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Title:
CUTTING BLADE AND HAIR REMOVAL DEVICE
Document Type and Number:
WIPO Patent Application WO/2021/209311
Kind Code:
A1
Abstract:
The present invention relates to a cutting blade (1) having a first face (2), a second face (3) opposed to the first face and different from the first face as well as a cutting edge (4) at the intersection of the first face and the second face. The first face comprises a first surface (9) and a primary bevel (7) with a first wedge angle (θ1) between the first surface and the primary bevel. The second face comprises a secondary bevel (5) and a tertiary bevel (6) with a second wedge angle (θ2) between the first surface on the first face and the secondary bevel and a third wedge angle (θ3) between the first surface on the first face and the tertiary bevel. Moreover, the present invention relates to a hair removal device comprising this cutting blade.

Inventors:
GLUCHE PETER (DE)
GRETZSCHEL RALPH (DE)
MERTENS MICHAEL (DE)
Application Number:
PCT/EP2021/059187
Publication Date:
October 21, 2021
Filing Date:
April 08, 2021
Export Citation:
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Assignee:
GFD GES FUER DIAMANTPRODUKTE MBH (DE)
International Classes:
B26B21/56; B26B21/58
Attorney, Agent or Firm:
PFENNING, MEINIG & PARTNER MBB (DE)
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Claims:
Claims

1. A cutting blade (1) having a first face (2), a second face (3) opposed to the first face (2) and different from the first face (2) as well as a cutting edge (4) at the intersection of the first face (2) and the second face (3), wherein

• the first face (2) comprises a first surface (9) and a primary bevel (7) with

• the primary bevel (7) extending from the cutting edge (4) to the first surface (9),

• a first intersecting line (12) connecting the primary bevel (7) and the first surface (9) and

• a first wedge angle qi between an imaginary extension of the first surface (9') and the primary bevel (7) and

• the second face (3) comprises a secondary bevel (5) and a ter tiary bevel (6) with

• the secondary bevel (5) extending from the cutting edge (4) to the tertiary bevel (6),

• a second intersecting line (11) connecting the secondary bevel (5) and the tertiary bevel (6),

• a second wedge angle 02 between the first surface (9) and the secondary bevel (5) and

• a third wedge angle 03 between the first surface (9) and the tertiary bevel (6) wherein 0i > 02 and 02 < 03.

2. The cutting blade of claim 1, characterized in that the first wedge angle 0i ranges from 5° to 75°, preferably 10° to 60°, more preferably 15° to 46°, and even more pref erably 20° to 45° and/or the second wedge angle 02 ranges from -5° to 40°, preferably 0° to 30°, more preferably 5° to 25° and/or the third wedge angle Q3 ranges from 1° to 60°, preferably 10° to 55°, more pref erably 19° to 46°, and most preferably is 45°.

3. The cutting blade of any of claims 1 or 2, characterized in that the primary bevel (7) has a length di being the di mension projected onto the imaginary extension of the first surface (9') taken from the cutting edge (4) to the first intersecting line (12) from 0.1 to 7 pm, preferably from 0.5 to 5 pm, more preferably from 1 to 3 pm.

4. The cutting blade of any of claims 1 to 3, characterized in that the dimension projected onto the first surface (9) and/or the imaginary extension of the first surface (9') taken from the cutting edge (4) to the second intersecting line (11) has a length d2 which ranges from 1 to 150 pm, preferably 5 to 100 pm, more prefera bly from 10 to 75 pm, and in particular 15 to 50 pm.

5. The cutting blade of any of claims 1 to 4, characterized in that the cutting blade (1) comprises or consisting of a blade body (15) consisting of a first material (18) or comprises or con sists of a blade body (15) comprising or consisting of a first material (18) and a second material (19) joined with the first material (18).

6. The cutting blade of claim 5, characterized in that the first material (18) comprises or consists of a material selected from the group consisting of

• metals, preferably titanium, nickel, chromium, niobium, tung sten, tantalum, molybdenum, vanadium, platinum, germanium, iron, and alloys thereof, in particular steel, • ceramics comprising at least one element selected from the group consisting of carbon, nitrogen, boron, oxygen and combi nations thereof, preferably silicon carbide, zirconium oxide, alu minum oxide, silicon nitride, boron nitride, tantalum nitride, TiAIN, TiCN, and/or TiB ,

• glass ceramics; preferably aluminum-containing glass-ceramics,

• composite materials made from ceramic materials in a metallic matrix (cermets),

• hard metals, preferably sintered carbide hard metals, such as tungsten carbide or titanium carbide bonded with cobalt or nickel,

• silicon or germanium, preferably with the crystalline plane par allel to the second face (2), wafer orientation <100>, <110>, <111> or <211>,

• single crystalline materials,

• glass or sapphire,

• polycrystalline or amorphous silicon or germanium,

• mono- or polycrystalline diamond, diamond like carbon (DLC), adamantine carbon and

• combinations thereof.

