent parts of the plastics housing, including a guard 69 arranged adjacent the leading side of the cartridge, and a cap 70 arranged adjacent its trailing side, the guard and the cap encountering the user's skin respectively in advance of and behind the cutting edges of the blades respectively when the cartridge is moved across the user's skin.

An attachment tongue 80 is located centrally on the leading side of the cartridge 60 and orientated towards the underside of the cartridge 60. The tongue 80 comprises an enlarged portion 81 at its remote end, in this embodiment in the form of a rounded lozenge which extends lengthwise in a direction parallel to length of the cartridge. The tongue 80 fixedly attaches the cartridge 60 to handle 1 by locating in a correspondingly shaped void in the handle 1 , which is explained further below.

The cartridge will preferably be sold in a dispenser and presented to the razor handle by the user whilst still in the dispenser so that the user does not actually contact the cartridge itself. Dispensers are known for replaceable cartridges of this type and comprise a one-piece plastics moulding defining a shallow tray having outer walls and a generally flat base and a plurality of compartments.

Each compartment includes a retaining structure which is adapted to retain a cartridge in a retained position in the respective compartment, and to release the cartridge when the cartridge is attached to the handle and retracted from the dispenser.

The mounting portion 30 of the handle comprises a cartridge engaging structure as shown best in the enlarged figures 3 to 6. In this embodiment the handle 1 is composed of a two shot moulding of two plastic materials, a first relatively rigid plastic material such as polypropylene and a second more elastomeric material such as a thermo plastic elastomer (tpe). In particular there are two roles of the mounting portion 30, the main one being to provide the flexible support to the razor cartridge 60. This is provided by the hinge area 4 which is created by the reduced dimension of the arms 3 forming narrower parts and cutaway portions 8 at least in part comprising the more elastomeric material which permits the remote end portions 5 to flex and they are in turn connected to each end of the cartridge 60. The other role is to provide a releasable fixing of the cartridge 60 to the mounting portion 30 of the handle 1 .

The first relatively rigid material could be any suitable relatively rigid plastic material and could also be a metal material formed for example by die casting.

As referred to above the elastomeric material forms the hinge parts 4 on each of the two fork arms 3 to allow the end portions 5 of the fork arms 3, as well as the mounting portion arranged between them, to flex in relation to the main part of the fork arm which is made of the first rigid material. Each hinge 4 comprises a living hinge, which is a relatively thin portion of the relatively rigid base component, surrounded by an elastic portion of the body of elastomeric material, the elastic portion providing a restoring force that urges the mounting portion 30 resiliently to the rest position with respect to the handgrip portion. A larger part of the elastic portion is arranged below the living hinge and bonded to the base component during moulding so that it acts in tension to exert the restoring force against the user's skin, while a smaller part, arranged above the thin portion, acts simultaneously in compression.

Suitable elastomeric materials will be readily identified by those skilled in the art, and include for example thermoplastic elastomers such as Santoprene (RTM), manufactured by Advanced Elastomer Systems, LP of Akron, Ohio, USA, an affiliate of Exxon Mobil Chemical Company of Houston, Texas, USA; and Thermolast K (RTM), manufactured by Kraiburg TPE GmbH & Co. KG of Waldkraiburg, Germany. Thermoset elastomers could also be used. The mounting portion 30 extends from one end portion to the other by means of a mounting bar 33 and thus also flexes with the end portions 5 and the attached cartridge 60 during shaving. The mounting portion is generally longitudinal; and also comprises of the same two relatively rigid and

elastomeric materials in a single two shot moulding. The bar 33 includes a central part 37 of the mounting portion 30 which includes a recess 36 which is adapted to receive the attachment tongue 80 of the cartridge. The recess 36 thus extends along the mounting portion 30 to the same extent as the width of the attachment tongue 80. The recess 36 is formed in a lozenge shape and includes a detent 35 which fits behind the underside of the enlarged portion 81 of the tongue 80 when the cartridge is fitted to the handle 1 . Thus when the cartridge is attached to the handle the attachment tongue 80 fits into the recess 36 and forms a secure attachment of the cartridge 60 to the handle 1 by means of the detent 35 acting against the enlarged portion 81 . The thickness of the attachment tongue corresponds with that of the recess 36 so that an intimate fit is achieved. It will also be observed that the attachment tongue 80 is rounded and the recess 36 is correspondingly tapered to allow for easy location of the attachment tongue 80 in the recess 36 during fitting, the depth of the recess 36 and the attachment tongue being such as to ensure an intimate contact, as shown in Fig 5.

