Method of manufacturing a personal care appliance

Abstract

A personal care appliance and a method of manufacturing the personal care appliance. The method comprises forming an injection moulded component comprising a handle portion. The handle portion comprises a first handle portion, a second handle portion and a living hinge connecting the first handle portion and the second handle portion together. The method further comprises folding the handle portion at the living hinge such that the first handle portion at least partially covers the second handle portion to form a handle of the personal care appliance defining a hollow cavity. Finally, the first handle portion and the second handle portion are joined together to form the handle of the personal care appliance.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 593,578, filed October 27, 2023, the entire contents of which are incorporated herein by reference. Background Technology

[0003] A current trend in many industries is to reduce the amount of plastic used in consumer products. This has two effects: (1) it reduces costs for manufacturers; and (2) it reduces plastic in landfills. Personal care appliances such as toothbrushes, hairbrushes, and razors are typically made of plastic. Although these products are relatively small, they are numerous and, in the case of toothbrushes and razors, are frequently replaced. Therefore, there is an ongoing need to develop personal care appliances that reduce plastic use without compromising functionality. Summary of the Invention

[0004] This invention relates to a personal care device and a method for manufacturing the personal care device.

[0005] In one aspect, the invention can be a method of manufacturing a personal care appliance, the method comprising: forming an injection-molded part including a handle portion, the handle portion including a first handle portion, a second handle portion and a movable hinge connecting the first handle portion to the second handle portion; folding the handle portion at the movable hinge such that the first handle portion at least partially covers the second handle portion to form a handle of a defined hollow cavity of the personal care appliance; and joining the first handle portion and the second handle portion together.

[0006] On the other hand, the present invention can be a method of manufacturing a personal care device, the method comprising: forming a handle portion of the personal care device, the handle portion including: a first handle portion; a second handle portion; and a hinge connecting the first handle portion to the second handle portion; folding the second handle portion relative to the first handle portion around the hinge such that the second handle portion at least partially covers the first handle portion, and the first handle portion and the second handle portion define a hollow cavity; and connecting the first handle portion to the second handle portion to form a handle of the personal care device.

[0007] In another aspect, the present invention can be a personal care device comprising: an injection-molded component including: a handle portion including: a first handle portion; a second handle portion; and a movable hinge connecting the first handle portion to the second handle portion.

[0008] Further applicability of the invention will become apparent from the detailed description provided below. It should be understood that the detailed description and specific examples (although indicating preferred embodiments of the invention) are intended for illustrative purposes and not for limiting the scope of the invention. Attached Figure Description

[0009] The invention will be more fully understood from the detailed description and accompanying drawings, in which:

[0010] Figure 1 This is a front perspective view of an injection-molded component according to an embodiment of the present invention;

[0011] Figure 2 yes Figure 1 Rear perspective view of the injection-molded part;

[0012] Figure 2A It is along Figure 2 A cross-sectional view taken from line IIA-IIA;

[0013] Figure 2B It is along Figure 2 A cross-sectional view taken from line IIB-IIB;

[0014] Figure 3A It is along Figure 1 A cross-sectional view taken by line III;

[0015] Figure 3B According to the first alternative embodiment along Figure 1 A cross-sectional view taken by line III;

[0016] Figure 3C According to the second alternative embodiment along Figure 1 A cross-sectional view taken by line III;

[0017] Figure 4A It shows the method for... Figure 1 The mold in the open state is used for injection molding of injection-molded parts;

[0018] Figure 4B It shows the closed state. Figure 4A The mold;

[0019] Figures 5A-5E Is it through Figure 4A and Figure 4B A schematic cross-sectional view of the mold cut, showing the use of Figure 4A and Figure 4B Mold manufacturing Figure 1 Methods for injection molding parts;

[0020] Figures 6A-6C It shows that Figure 1 The second handle portion of the injection-molded part relative to Figure 1 The first handle portion of the injection-molded part is folded to form Figure 6C The process of making the handle of the personal care device shown;

[0021] Figure 7 It is along the embodiment of the present invention Figure 6C A cross-sectional view taken by line VII-VII;

[0022] Figure 8A It shows Figure 6C Personal care appliances in which added material is molded at the interface between the first handle portion and the second handle portion;

[0023] Figure 8B It is along Figure 8A A cross-sectional view taken from line VIII-VIII;

[0024] Figure 9 It is along Figure 6C A cross-sectional view taken by line IX-IX;

[0025] Figure 10A This is a perspective view of an injection-molded part according to another embodiment of the present invention; and

[0026] Figure 10B and Figure 10C It shows that Figure 10A The second handle portion of the injection-molded part relative to Figure 10A The first handle portion of the injection-molded component is folded to form the handle of a personal care appliance. Detailed Implementation

[0027] The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its uses.