7. The cutting blade of any of claims 5 or 6, characterized in that the material of the second material (19) com prises or consists of a material selected from the group consisting of

• oxides, nitrides, carbides, borides, preferably aluminum nitride, chromium nitride, titanium nitride, titanium carbon nitride, titanium aluminum nitride, cubic boron nitride

• boron aluminium magnesium

• carbon, preferably diamond, poly-crystalline diamond, nano-crystalline diamond, diamond like carbon (DLC) and

• combinations thereof.

8. The cutting blade of any of claims 5 to 7, characterized in that the second material (19) fulfills at least one of the following properties:

• a thickness of 0.15 to 20 pm, preferably 2 to 15 pm and more preferably 3 to 12,

• a modulus of elasticity of less than 1200 GPa, preferably less than 900 GPa, more preferably less than 750 GPa,

• a transverse rupture stress oo of at least 1 GPa, preferably at least 2.5 GPa, more preferably at least 5 GPa

• a hardness of at least 20 GPa.

9. The cutting blade of any of claims 5 to 8, characterized in that the material of the second material (19) is nano crystalline diamond and fulfills at least one of the following properties:

• an average surface roughness RRMS of less than 100 nm, less than 50 nm, more preferably less than 20 nm,

• an average grain size dso of the nano-crystalline diamond of 1 to 100 nm, preferably from 5 to 90 nm, more preferably from 7 to 30 nm, and even more preferably 10 to 20 nm.

10. The cutting blade of any of any of claims 5 to 9, characterized in that the first material (18) and/or the second material (19) are coated at least in regions with an low-friction material, prefer ably selected from the group consisting of fluoropolymers, parylene, polyvinylpyrrolidone, polyethylene, polypropylene, polymethyl meth acrylate, graphite, diamond-like carbon (DLC) and combinations thereof.

11. The cutting blade of any of claims 5 to 10, characterized in that the first intersecting line (12) is shaped within the second material (19).

12. The cutting blade of any of claims 5 to 11, characterized in that the second intersecting line (11) is arranged at a boundary surface (20) of the first material (18) and the second mate rial (19).

13. The cutting blade of any of claims 1 to 12, characterized in that the cutting edge (4) has a tip radius of less than 200 nm, preferably less than 100 nm and more preferably less than 50 nm.

14. The cutting blade of any of claims 1 to 13, characterized in that the secondary bevel (5) comprises a further bev eled region (8) extending from the cutting edge (4) to a third intersect ing line (11) connecting the secondary bevel (5) and the beveled region (8), the beveled region (8) preferably having a fourth wedge angle 04 between the first surface (9) and the beveled region (8).

15. The cutting blade of any of claims 5 to 14 characterized in that the bev eled region (8) is shaped in the second material (19).

16. A hair removal comprising a cutting blade of any of claims 1 to 15.

Description:
Cutting Blade and hair removal device

The present invention relates to a cutting blade having a first face, a second face opposed to the first face and different from the first face as well as a cut- ting edge at the intersection of the first face and the second face. The first face comprises a first surface and a primary bevel with a first wedge angle qi be tween the first surface and the primary bevel. The second face comprises a sec ondary bevel and a tertiary bevel with a second wedge angle Q2 between the first surface on the first face and the secondary bevel and a third wedge angle Q3 between the first surface on the first face and the tertiary bevel. Moreover, the present invention relates to a hair removal device comprising this cutting blade.

The following definitions are used in the present application: · the rake face is the surface of a cutting blade over which the cut hair slides that is removed in the cutting process

• the clearance face is the surface of a cutting tool that passes over the skin; the angle between the clearance face and the contacting surface to the skin is the clearance angle a • The cutting bevel of a cutting blade is enclosed by the rake face and the clearance face and denoted by the bevel angle Q

• The cutting edge is the line of intersection of the rake face and the clear ance face

Cutting blades, in particular razor blades, are typically made out of a suitable substrate material such as stainless steel in which a symmetric wedge-shaped cutting edge is formed.

