Method of making a lubrication box for a wet shaving implement

摘要

According to one aspect of the present invention, a lubrication box includes a first portion, a shaving aid material, and a second portion. The first portion of the lubrication box has a skin-engaging surface and at least one sidewall that, together, form a cavity. The skin-engaging surface includes at least two holes therethrough. The shaving aid material, which is optionally distributed in the cavity in a series of layers, is ultrasonically compressed into the cavity such that it at least partially fills at least one of the holes in the skin-engaging surface and at least a portion of the cavity. The second portion of the lubrication box is attached to the first portion such that the cavity is substantially closed. A gap exists between in the cavity between the shaving aid and the second portion of the lubrication box to permit the shaving aid material to expand during normal use.

主权项

1. A method of making a lubrication box, the method comprising the steps of:
providing a first portion of the lubrication box, the first portion having a skin-engaging surface and at least one sidewall that forms a cavity, the skin-engaging surface having at least two holes therethrough; distributing a first amount of shaving aid into the cavity of the first portion of the lubrication box; ultrasonically compressing the first amount of shaving aid to form a first layer of shaving aid such that the first layer fills at least a portion of one of the holes; providing a second portion of the lubrication box that covers an open end of the cavity of the first portion such that a gap remains between the ultrasonically compressed shaving aid and an inner surface of the second portion of the lubrication box; and affixing the second portion of the lubrication box to the first portion of the lubrication box.