[0028] The description of illustrative embodiments of the invention is intended to be read in conjunction with the accompanying drawings, which are considered an integral part of the entire written description. Any references to direction or orientation in the description of embodiments of the invention disclosed herein are intended only for convenience of description and not to limit the scope of the invention in any way. Relative terms (such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “upward,” “downward,” “top,” and “bottom,” and their derivatives (e.g., “horizontally,” “downward,” “upward,” etc.)) should be interpreted as referring to the orientation described subsequently or shown in the discussed drawings. These relative terms are for convenience of description only and do not require the device to be constructed or operated in a particular orientation unless expressly indicated otherwise. Terms such as “attach,” “fixed,” “connect,” “join,” “interconnect,” and the like refer to a relationship in which structures are directly or indirectly fixed or attached to each other or through intermediate structures, and to movable or rigid attachments or relationships between the two, unless expressly described otherwise. Furthermore, the features and benefits of the invention are illustrated by reference to illustrative embodiments. Therefore, the present invention should not be explicitly limited to such exemplary embodiments showing some possible non-limiting combinations of features that may exist alone or in other combinations of features; the scope of the invention is defined by the appended claims.

[0029] First refer to Figures 1-3A The illustration shows a personal care appliance 1000 according to an embodiment of the present invention. The personal care appliance 1000 may include an injection-molded component 100 and a plurality of dental cleaning elements 400 coupled to the injection-molded component 100. Figure 1 and Figure 2 In this context, the personal care appliance 1000 is shown in an unassembled or intermediate state prior to the final manufacturing process or step described below. That is, additional steps can be used to assemble the personal care appliance 1000 from... Figure 1 and Figure 2 The unassembled state shown has changed to Figure 6C The assembly state is shown. As described herein, the injection-molded part 100 can be the form in which the article takes place after injection molding but before the final manufacturing process.

[0030] In one embodiment, the personal care appliance 1000 may be a toothbrush, with non-limiting examples including... Figure 6C It was described in the text. Therefore, in Figure 1 and Figure 2In this embodiment, the dental cleaning element 400 is depicted as being coupled to the injection-molded component 100. However, the invention is not limited to this in all embodiments, and the personal care appliance 1000 may take other forms, such as a hairbrush, razor, applicator (e.g., for makeup, skin care, hair care, etc.), dental flosser, or generally any device with a handle for gripping and usable for personal care purposes. Therefore, the dental cleaning element 400 may be omitted, and other functional features may be coupled to the injection-molded component 100 for the desired end use. Alternatively, the injection-molded component 100 may be structurally modified to perform the desired personal care function without attaching separate functional features to it (e.g., in the case of a hairbrush, the hairbrush bristles may be integrally formed with the injection-molded component 100).

[0031] Injection-molded component 100 may include a handle portion 200 and a head portion 300. In some embodiments, the head portion 300 may be a separate portion from the handle portion 200. The head portion 300 may be configured for detachable coupling to the handle portion 200. Thus, in some embodiments, injection-molded component 100 may include only the handle portion 200, and the head portion 300 may be a separate injection-molded component. In such embodiments, the handle portion 200 and the head portion 300 may have mating engagement features or connection features to facilitate detachable coupling between the head portion 300 and the handle portion 200. Such features may include snap-fit ​​features, threaded fastening features, friction fit features, mating convex / concave connection features, etc.

[0032] The injection-molded part 100 may be formed from a rigid plastic material, such as, but not limited to, polyethylene, polypropylene, acrylonitrile butadiene styrene, or the like. The head portion 300 may also be referred to herein as the working portion, as the head portion 300 may be used to perform personal care functions, or may have functional features coupled thereto to perform personal care functions. For example, in the illustrated embodiment, the head portion 300 includes a dental cleaning element 400 extending therefrom, which can be used to clean the user's teeth. The head portion 300 may alternatively include a strand of dental floss, a razor blade, bristles for combing hair, an applicator for applying substances to the user's skin or hair, etc. Furthermore, the overall shape of the injection-molded part 100 may be modified from a shape shown for aesthetic reasons or to enhance the use of the injection-molded part for a particular function. For example, a razor handle may have a different shape than a toothbrush handle due to their different intended uses.