With respect to razor blades, the design of the cutting blade must be optimized to find the best compromise between the sharpness of the blade and the me chanical strength and hence durability of the cutting edge. The fabrication of conventional stainless steel razor blades involves a hardening treatment of the steel substrates before the blade is sharpened from both sides to form a sym metric cutting edge usually by grinding the hardened steel substrate.

A further coating may be applied to the steel blade after sharpening to optimize the mechanical properties of the blades. Hard coating materials such as dia mond, amorphous diamond, diamond-like carbon (DLC), nitrides, carbides, or oxides are suitable to improve the mechanical strength of the cutting edge.

Thus, the harder the cutting edge material, the longer the edge holding prop erty and in consequence the less wear is expected. Other coatings may be ap plied to increase the corrosion resistance or reduce the blade friction.

Most blades in the prior art are focused on blades with a symmetric blade body. However, some approaches exist where blades with an asymmetric blade are taught.

In US 3,606,682, a razor blade with improved cutting ease and shaving comfort is described. The blade has a recessed portion adjacent to the cutting edge which allows an improved shaving comfort. This effect is shown for symmetric and asymmetric blade bodies. US 3,292,478 describes a cutting die knife for textiles, leather and similar sheet materials wherein the knife has suitably inclined surfaces on both sides with the consequence that the cutting edge is not positioned centrally between the side surfaces and the knife has an asymmetric shape.

There is a continuing desire to cut an object as close as possible to the surface but on the other hand to reduce or avoid the risk of cutting the surface itself.

In the context of shaving, cutting hairs close to the skin without injuring the skin is desired to fulfill the requirements of accurate and safe shaving.

The present invention therefore addresses the mentioned drawbacks in the prior art and to provide cutting blades with a design which allows, at the same time, a good closeness to the surface where the object is to be cut and a high safety to avoid any cutting into the surface.

This problem is solved by the cutting blade with the features of claim 1 and the hair removal device with the features of claim 16. The further dependent claims define preferred embodiments of such a blade.

The term "comprising" in the claims and in the description of this application has the meaning that further components are not excluded. Within the scope of the present invention, the term "consisting of" should be understood as pre ferred embodiment of the term "comprising". If it is defined that a group "com prises" at least a specific number of components, this should also be under stood such that a group is disclosed which "consists" preferably of these com ponents.

In the following, the term cross-sectional refers to the cross-section perpendic ular to the linear extension of the cutting edge (if the cutting edge is straight) or the tangent of the cutting edge (if the cutting edge is curved).

The term intersecting line has to be understood as the linear extension of an intersecting point (according to a cross-sectional view as in Fig. 3) between dif ferent bevels regarding the perspective view (as in Fig. 1). As an example, if a straight bevel is adjacent to a straight bevel the intersecting point in the cross- sectional view is extended to an intersecting line in the perspective view. According to the present invention a cutting blade is provided having a first face and a second face which is opposed to the first face and different from the first face as well as a cutting edge wherein

• the first face comprises a first surface and a primary bevel with

• the primary bevel extending from the cutting edge to the first surface,

• a first intersecting edge connecting the primary bevel and the first surface and

• a first wedge angle 0i between an imaginary extension of the first surface (9 ' ) and the primary bevel and

• the second face comprises a secondary bevel and a tertiary bevel with

• the secondary bevel extending from the cutting edge to the ter tiary bevel,

• a second intersecting edge connecting the secondary bevel and the tertiary bevel,

• a second wedge angle 0 2 between first surface and the second ary bevel and

• a third wedge angle 0 3 between the first surface and the ter tiary bevel

It was surprisingly found that a cutting blade with the best compromise be tween closeness to the surface and safety during cutting while also having a very stable cutting edge together with a very good cutting performance can be provided when the wedge angles fulfill the following conditions: qi > 02 and 02 < 03-

The cutting blades according to the present invention have low cutting force due to a thin secondary bevel with a low wedge angle.