The enlarged portion 81 extends through the recess 36 and protrudes to the other side of the razor handle 1 and is available for contacting by the users thumb or other digit on the opposite side to the cutting edges of the blades. When the cartridge 60 is spent and the user wishes to remove the cartridge 60 from the handle 1 , the user presses a thumb or other digit against the enlarged portion 81 . A suitably shaped indented portion on the enlarged portion 81 (not shown) provides an indication to the user to direct the pushing action and to locate the end of the thumb or digit thereon. This pushing action deflects the detent 35 as a result of the rounded shape of the enlarged portion 81 and causes the cartridge to be released from the razor handle. This has been achieved by a simple single one push action by the user.

Referring to Figs 7 to 9 a further embodiment is shown in which the mounting portion 30 similarly extends from one end portion 5 to the other and thus also flexes with the end portions 5 during shaving. Common parts are shown by the same identifiers. The mounting portion 30 is generally longitudinal; and is also comprises of the same two relatively rigid and elastomeric materials in a single two shot moulding as the rest of the handle. In this embodiment however an inner part 32 is relatively rigid and an outer part 35 is elastomeric. The rigid inner part 32 of the mounting portion 30 extends from one end portion 5 to the other and includes a recess 136 which is adapted to receive the attachment tongue 180 of the cartridge 60. The recess 136 thus extends along the mounting portion 30 to the same extent as the width of the

attachment tongue 180. The outer part 35 has a corresponding outer recess 34 which forms a continuation of the inner part of the recess 136 so that the complete recess corresponds with the depth of the attachment tongue 180. The recess length is preferably slightly less than the tongue length to allow for the take up of manufacturing tolerance, by means of the resulting slight compression of the elastomeric outer part 35 which acts as a spring washer. Thus when the cartridge 60 is attached to the handle the attachment tongue fits into the recess 136 and forms a secure attachment of the cartridge 60 to the handle 1 . The thickness of the attachment tongue 180 corresponds with that of the recess 136 so that an intimate fit is achieved. It will also be observed that the attachment tongue 180 is tapered and the recess 136 is correspondingly tapered to allow for easy location of the attachment tongue 180 in the recess 136 during fitting, the depth of the recess 136 and the attachment tongue 181 being such as to ensure an intimate contact, as shown in Fig 8.

The inner part recess 136 also includes a detent groove 38 which, when the cartridge 60 is in the fitted position, corresponds in shape and position of the protuberance 184 of the attachment tongue 180 of the cartridge 60 such that the cartridge 60 is securely retained in the fitted position and is ready for use by the user to shave. When the cartridge 60 is spent and the user wishes to remove the cartridge 60 from the handle 1 , the user presses a thumb or other digit against the outer part 35. A suitably shaped button portion 39 on the surface 40 of the outer part 35 provides an indication to the user to direct the pushing action and to locate the end of the thumb or digit thereon. This pushing action deflects and compresses the elastomeric material of the outer part 35. This compression of the outer part 35 causes it to press against an end surface 85 of the attachment tongue 180 causes the protuberance 184 to be released from the detent 38 groove so that continued pressing by the user causes the tongue 180 to be completely pushed out of the recess 136 and the cartridge is released from the handle. This has been achieved by a simple single one push action by the user. When the user releases the button 39, the outer part 35 returns to its original shape.

The elastomeric part 35 thus has a number of benefits. Firstly it acts to cushion the connection between the cartridge and the handle which provides the user with a gentle squeezing effect felt in the thumb when the cartridge is being ejected before the final release of the cartridge, this gives the user more control over the release of the cartridge. Secondly it assists in providing more intimate contact between the contacting surfaces of the cartridge and the cartridge mounting surfaces by accommodating any slight variations that may occur due to manufacturing tolerances or during extended use.