[0033] In addition, although Figure 1An injection-molded part 100 is shown, in which a dental cleaning element 400 is attached to a head portion 300. However, it should be understood that the dental cleaning element 400 can be attached to the head portion 300 in a subsequent step of the manufacturing process. Specifically, in a first step, the injection-molded part 100 can be formed. In a second step, the handle portion 200 can be manipulated as described below to form a handle of the personal care appliance 1000 suitable for gripping by a user. In a third step, the dental cleaning element 400 can be attached to the head portion 300. Therefore, although the dental cleaning element 400 is... Figure 1 and Figure 2 The tooth cleaning element 400 is shown attached to the head portion 300, but in other embodiments, the tooth cleaning element 400 may not be attached to the head portion 300 until a later step in the manufacturing process. In some embodiments, the third step may occur before the second step (i.e., the tooth cleaning element may be attached to the injection-molded part 100 before manipulating the handle portion 200 of the injection-molded part 100 to form the handle of the personal care appliance 1000). Furthermore, in other embodiments where the personal care appliance 1000 is not a toothbrush, the head portion 300 may be formed according to its desired function, or additional functional components (such as a strand of dental floss, a shaving blade, etc.) may be attached to the head portion 300 after the injection-molded part 100 has been formed.

[0034] In embodiments where the personal care appliance 1000 is a toothbrush, the term "teeth cleaning element" can be used in a general sense to refer to any structure that can be used to clean, polish, or wipe teeth and / or oral soft tissues (e.g., tongue, cheeks, gums, etc.) through relative surface contact. Common examples of "teeth cleaning elements" include, but are not limited to, bristle tufts, filamentous bristles, fiber bristles, nylon bristles, polybutylene terephthalate (PBT) bristles, spiral bristles, rubber bristles, elastomer protrusions, flexible polymer protrusions, combinations thereof, and / or structures comprising such materials or combinations. Thus, in some embodiments, any combination of these teeth cleaning elements can be used within the field of teeth cleaning elements. Furthermore, when bristles are used in one or more of the teeth cleaning elements 105, such bristles can be tapered, rounded at the ends, spiral, etc. When the dental cleaning element 400 includes bristle tufts, such bristle tufts can be attached to the head portion 300 in any manner known in the art, including staples, in-mold tufting (IMT), anchorless tufting (AFT), and modified AFT known as AMR or PTt.

[0035] In embodiments where an elastomeric material is used to form one or more of the dental cleaning elements 400, a suitable elastomeric material may include any biocompatible elastomeric material suitable for use in oral hygiene devices. To provide optimal comfort and cleaning benefits, the elastomeric material of any such dental cleaning element may have a hardness characteristic in the Shore hardness range of A10 to A70 in one embodiment, or in the Shore hardness range of A8 to A25 in another embodiment. A suitable elastomeric material is styrene-ethylene / butene-styrene block copolymer (SEBS) manufactured by GLS Corporation. However, SEBS materials from other manufacturers or other materials within and outside the stated hardness range may be used.

[0036] The handle portion 200 may include a first handle portion 210, a second handle portion 230, and a hinge 250. The hinge 250 may be a movable hinge or a one-piece hinge. The handle portion 200 may be molded in a single injection molding process, thereby forming a single, one-piece structure. The handle portion 200 may be formed of a rigid plastic material (such as the material described above for injection-molded component 100). Therefore, the first handle portion 210, the second handle portion 230, and the hinge 250 may be integrally formed of a rigid plastic material such as polyethylene, polypropylene, or acrylonitrile butadiene styrene. The first handle portion 210, the second handle portion 230, and the hinge 250 may form a single-piece structure or component. In the illustrated embodiment, the head portion 300 is also integrally formed with the handle portion 200, and therefore the head portion 300, the first handle portion 210, the hinge 250, and the second handle portion 230 may be integrally formed as a single-piece structure. In other embodiments described below, the first handle portion 210 and the second handle portion 230 may be formed separately and then joined together.

[0037] The first handle portion 210 can be directly coupled to the head portion 300. Specifically, the first handle portion 210 can be coupled to the head portion 300 via the neck portion 190 of the injection-molded component 100. In other embodiments, the head portion 300 can be formed separately and can be mechanically coupled to the handle portion 200 (or mechanically coupled to the neck portion 190) using techniques known in the art. In other words, the head portion 300 can be a replacement head configured to be detachably coupled to the handle portion 200 or detachably coupled to the neck portion 190. The first handle portion 210 can be hingedly coupled to the second handle portion 230 via a hinge 250. Therefore, the hinge 250 can be located between the first handle portion 210 and the second handle portion 230, as further described below.