The cutting blades according to the present invention are strengthened by add ing a primary bevel with a primary wedge angle which is greater than the sec ondary wedge angle. The primary bevel with the first wedge angle 0i has there fore the function to stabilize the cutting edge mechanically against damage from the cutting operation which allows a slim blade body in the area of the secondary bevel without affecting the cutting performance of the blade. More over, the primary bevel with the wedge angle qi allows to lift the cutting edge from the surface which reduces the risk of injuring the surface and thereby in creasing the safety of the cutting operation.

The primary bevel with the first wedge angle qi has therefore the function of a stabilizing angle of the cutting edge preventing damage to the cutting edge when an object is being cut, i.e. a bigger wedge angle qi increases the mechan ical stability of the cutting edge. In consequence, by using a primary bevel with the wedge angle qi the second wedge angle 02 can be reduced.

The wedge angle 0i has the function to stabilize the cutting edge which allows a slim blade body in the area of the secondary bevel without effecting the cut ting performance of the blade. Moreover, the primary bevel with the wedge angle 0i allows to lift the cutting edge from the object to be cut which makes the cutting step safer, e.g. by raising the distance between skin and cutting edge a cutting into the skin can be avoided.

The second wedge angle 0 2 represents the penetration angle of the blade pen etrating in the object being cut. The smaller the penetrating angle 0 2 , the lower the force to penetrate the object being cut.

The cutting blades according to the present invention are further strengthened by adding a thick and strong tertiary bevel that has a tertiary wedge angle greater than the secondary wedge angle and by employing this tertiary bevel to split the object to be cut, thus reducing the forces acting on the thin second ary bevel.

The third wedge angle 0 3 represents the splitting angle, i.e. the angle necessary to split the object to be cut. For this function the third wedge angle 0 3 must be larger than the second wedge angle 02.

According to a preferred embodiment, the cutting blade has an asymmetric cross-sectional shape. The asymmetrical cross-sectional shape refers to the symmetry with respect to an axis which is the bisecting line of the secondary wedge angle 02 and anchored at the cutting edge. According to a preferred embodiment, the first wedge angle qi ranges from 5° to 75°, preferably 10° to 60°, more preferably 15° to 46°, and even more pref erably 20° to 45° and/or the second wedge angle 0 2 ranges from -5° to 40°, preferably 0° to 30°, more preferably 5° to 25°, and even more preferably from 10° to 15° and/or the third wedge angle 0 3 ranges from 1° to 60°, preferably 10° to 55°, more preferably 19° to 46°, and most preferably is 45°. and even more preferably 20° to 45°.

According to a further preferred embodiment, the primary bevel has a length di being the dimension projected onto the first surface of the length taken from the cutting edge to the first intersecting edge from 0.1 to 7 pm, preferably from 0.5 to 5 pm, and more preferably 1 to 3 pm. A length di < 0.1 pm is difficult to produce since an edge of such length is too fragile and would not allow a stable use of the cutting blade. It has been surprisingly found that the primary bevel stabilizes the blade body with the secondary and tertiary bevel which allows a slim blade in the area of the secondary bevel which offers a low cutting force. On the other hand, the primary bevel does not affect the cutting performance provided the length di is not larger than 7 pm.

Preferably, the length d2 being the dimension projected onto the first surface (i.e. the projection of the primary and secondary bevel) and/or the imaginary extension of the first surface taken from the cutting edge to the second inter secting edge ranges from 1 to 150 pm, more preferably from 5 to 100 pm, even more preferably from 10 to 75 pm, and in particular 15 to 50 pm. The length d2 corresponds to the penetration depth of the cutting blade in the object to be cut. In general, d2 corresponds to at least 30% of the diameter of the object to be cut, i.e. when the object is human hair which typically has a diameter of around 100 pm the length d2 is around 30 pm.

The cutting blade is preferably defined by a blade body comprising or consisting of a first material and a second material joined with the first material. The sec ond material can be deposited as a coating at least in regions of the first mate rial, i.e. the second material can be an enveloping coating of the first material or a coating deposited on the first material on the first face. The material of the first material is in general not limited to any specific mate rial as long it is possible to bevel this material.

However, according to an alternative embodiment the blade body consists only of the first material, i.e. an uncoated first material. In this case, the first material is preferably a material with an isotropic structure, i.e. having identical values of a property in all directions. Such isotropic materials are often better suited for shaping, independent from the shaping technology.

