US 11,945,130 B2
Methods of forming a razor blade assembly
Michel Denis Hamelin, West Roxbury, MA (US); and Craig Stephen Vickery, Reading, MA (US)
Assigned to The Gillette Company LLC, Boston, MA (US)
Filed by The Gillette Company LLC, Boston, MA (US)
Filed on May 3, 2021, as Appl. No. 17/306,702.
Prior Publication US 2022/0347875 A1, Nov. 3, 2022
Int. Cl. B26B 21/40 (2006.01); B23K 26/06 (2014.01); B23K 26/082 (2014.01); B23K 31/00 (2006.01); G02B 13/00 (2006.01); G02B 13/22 (2006.01)
CPC B26B 21/4068 (2013.01) [B23K 26/0626 (2013.01); B23K 26/0648 (2013.01); B23K 26/0652 (2013.01); B23K 26/0665 (2013.01); B23K 26/082 (2015.10); B23K 31/003 (2013.01); B26B 21/4012 (2013.01); G02B 13/0005 (2013.01); G02B 13/22 (2013.01)] 29 Claims
OG exemplary drawing
 
1. A method of joining a razor blade to a blade support to form a razor blade assembly, the method comprising:
directing a laser beam having an adjustable power output at an upper surface of the razor blade; and
while advancing the laser beam along the razor blade:
a) applying the laser beam at a first power output to the razor blade for a first time period to form a first portion of a weld area;
b) reducing the first power output of the laser beam to a second power output; and
c) applying the laser beam at the second power output to the razor for a second time period to form a second portion of the weld area joining the razor blade to the blade support, wherein the weld area formed in steps a) and c) has at least one of a ratio of depth/width that is greater than about 2/1 and a ratio of length/width that is greater than about 5/1;
wherein a ratio of the second time period/first time period is greater than about 5/1; and
wherein any protrusions formed on the upper surface during steps a) and c) have a height above the upper surface that is no more than 0.025 mm.