[0038] The first handle portion 210 includes a first end 211 and a second end 212. A head portion 300 may be coupled to and extend directly from the first end 211 of the first handle portion 210 (or this may be achieved via the neck portion 190 as described above). The first handle portion 210 may extend along a longitudinal axis AA between the first end 211 and the second end 212. The first handle portion 210 further includes a first surface 213 and a second surface 214 opposite to the first surface 213. The first surface 213 of the first handle portion 210 may, upon assembly, form part of the front surface of the handle of the personal care appliance 1000, as further described below. The second surface 214 of the first handle portion 210 may include a first recess 215. The first recess 215 may include a first base plate 216 and a first sidewall 217 extending from the first base plate 216 to the second surface 214. In the illustrated embodiment, the first recess 215 extends along the entire length of the first handle portion 210 from the first end 211 to the second end 212. In other embodiments, the first recess 215 may exist along a portion, rather than the entire length, of the first handle portion 210. The recess 215 reduces the total material (i.e., plastic) used to form the first handle portion 210. The first handle portion 210 may have a first thickness T1 measured from the first surface 213 to the first base plate 216 of the first recess 215. The first thickness T1 may be between 1 mm and 5 mm, and more specifically between 1 mm and 4 mm, and even more specifically between 1 mm and 3 mm. The first thickness T1 of the first handle portion 210 along its length may be constant or variable within the range set forth herein.

[0039] Due to the first recess 215 in the second surface 214 of the first handle portion 210, the first handle portion 210 can have a U-shaped lateral cross-sectional area, such as Figure 2A The best view is shown in the figures. The precise U-shape including the radius between the first sidewall 217 and the first base plate 216 can be constant or variable, and can differ from the shape shown in the figures, which are intended to be illustrative. In some embodiments, the first sidewall 217 may be perpendicular to the first base plate 216. Alternatively, the first handle portion 210 may have a V-shaped lateral cross-sectional area. Of course, it should be understood that the lateral cross-sectional shape of the first handle portion 210 does not limit the invention in all embodiments, and other shapes, including the first recess 215 to facilitate an overall reduction in material, are also possible.

[0040] The second handle portion 230 may include a first end 231 and a second end 232. The second handle portion 230 may be coupled to and extend from a second end 212 of the first handle portion 230. The second handle portion 230 may extend along a longitudinal axis AA between the first end 231 and the second end 232. Thus, the longitudinal axis AA may be a common longitudinal axis of both the first handle portion 210 and the second handle portion 230. The second handle portion 230 may further include a first surface 233 and a second surface 234 opposite to the first surface 233. The first surface 233 of the second handle portion 230 may form the rear surface of the handle of the personal care appliance 1000 after assembly, as further described below. Thus, when forming the injection-molded part 100, the first surface 213 of the first handle portion 210 and the first surface 233 of the second handle portion 230 face the same direction, and the second surface 214 of the first handle portion 210 and the second surface 234 of the second handle portion 230 face the same direction. When the second handle portion 230 is folded relative to the first handle portion 210 around the hinge 250 to form the handle of the personal care appliance 1000 as described below, the first surface 233 of the second handle portion 230 can be positioned opposite to the first surface 213 of the first handle portion 210 and can together form the entire exposed outer surface of the handle of the personal care appliance 1000.

[0041] The second surface 234 of the second handle portion 230 includes a second recess 235. The second recess 235 may extend along the entire length of the second handle portion 230 or only along a portion of the second handle portion 230. The second recess 235 may include a second base plate 236 and a second sidewall 237 extending from the second base plate 236 to the second surface 234 of the second handle portion 230.

[0042] The second handle portion 230 may have a second thickness T2 measured from the first surface 233 to the first recess 235 by the first base plate 236. The second thickness T2 may be between 1 mm and 5 mm, and more specifically between 1 mm and 4 mm, and more specifically between 1 mm and 3 mm. The second thickness T2 of the second handle portion 230 may be constant or variable within the range set forth herein.

[0043] Due to the second recess 235 in the second surface 234 of the second handle portion 230, the second handle portion 230 can have a U-shaped lateral cross-sectional area, such as Figure 2BThe best view is shown in the figures. The precise U-shape including the radius between the second sidewall 237 and the second base plate 236 can be constant or variable, and can differ from the shape shown in the figures, which are intended to be illustrative. In some embodiments, the second sidewall 237 may be perpendicular to the second base plate 236. Of course, it should be understood that the transverse cross-sectional shape does not limit the invention in all embodiments, and other shapes including the second recess 235 are also possible.

[0044] A hinge 250 may be located between the second end 212 of the first handle portion 210 and the first end 232 of the second handle portion 230. The first handle portion 210 and the second handle portion 230 may be connected together by the hinge 250. The hinge 250 may be integrally formed with the first handle portion 210 and the second handle portion 230. The hinge 250, the first handle portion 210, and the second handle portion 230 may be integrally connected as a single component, referred to herein as injection-molded component 100. Thus, as described above, the hinge 250 may be a movable hinge or a one-piece hinge. The hinge 250 may define a hinge axis BB, on which the second handle portion 230 is configured to rotate, pivot, or fold relative to the first handle portion 210. The hinge axis BB may be perpendicular to the longitudinal axis AA of the first handle portion 210 and the second handle portion 230. The hinge 250 may have a third thickness T3, which is less than each of the first thickness T1 of the first handle portion 210 and the second thickness T2 of the second handle portion 230. Therefore, hinge 250 can be a movable hinge that connects the first handle portion 210 and the second handle portion 230 together, while allowing the second handle portion 230 to fold or rotate relative to the first handle portion 210 about the hinge axis BB at hinge 250.