The first material comprises or consists of a material selected from the group consisting of

• metals, preferably titanium, nickel, chromium, niobium, tungsten, tan talum, molybdenum, vanadium, platinum, germanium, iron, and alloys thereof, in particular steel,

• ceramics comprising at least one element selected from the group con sisting of carbon, nitrogen, boron, oxygen and combinations thereof, preferably silicon carbide, zirconium oxide, aluminum oxide, silicon ni tride, boron nitride, tantalum nitride, TiAIN, TiCN, and/or T1B2,

• glass ceramics; preferably aluminum-containing glass-ceramics,

• composite materials made from ceramic materials in a metallic matrix (cermets),

• hard metals, preferably sintered carbide hard metals, such as tungsten carbide or titanium carbide bonded with cobalt or nickel,

• silicon or germanium, preferably with the crystalline plane parallel to the second face, wafer orientation <100>, <110>, <111> or <211>,

• single crystalline materials,

• glass or sapphire,

• polycrystalline or amorphous silicon or germanium, • mono- or polycrystalline diamond, diamond like carbon (DLC), adaman tine carbon and

• combinations thereof.

The steels used for the first material are preferably selected from the group consisting of 1095, 12C27, 14C28N, 154CM, BCrlBMoV, 4034, 40X10C2M, 4116, 420, 440A, 440B, 440C, 5160, 5Crl5MoV, 8Crl3MoV, 95X18, 9Crl8MoV, Acuto+, ATS-34, AUS-4, AUS-6 (= 6A), AUS-8 (= 8A), C75, CPM-10V, CPM-3V, CPM-D2, CPM-M4, CPM-S-30V, CPM-S-35VN, CPM-S-60V, CPM-154, Cronidur- 30, CTS 204 P, CTS 20CP, CTS 40CP, CTS B52, CTS B75P, CTS BD-1, CTS BD-30P, CTS XHP, D2, Elmax, GIN-1, HI, N690, N695, Niolox (1.4153), Nitro-B, S70, SGPS, SK-5, Sleipner, T6M0V, VG-10, VG-2, X-15T.N., X50CrMoV15, ZDP-189.

It is preferred that the second material comprises or consists of a material se lected from the group consisting of

• oxides, nitrides, carbides, borides, preferably aluminum nitride, chromium nitride, titanium nitride, titanium carbon nitride, ti tanium aluminum nitride, cubic boron nitride

• boron aluminum magnesium

• carbon, preferably diamond, poly-crystalline diamond, nano crystalline diamond, diamond like carbon (DLC), and

• combinations thereof.

The second material may be preferably selected from the group consisting of TiB , AITiN, TiAIN, TiAISiN, TiSiN, CrAI, CrAIN, AICrN, CrN, TiNJiCN and combi nations thereof.

Moreover, all materials cited in the VDI guideline 2840 can be chosen for the second material.

It is particularly preferred to use a second material of nano-crystalline diamond and/or multilayers of nano-crystalline and polycrystalline diamond as second material. Relative to monocrystalline diamond, it has been shown that produc tion of nano-crystalline diamond, compared to the production of monocrystal line diamond, can be accomplished substantially more easily and economically. Hence, also longer and larger area cutting blades can be provided. Moreover, with respect to their grain size distribution nano-crystalline diamond layers are more homogeneous than polycrystalline diamond layers, the material also shows less inherent stress. Consequently, macroscopic distortion of the cutting edge is less probable.

It is preferred that the second material has a thickness of 0.15 to 20 pm, pref erably 2 to 15 pm and more preferably 3 to 12 pm.

It is preferred that the second material has a modulus of elasticity (Young ' s modulus) of less than 1200 GPa, preferably less than 900, and more preferably less than 750 GPa. Due to the low modulus of elasticity the hard coating be comes more flexible and more elastic and may be better adapted to the sub strate, object or the contour to be cut. The Young ' s modulus is determined ac cording to the method as disclosed in Markus Mohr et al., "Youngs modulus, fracture strength, and Poisson ' s ratio of nanocrystalline diamond films", J. Appl. Phys. 116, 124308 (2014), in particular under paragraph III. B. Static measure ment of Young ' s modulus.

The second material has preferably a transverse rupture stress oo of at least 1 GPa, more preferably of at least 2.5 GPa, and even more preferably at least 5 GPa.