In both embodiments additional support for the cartridge is provided by the end portions 5 which each comprise support surfaces which bear against the side walls of the cartridge. The elastomeric material extends along the arms 3 to provide gripping surfaces 7 on the handgrip portion, and also extends around each digit receiving surface to provide additional grip as well as. The elastomeric material is preferably a different colour from the base component a visual indication to the user of the correct position to place the digit.

The flexing axis of the hinge 4 is arranged just in front of the leading side of the cartridge when considered in the shaving direction, which ensures that any rotation of the handle about the flexing axis will load or unload the elastic portion of the hinge and hence vary the pressure of the cartridge against the user's skin, so that the maximum shaving force applied in normal use corresponds to the restoring force exerted by the elastic portion of the hinge. This combination of hinge geometry and elasticity provides the user with control and "feel" for the shaving process, and at the same time protects the user's skin by making it very difficult to apply direct pressure to the skin in line with the flexing axis.

In these embodiments the flexing axis is advantageously arranged as shown substantially in parallel with the length dimension of the cartridge and with the blades, and the mounting portion is preferably not free to flex about any other axis. This ensures that the cutting edges of the blades remain generally orthogonal to the plane of symmetry as the cartridge flexes, making it easier to control the position of the blades and to attach and remove the cartridge and helping to prevent any inadvertent slicing motion of the cartridge in the longitudinal direction of the blades which could otherwise cut the skin.

Most preferably, the flexing axis is arranged proximate the leading side of the cartridge as shown, or as close to the leading side as possible, as this enables the user to achieve the required shaving pressure with only very light pressure on the handle and maximises controllability and tactile feedback during the shaving process.

In an alternative embodiment as shown in Fig. 1 0 and Fig. 1 1 , the hinge 204 is provided entirely of elastomeric material and permits independent swivelling of the cartridge and mounting portion is a direction orthogonal to the length dimension of the cartridge or cutting edges as well as parallel to it. Such limited and controlled movement in this direction is advantageous in

maintaining more intimate contact of the razor cartridge with the skin which helps in producing a closer shave. The control is provided by the selection and dimensioning of the elastomeric material of the hinge 204 and of the retaining detents 235 which retain the attachment tongue 281 of the cartridge 260 securely to the handle. This combination of the elastomeric hinge 204 and the retaining detents 235 and tongue 281 provides the required level of tuning in the movement of the cartridge 260 in the direction orthogonal to the length dimension of the cartridge or cutting edges. The mounting portion 30 also includes a fixed skin engaging structure 52 extends along the same plane as the cartridge and forms part of the base component. The flexible cantilever structure extends in fixed relation from the edge of the support wall in the shaving direction and defines a skin engaging surface 52 which is arranged in the shaving plane in advance of the cartridge, so that it frictionally engages the region of skin that is about to be shaved immediately in front of the cutting edges as the shaving plane travels across the user's skin in use, stretching the skin to erect the hairs in advance of the blades.

The skin engaging surface is preferably textured to define a pattern of bumps and hollows which act as a temporary reservoir of lubricating fluids applied to the skin (e.g. by the user and/or from a leachable strip arranged on the cartridge), distributing the fluids over the region which is about to be shaved so as to ensure a smooth, close shave. The textured surface is generally flat (i.e. the asperities lie approximately in a flat plane) and extends substantially in alignment with the shaving plane, closely adjacent and directly in front of the guard and side wall 66 of the cartridge in its installed position and in advance of the cutting edges when considered in the shaving direction.

The unitary co-moulding of the handle incorporating multiple functional elastomeric elements is economical and easily cleaned, avoiding the

accumulation of shaving debris which can impair hinges and other more intricate assemblies of prior art razors. When the cartridge 60 is in its retained position in a dispenser, it is easy for the user to insert the attachment tongue 80, 180 into the recess 36, 136 and the user will feel and/or hear the click which informs the user that the handle razor is successfully connected to the cartridge.

It is found in practice that the features of the mounting portion, the cartridge and the dispenser cooperate to provide an exceptionally easy and intuitive procedure for engaging the cartridge, which requires very little dexterity and which if necessary can be accomplished by touch alone. Also in a further embodiment which is not shown the tongue may be made in an assymetrical shape of the tongue makes it impossible to engage the cartridge in an incorrect orientation so that (unlike, for example, prior art handles which engage the cartridge only at two pivot points) no additional asymmetric feature or the like is required to prevent incorrect engagement.