[0045] refer to Figure 3B An alternative embodiment is shown, in which a second material 260 is laminated onto the hinge 250. The second material 260 may be an elastomeric material, such as a thermoplastic elastomer, rubber, silicone, or other elastomeric material. In some embodiments, the second material 260 may be injection molded onto the hinge 250. Alternatively, the second material 260 may be attached to the hinge 250 using other techniques, such as adhesives. The second material 260 may be located on opposing first surfaces 251 and second surfaces 252 of the hinge 250. Alternatively, the second material 260 may be located on the first surface 251 but not on the second surface, or the second material 260 may be located on the second surface 252 but not on the first surface 251. When the first handle portion 210 and the second handle portion 230 are coupled or connected together as described below, the second material 260 can facilitate improved sealing between the first handle portion 210 and the second handle portion 230.

[0046] refer to Figure 3C This illustrates another alternative embodiment. Except for the use of the suffix "a", the same reference numerals will be used herein to describe the same parts as described above. In this embodiment, the first handle portion 210a and the second handle portion 230a are formed separately from each other, rather than being formed as shown in the reference numerals. Figures 1-3A The integrated component is described herein. Furthermore, in this embodiment, hinge 250a is used to connect the second end 212a of the first handle portion 210a to the first end 231a of the second handle portion 230. In this embodiment, the first handle portion 210a and the second handle portion 230a can be formed of a rigid plastic material (such as polypropylene, polyethylene, acrylonitrile butadiene styrene, or the like). Furthermore, in this embodiment, hinge 250a can be formed of an elastomeric material (such as thermoplastic elastomers, rubber, silicone, etc.). Therefore, hinge 250a is capable of bending itself to allow the second handle portion 230a to fold or rotate relative to the first handle portion 210a to form a handle for a personal care appliance, as described herein. The hinge 250a formed of an elastomeric material is an alternative to a rigid plastic hinge 250 integrally formed with the first handle portion 210a and the second handle portion 230.

[0047] refer to Figure 4A and Figure 4B The image shows a mold 500 for forming an injection-molded part 100. The mold 500 may include a first mold half 510 and a second mold half 520. At least one of the first mold half 510 and the second mold half 520 may be positioned relative to the other as shown in the image. Figure 4A The opening position shown and as Figure 4B Move between the indicated closed positions. Figure 4A and Figure 4B In this embodiment, the second half-mold 520 is shown to be movable relative to the first half-mold 510; however, in other embodiments, only the second half-mold 510 may be movable, or both the first half-mold 510 and the second half-mold 520 may be movable. When the mold 500 is in the closed position, material may be introduced into the cavity of the mold 500 to form the injection-molded part 100. The mold 500 may then be changed to the open position, thereby allowing the injection-molded part 100 to be removed from the cavity, preparing for further processing steps (such as attaching a dental cleaning element, folding the second handle portion 230 relative to the first handle portion 210, etc.).

[0048] refer to Figures 5A-5E The description will cover the use of mold 500 to form injection molded part 100. Figure 5A The first half-mold 510 and the second half-mold 520 are shown in the open position, which is similar to... Figure 4AThe position is shown. To begin the injection molding process, the second mold half 520 is moved toward the first mold half 510, as indicated by the arrow. (Reference) Figure 5B The first mold half 510 and the second mold half 520 are shown in a closed position. In the closed position, the first mold half 510 and the second mold half 520 of the mold 500 define a mold cavity 530. The second mold half 520 may include a first injection port 521 and a second injection port 522 through which material can be introduced into the mold cavity 530 to form an injection-molded part. It should be understood that, in alternative embodiments, the second mold half 520 may include only one of the first injection port 521 and the second injection port 522, and not both. In other embodiments, the position of the injection ports may be modified relative to the first injection port 521 and the second injection port 522 shown in the figures. In other embodiments, the second mold half 520 may not have injection ports, which may instead be formed into the first mold half 510. Therefore, details regarding the number, position, structure, shape, size, etc., of the injection ports may be modified from what is shown in the figures, which are intended to be illustrative only.