With respect to the definition of transverse rupture stress oo, reference is made to the following literature references:

• R. Morrell et al., Int. Journal of Refractory Metals & Hard Materials, 28 (2010), p. 508 - 515;

• R. Danzer et al. in "Technische keramische Werkstoffe", published by J. Kriegesmann, HvB Press, Ellerau, ISBN 978-3-938595-00-8, chapter 6.2.3.1 "Der 4-Kugelversuch zur Ermittlung der biaxialen Biegefestigkeit sproder Werkstoffe" The transverse rupture stress oo is thereby determined by statistical evaluation of breakage tests, e.g. in the B3B load test according to the above literature details. It is thereby defined as the breaking stress at which there is a probability of breakage of 63%.

Due to the extremely high transverse rupture stress of the second material the detachment of individual crystallites from the second material, in particular from the cutting edge, is almost completely suppressed. Even with long-term use, the cutting blade therefore retains its original sharpness.

The second material has preferably a hardness of at least 20 GPa. The hardness is determined by nanoindentation (Yeon-Gil Jung et. al., J. Mater. Res., Vol. 19, No. 10, p. 3076).

The second material has preferably a surface roughness RRMS of less than 100 nm, more preferably less than 50 nm, and even more preferably less than 20 nm, which is calculated according to

A = evaluation area

Z(x,y) = the local roughness distribution

The surface roughness RRMS is determined according to DIN EN ISO 25178. The mentioned surface roughness makes additional mechanical polishing of the grown second material superfluous.

In a preferred embodiment, the second material has an average grain size dso of the nano-crystalline diamond of 1 to 100 nm, preferably 5 to 90 nm and more preferably from 7 to 30 nm, and even more preferably 10 to 20 nm. The average grain size dso may be determined using X-ray diffraction or transmission elec tron microscopy and counting of the grains. It is preferred that the first material and/or the second material is/are coated at least in regions with a low-friction material, preferably selected from the group consisting of fluoropolymers (e.g. PTFE), parylene, polyvinylpyrrolidone, polyethylene, polypropylene, polymethyl methacrylate, graphite, diamond-like carbon (DLC) and combinations thereof.

The line intersecting the primary bevel and the secondary bevel is preferably shaped within the second material.

It is further preferred that the line between secondary and tertiary bevel is ar ranged at the boundary surface of the first material and the second material which makes the process of manufacture easier to handle and therefore more economic, e.g. the blades can be manufactured according to the process of Fig. 7a-d.

The cutting edge ideally has a round configuration which improves the stability of the blade. The cutting edge has preferably a tip radius of less than 200 nm, more preferably less than 100 nm and even more preferably less than 50 nm determined e.g. by cross sectional SEM using the method illustrated in Fig. 8.

It is preferred that the tip radius r of the cutting edge correlates with the aver age grain size dso of the hard coating. It is hereby advantageous if the ratio be tween the rounded radius r of the nano-crystalline diamond as second material at the cutting edge and the average grain size d50 of the nano-crystalline dia mond as second material r/dso is from 0.03 to 20, preferably from 0.05 to 15, and particularly preferred from 0.5 to 10.

In a further preferred embodiment, the secondary bevel comprises a further beveled region extending from the cutting edge to a third intersecting line con necting the secondary bevel and the beveled region, wherein the beveled re gion preferably has a fourth wedge angle 0 4 between the first surface and the beveled region.

It is preferred that the first face corresponds to the clearance face and the sec ond face corresponds to the rake face of the cutting blade. Hence, according to the present invention also a hair removal device compris ing a razor blade as described above is provided.

The present invention is further illustrated by the following figures which show specific embodiments according to the present invention. However, these spe cific embodiments shall not be interpreted in any limiting way with respect to the present invention as described in the claims in the general part of the spec ification.

FIG. 1 is a perspective view of a cutting blade in accordance with the pre sent invention

FIG. 2 is a cross-sectional view of a cutting blade in accordance with the present invention

FIG. 3 is another cross-sectional view of a cutting blade in accordance with the present invention with a second material

FIG. 4 is a cross-sectional view of a further cutting blade in accordance with the present invention with an additional beveled region of the sec ondary bevel

FIG. 5 is a cross-sectional view of a further cutting blade in accordance with the present invention with an additional beveled region of the sec ondary bevel with a second material

Fig. 6 is a perspective view of a first cutting blade in accordance with the present invention with a non straight cutting edge comprising curved segments

Fig. 7a-d shows a flow chart of the process for manufacturing the cutting blades

Fig. 8 is a schematic cross sectional view of a round tip showing the deter mination of the tip radius The following reference signs are used in the figures of the present application.