The cartridge 60 is then retracted from the compartment together with the mounting portion 30 by separating the razor from the dispenser in almost any direction. The holding force between the handle and the cartridge being much greater than that between the dispenser and the cartridge. The used cartridge can be returned to the dispenser with equal ease, with the user merely pushing the digit engaging surface of the enlarged portion 81 , or the button 39, when the cartridge is located in the dispenser chamber.

Advantageously, the elastomeric skin engaging surface 52 is moulded at relatively low cost as an integral, fixed part of the mounting portion of the reusable handle. Since the handle preferably includes other elastomeric elements, this is accomplished without any additional manufacturing step and hence at very little cost. Moreover, the skin engaging surface on the handle makes it unnecessary to provide an elastomeric skin-engaging element on each disposable cartridge as known in the art, which makes the cartridge cheaper and more convenient to manufacture (e.g. by a single shot moulding process rather than a co-moulding process), which cost saving is of course multiplied many times over since many disposable cartridges will be used with each handle. Since the cartridge does not include an elastomeric skin- engaging surface, it can also be more compact, which in turn simplifies the design of the dispenser and reduces the size and cost of the display

packaging; again, the benefit of compactness is multiplied by the number of cartridges in each package. Moreover, the elastomeric skin engaging surface on the handle can extend as far as required in the shaving direction, whereas if it were formed as part of the cartridge, its size would have to be limited, not only to avoid packaging problems but also in order to avoid forming a lever which could pop the cartridge out of its snap-fit mounting during use.

The elastomeric material gives the skin-engaging surface advantageous frictional properties which help it to engage and stretch the skin. It is found that elastomers falling between 20 and 85 Shore "A" scale hardness are suitable for use in forming the hinges and also have suitable frictional properties for use in forming the skin engaging surface, although if preferred, the skin- engaging surface could alternatively be formed in a separate moulding step from a different elastomer from that used for the hinges.

In yet further embodiments, the skin-engaging surface could be non- elastomeric, and an elastomeric or non-elastomeric skin-engaging surface could alternatively or additionally be arranged on the mounting portion adjacent the trailing side of the cartridge. Of course, in alternative

embodiments, the skin engaging structure may be omitted. The side walls of the cartridge may blend smoothly and continuously into the top and bottom sides, rather than meeting the top and bottom sides at defined edges, and the sides and side walls may be generally rectilinear, round, ovoidal, or any other desired shape. Normally the top side of the cartridge will include skin engaging surfaces comprising both a cap and a guard, but if preferred, one or more skin engaging surfaces defining the shaving plane may also be provided on the mounting portion of the handle. In yet further embodiments, the handle may include a body portion made from wood, carbon fibre, injection moulded or die-cast metal, or other material. Conveniently, the mounting portion and hinges are moulded as described above integrally with a bifurcated portion and handgrip portion in a two-shot or equivalent moulding process, after which the bifurcated portion and handgrip portion of the finished moulding (comprising a polypropylene or equivalent base component plus an elastomeric component, which provides the gripping surfaces) are clipped or glued into a recess in the body portion, which includes an aperture through which the moulding extends so as to provide gripping surfaces on both the upper and lower faces of the handgrip.

Advantageously, the cartridge is engaged with a snap-fit action by a simple movement of the mounting portion along a single engagement axis, although in less preferred embodiments, more than one engagement axis (requiring consecutive movements or a compound movement of the mounting portion to engage the cartridge) could be provided. In alternative embodiments the retaining structure of the dispenser may be any recess, protuberance or other feature, whether rigid or resilient, which receives, abuts, engages or otherwise cooperates with a corresponding part of the cartridge to retain the cartridge in the dispenser. Similarly it may be that each elastomeric 4 hinge is a compound hinge permitting movement of the mounting portion 30 and cartridge 60 about more than one axis. Numerous other adaptations will be evident to those skilled in the art on perusing the foregoing description, the scope of the invention being limited solely by the claims.