[0049] The mold cavity 530 may include: a first portion 531 having a shape corresponding to the shape of the head portion 300 and the neck portion 190 of the injection molded component 100; a second portion 532 having a shape corresponding to the shape of the first portion 210 of the handle portion 200 of the injection molded component 100; a third portion 533 having a shape corresponding to the shape of the second portion 230 of the handle portion 200 of the injection molded component 100; and a fourth portion 534 having a shape corresponding to the shape of the hinge 250 of the handle portion 200 of the injection molded component 100. As described above, in some embodiments, the head portion 300 may be a separate part. In such embodiments, the mold cavity 530 may include the second portion 532, the third portion 533, and the fourth portion 334, while omitting the first portion 531.

[0050] Next, refer to Figure 5CMolten plastic material 540 is introduced into the mold cavity 530 through the first injection port 521 and the second injection port 522. The molten plastic material 430 may be stored in a molten plastic material source 580, which is operatively coupled to the first injection port 521 and / or the second injection port 522. The molten plastic material 430 may be formed from molten granules before being introduced into the mold cavity 530. As mentioned above, more or fewer injection ports may be present, and in other embodiments, the more or fewer injection ports may be located at different locations. The molten plastic material 540 may be molten polyethylene, polypropylene, acrylonitrile butadiene styrene copolymer, or other plastic materials that may be desired for forming the injection-molded part 100. Molten plastic material 540 continues to be introduced through the first injection port 521 and the second injection port 522 until the mold cavity 530 is filled with molten plastic material 540, as... Figure 5D As shown. Next, the molten plastic material 540 is allowed to cool and harden to form the injection-molded part 100.

[0051] Finally, as Figure 5E As shown, for example, by moving the second mold portion 520 relative to the first mold portion 510 or using other techniques as described herein or otherwise known, the mold 500 is changed from a closed position to an open position. Once the mold 500 is changed to the open position, the injection-molded part 100 can be removed from the mold cavity 530. In some embodiments, after the injection-molded part 100 is removed from the mold cavity 530, additional processing / manufacturing steps are performed to form the personal care appliance 1000. Figure 5E As seen, when the injection-molded part 100 is removed from the mold cavity 530, the injection-molded part 100 can be a single, integral, single part formed from rigid plastic introduced into the mold cavity 530 and allowed to cool. In some embodiments, at this stage of the process, the dental cleaning element or other functional components are not attached to the injection-molded part 100. The dental cleaning element or other functional features can be added in subsequent stages of the manufacturing process (e.g., in...). Figures 6A-6C (Before or after the steps discussed in the text) is connected to the injection-molded part 100.

[0052] refer to Figures 6A-6C The formation of personal care appliances 1000 will be further described. Figure 6A In this embodiment, the injection-molded component 100 is shown as having a dental cleaning element 400 coupled thereto. In other embodiments, Figures 6A-6CThe steps shown can be completed before the dental cleaning element 400 is attached to the injection-molded part 100. Regardless of the specific time during the manufacturing process when the dental cleaning element 400 is attached to the injection-molded part 100, the attachment of the dental cleaning element 400 to the injection-molded part 100 can be achieved using any of the techniques described herein, including stapling, AFT, AMR, PTt, injection molding of elastomer materials to form sheets, etc.

[0053] Figure 6A A personal care appliance 1000 with the injection-molded component 100 in an unassembled state is shown. Specifically, in the unassembled state, the second handle portion 230 extends from the second end 212 of the first handle portion 210, wherein the first handle portion 210 and the second handle portion 230 are integrally connected via a hinge (i.e., a movable hinge) 250. Next, as... Figure 6B As shown, the second handle portion 230 is folded, rotated, or pivoted relative to the first handle portion 210 about the hinge 250 until the second surface 234 of the second handle portion 230 contacts / adjacent to the second surface 214 of the first handle portion 210 at the interface 249 of the first handle portion 210 and the second handle portion 230, as... Figure 6C As shown. The second handle portion 230 can be folded relative to the first handle portion 210, such that the second handle portion 230 at least partially covers the first handle portion 210.

[0054] No additional actions are required to connect the first handle portion 210 and the second handle portion 230 together; the second handle portion 230 can rotate around the hinge 250 from... Figure 6C The assembly / folding state shown unfolds to Figure 6A The unassembled / unfolded state is shown. Therefore, when the second handle portion 230 is folded relative to the first handle portion 610... Figure 6C After the indicated position, the second handle portion 230 can be coupled to the first handle portion 210 at interface 249. The term "coupled" used in this sense is intended to mean that the second handle portion 230 is attached or secured to the first handle portion 210 such that the second handle portion 230 cannot be unfolded around the hinge 250 without compromising the integrity of the injection-molded part 100. Therefore, in one embodiment, once the second handle portion 230 is folded into an assembled state around the hinge 250 and subsequently coupled to the first handle portion 210, the second handle portion 230 is no longer intended to be able to fold or unfold around the hinge 250.