Reference sign list

1 blade

2 first face

3 second face

4 cutting edge

5 secondary bevel

6 tertiary bevel

7 primary bevel

9 first surface

9 ' imaginary extension of the first surface

11 second intersecting line

12 first intersecting line

15 blade body

18 first material

19 second material

20 boundary surface

60 bisecting line

61 perpendicular line

62 circle

65 construction point

66 construction point

67 construction point

260 bisecting line

In Fig.l a perspective view of the cutting blade according to the present inven tion is shown. This cutting blade 1 has a blade body 15 which comprises a first face 2 and a second face 3 which is opposed to the first face 2. At the intersec tion of the first face 2 and the second face 3 a cutting edge 4 is located. The cutting edge 4 is shaped straight or substantially straight. The first face 2 com prises a planar first surface 9 and a primary bevel 7 while the second surface 3 is segmented in two bevels. The second face 3 comprises a secondary bevel 5 and a tertiary bevel 6. The primary bevel 7 is connected via a first intersecting line 12 with the first surface 9. The secondary bevel 5 is connected to the ter tiary bevel 6 via a second intersecting line 11.

In Fig. 2, a cross-sectional view of the cutting blade according to Fig. 1 is shown. The first face 2 comprises a planar first surface 9 and a primary bevel 7 con nected by the first intersecting line 12. The primary bevel 7 has a first wedge angle qi between the imaginary extension of the first surface 9 ' and the primary bevel 7 while the second face 3 is segmented in two bevels, i.e. a secondary bevel 5 with a second wedge angle 0 2 between the first surface 9 and the sec ondary bevel 5 with a bisecting line 260 of the secondary wedge angle 0 2 . The tertiary bevel 6 has a third wedge angle 0 3 between the first surface 9 and the tertiary bevel 6 which is larger than 0 2 . The tertiary bevel 6 has a third wedge angle 0 3 which is larger than 0 2 . The primary bevel 7 has a length di being the dimension projected onto the imaginary extension of the first surface 9 ' which is in the range from 0.1 to 7 pm. The secondary bevel 5 has a length d2 being the dimension projected onto the first surface 9 and the imaginary extension of the first surface 9 ' which is in the range from 1 to 150 pm.

In Fig. 3, a further cross-sectional view of a cutting blade of the present inven tion is shown which corresponds largely with the embodiment of Fig. 2. The main difference is that the blade body 15 comprises a first material 18, and a second material 19 joined with the first material 18, wherein the first material 18 e.g. is silicon and the second material 19 e.g. is a diamond layer. The primary bevel 7 and secondary bevel 5 are located in the second material 19 while the tertiary bevel 6 is located in the first material 18. The first material 18 and the second material 19 are separated by a boundary surface which ends up with the second intersecting line 11.

In Fig. 4, a cross-sectional view of a further cutting blade according to the pre sent invention is shown. The cutting blade 1 has a blade body which comprises a first face 2 and a second face 3 which is opposed to the first face 2. The first face 2 comprises a first surface 9 and a primary bevel 7 having a length di. The second face 3 comprises a secondary bevel 5 and a tertiary bevel 6. The sec ondary bevel 5 is connected to the tertiary bevel 6 via a second intersecting line 11. Moreover, the second bevel 5 comprises a beveled region 8 which extends from the second intersecting line 11 to the cutting edge 4. Cutting edge 4 is located in the intersection of primary bevel 7 and the beveled region 8 of the secondary bevel 5. The length di of the primary bevel 7 and the wedge angle qi define the distance of the cutting edge 4 to the object to be cut in the case that the object to be cut is on the first face 2.

Fig. 5 shows a further sectional view of the cutting blade of the present inven tion which corresponds largely with the embodiment of Fig. 4. However, the embodiment of Fig. 4 has a blade body 15 which comprises a first material 18 and a second material 19. The primary bevel 7, the secondary bevel 5 and the beveled region 8 are all located in the second material 19 while the tertiary bevel 6 is located in the first material 18. The first material 18 and the second material 19 are joined along a boundary surface 20 which ends up with the sec ond intersecting edge 11.