[0055] Once the first handle portion 210 and the second handle portion 230 have been connected or joined together, further details of which are provided below according to various alternative embodiments, the first handle portion 210 and the second handle portion 230 together form the handle 1100 of the personal care appliance 1000. The first surface 213 of the first handle portion 210 forms the front surface 1101 of the handle 1100, while the first surface 233 of the second handle portion 230 forms the rear surface 1102 of the handle 1100. Therefore, the first surface 213 of the first handle portion 210 and the second surface 233 of the second handle portion 230 together form the outer surface of the handle 1100 of the personal care appliance 1000. The first surface 213 of the first handle portion 210 and the first surface 233 of the second handle portion 230 may be flush at the interface 249 of the first handle portion 210 and the second handle portion 230 to form a comfortable handle for the user to grip during personal care functions using the personal care appliance 1000. The handle 1100 may include a coronal plane, with a longitudinal axis AA located on the coronal plane, such that the front surface 1101 of the handle 1100 is located on a first side of the coronal plane, and the rear surface 1102 of the handle 1100 is located on a second side of the coronal plane. During use of the personal care appliance 1000, the user may wrap her hand / fingers around the handle 1100 to manipulate and move the personal care appliance 1000 while performing the desired personal care function.

[0056] In one embodiment, the second handle portion 230 can be ultrasonically welded to the first handle portion 210 at interface 249. In other embodiments, the first handle portion 210 and the second handle portion 230 can be joined at interface 249 by an adhesive that can be applied to the second surfaces 214, 234 of at least one of the first handle portions 210, 230. In yet another embodiment, the first handle portion 210 and the second handle portion 230 may include connecting features that engage with each other when the second handle portion 230 is folded about a hinge 250 into an assembled state. For example, as... Figure 7As shown, the first handle portion 210 may include a first connecting feature or element 218, while the second handle portion 230 may include a second connecting feature or element 238. In the illustrated embodiment, the first connecting feature 218 is a female feature, such as a cavity or recess, while the second connecting feature is a male feature, such as a protrusion. In other embodiments, the first connecting feature 218 may be a male feature, while the second connecting feature 238 may be a female feature. The first connecting feature 218 may be located on or along the second surface 214 of the first handle portion 210, while the second connecting feature 238 may be located on or along the second surface 234 of the second handle portion 210. When the second surface 214 of the first handle portion 210 and the second surface 234 of the second handle portion 230 meet at the interface, the second connecting feature 238 (i.e., the protrusion) may be received within the first connecting feature 218 (i.e., the recess) to lock the second handle portion 230 in a folded position. Each of the first handle portion 210 and the second handle portion 230 may include a plurality of first connecting features 218 and second connecting features 238 to enhance the locking between the first handle portion 210 and the second handle portion 230.

[0057] refer to Figure 8A and Figure 8B This illustrates another technique or additional technique for connecting the first handle portion 210 and the second handle portion 230 together. Figure 8A and Figure 8B A handle 1100 of a personal care appliance 1000 is shown, wherein an additional material 290 is molded around an interface 249 between a first handle portion 210 and a second handle portion 230. As shown, the additional material 290 may be molded along the entire interface 249 between the first handle portion 210 and the second handle portion 230. The additional material 290 may be another rigid plastic material compatible with the rigid plastic material of the injection-molded part 100. Alternatively, the additional material 290 may be an elastomeric material (such as a thermoplastic elastomer, rubber, silicone, etc.) to seal the handle 1100 at the interface 249. The additional material 290 can seal the interface 249 and prevent liquids (such as water) from entering the cavity defined by the first handle portion 210 and the second handle portion, which will be further described below. The additional material 290 may be used as an alternative to the other techniques described above (ultrasonic welding, mechanical locking features, adhesives), or may be used in addition to other techniques described herein.

[0058] In another embodiment, additional material may be molded onto the handle 1100 to cover portions of each of the first handle portion 210 and the second handle portion 230, as well as portions of the interface 249. Such additional material may be another rigid plastic or elastomeric material as described above, which can enhance grip comfort during use. Therefore, the additional material is not limited to being located only at the interface 249, but may also cover additional portions of the first surface 214 of the first handle portion 210 and the first surface 234 of the second handle portion 230.