In Fig. 6 a perspective view of a further cutting blade according to the present invention is shown. The cutting blade 1 has a blade body 15 which comprises a first face 2 and a second face 3 which is opposed to the first face 2. A cutting edge 4 is located at the intersection of the first face 2 and the second face 3. In this embodiment, the cutting edge 4 is shaped not straight but comprising curved segments. The first face 2 comprises a planar first surface 9 and a pri mary bevel 7 while the second surface 3 is segmented in a secondary bevel 5 and a tertiary bevel 6. The primary bevel 5 is connected via a first intersecting line 12 with the first surface 9 and the secondary bevel is connected to the ter tiary bevel 7 via a second intersecting line 11. The intersecting lines 11 and 12 follow the shape of the cutting edge 4 and are therefore shaped not straight but comprising curved segments as well.

In Fig. 7a to 7d a flow chart of the inventive process is shown. In a first step 1, a silicon wafer 101 is coated by PE-CVD or thermal treatment (low pressure CVD) with a silicon nitride (S13N4) layer 102 as protection layer for the silicon. The layer thickness and deposition procedure must be chosen carefully to ena ble sufficient chemical stability to withstand the following etching steps. In step 2, a photoresist 103 is deposited onto the S13N4 coated substrate and subse quently patterned by photolithography. The (S13N4) layer is then structured by e.g. CF4-plasma reactive ion etching (RIE) using the patterned photoresist as mask. After patterning, the photoresist 103 is stripped by organic solvents in step 3. The remaining, patterned S13N4 layer 102 serves as a mask for the fol lowing pre-structuring step 4 of the silicon wafer 101 e.g. by anisotropic wet chemical etching in KOH. The etching process is ended when the structures on the second face 3 have reached a predetermined depth and a continuous sili con first face 2 remains. Other wet- and dry chemical processes may be suited, e.g. isotropic wet chemical etching in HF/HNO3 solutions or the application of fluorine containing plasmas. In the following step 5, the remaining S13N4 is re moved by, e.g. hydrofluoric acid (HF) or fluorine plasma treatment. In step 6, the pre-structured Si-substrate is coated with an approx. 10 pm thin diamond layer 104, e.g. nano-crystalline diamond. The diamond layer 104 can be depos ited onto the pre-structured second surface 3 and the continuous first surface 2 of the Si-wafer 101 (as shown in step 6) or only on the continuous fist surface 2 of the Si-wafer (not shown here). In the case of double-sided coating, the di amond layer 104 on the structured second surface 3 has to be removed in a further step 7 prior to the following edge formation steps 9-11 of the cutting blade. The selective removal of the diamond layer 104 is performed e.g. by us ing an Ar/02-plasma (e.g. RIE or ICP mode), which shows a high selectivity to wards the silicon substrate. In step 8, the silicon wafer 101 is thinned so that the diamond layer 104 is partially free standing without substrate material and the desired substrate thickness is achieved in the remaining regions. This step can be performed by wet chemical etching in KOH or HF/HNO3 etchants or pref erably by plasma etching in CF4, SF 6 , or CHF3 containing plasmas in RIE or ICP mode.

In a next step 9, the diamond film is etched anisotropically by an Ar/02-plasma in an RIE system to form an almost vertical bevel 5' with a 90° corner in the diamond layer 104, which is required to form the primary bevel 7 on the first face 2 of the cutting blade as shown in step 10.

To form primary bevel 7 on the first face 2 of the cutting blade, the Si-wafer 101 is now turned to expose the first face 2 to the subsequent etching step 10 (Fig. 7b). By utilizing a physical enriched anisotropic RIE process in Ar/02-plasma the 90° corner 5' is chamfered to form primary bevel 7. Process details are disclosed for instance in EP 2 727880. Finally, in step 11 (Fig. 7c) the cutting edge formation is completed by pro cessing the Si-wafer 101 on the second face S to form secondary bevel 5 as shown in Fig. 7d. Multiple bevels may be formed by varying the process param- eters. Process details are disclosed for instance in DE 19859905 Al.

In Fig. 8, it is shown how the tip radius can be determined. The tip radius is determined by first drawing a line 60 bisecting the cross-sectional image of the first bevel of the cutting edge 1 in half. Where line 60 bisects the first bevel point 65 is drawn. A second line 61 is drawn perpendicular to line 60 at a dis tance of 110 nm from point 65. Where line 61 bisects the first bevel two addi tional points 66 and 67 are drawn. A circle 62 is then constructed from points 65, 66 and 67. The radius of circle 62 is the tip radius of the cutting edge 4.




 
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