[0059] refer to Figure 7 and Figure 9 A cross-sectional view of the assembled personal care appliance 1000 is shown. When the second handle portion 230 is folded relative to the first handle portion 210 around the hinge 250 to form the handle 1100 of the personal care appliance 1000, the first handle portion 210 and the second handle portion 230 together define a handle cavity 270. Specifically, a first recess 215 of the first handle portion 210 and a second recess 235 of the second handle portion 230 together form the handle cavity 270, which is a hollow cavity located inside the handle 1100. Therefore, by forming the personal care appliance 1000 from the first handle portion 210 and the second handle portion 230 connected at the hinge 250, the handle 1100 of the personal care appliance 1000 can achieve material reduction due to the hollow handle cavity 270. Figure 9 In this embodiment, the head portion 300 is part of the injection-molded component 100, but in other embodiments, the head portion 300 may be formed separately from the injection-molded component 100, such that the head portion 300 may be detachably connected to the handle portion 200.

[0060] The handle cavity 270 can be a completely enclosed cavity, so that there is no passage from the outside of the handle 1100 to the handle cavity 270. Specifically, once folded as described above, the second surface 234 of the second handle portion 230 can abut against the second surface 214 of the first handle portion 210 along the entire interface between the second surfaces 214 and 234. Therefore, unless the handle 1100 or a portion thereof is formed of a transparent material, the handle cavity 270 can be invisible to the user or consumer. This gives the handle 1100 of the personal care appliance 1000 an aesthetic similar to standard or more conventional handles, except that the handle 1100 requires less material due to the handle cavity 270, which can be achieved by forming an injection-molded part 100 having the first handle portion 210 and the second handle portion 230 joined together by a movable hinge 250.

[0061] In the illustrated embodiment, each of the first handle portion 210 and the second handle portion 230 includes a U-shaped transverse cross-sectional shape defining a handle cavity 270. In other embodiments, one of the first handle portion 210 and the second handle portion 230 may have a U-shaped transverse cross-sectional shape with an open recess, while the other of the first handle portion 210 and the second handle portion 230 may be formed as a flat plate that closes the opening of one of the first handle portion 210 and the second handle portion 230 when the second handle portion 210 is folded, to form the handle 1100 as described above. Thus, different shapes are possible for the first handle portion 210 and the second handle portion 230, including only one of the first handle portion 210 and the second handle portion 230 defining the shape of the handle cavity 270, while the other of the first handle portion 210 and the second handle portion 230 is a flat plate.

[0062] In one embodiment, the second surface 214 of the first handle portion 210 and the second surface 234 of the second handle portion 230 may be non-linear. In the illustrated embodiment, the second surfaces 214, 234 of each of the first and second handle portions 210, 230 have concave and convex portions, which results in close surface contact between the second surfaces 214, 234 when the second handle portion 230 is folded relative to the first handle portion 210. This can enhance the barrier preventing liquid from entering the handle cavity 270. However, in other embodiments, the second surfaces 214, 234 may be linear.

[0063] refer to Figures 10A-10C A personal care appliance 2000 according to another embodiment of the present invention is shown. The personal care appliance 2000 includes an injection-molded component 2100 and a plurality of dental cleaning elements 2400 coupled to the injection-molded component 2100. More specifically, the injection-molded component 2100 includes an integrally formed handle portion 2200 and a head portion 2300, wherein the dental cleaning elements 2400 are coupled to the head portion 2300. As with the previously described embodiments, the head portion 2300 may be formed separately from the injection-molded component 2100 and may be configured for detachable coupling to the injection-molded component 2100.

[0064] In this embodiment, the handle portion 2200 includes a first handle portion 2210, a second handle portion 2230, and a hinge or movable hinge 2250 connecting the first handle portion 2210 to the second handle portion 2230. However, the position of the hinge 2250 differs from that in the previous embodiment. Specifically, in this embodiment, the first handle portion 2210 includes a first end 2211, a second end 2212, a first side 2213 extending between the first end 2211 and the second end 2212, and a second side 2214 extending between the first end 2211 and the second end 2212. The first handle portion 2210 extends along a first longitudinal axis CC extending in the direction between the first end 2211 and the second end 2212. The second handle portion 2230 includes a first end 2231, a second end 2232, a first side 2233 extending between the first end 2231 and the second end 2232, and a second side 2234 extending between the first end 2231 and the second end 2232. The second handle portion 2230 extends along a second longitudinal axis DD extending in the direction between the first end 2231 and the second end 2232.

[0065] In this embodiment, the second handle portion 2230 is positioned adjacent to the first side 2213 of the first handle portion 2210. The second handle portion 2230 extends side-by-side with the first handle portion 2210 in the axial direction (i.e., in the direction of the first longitudinal axis CC and the second longitudinal axis DD). The second side 2234 of the second handle portion 2230 extends side-by-side with the first side 2213 of the first handle portion 2210 and is positioned adjacent to the first side of the first handle portion. The second handle portion 2230 does not extend axially beyond the second end portion 2212 of the first handle portion 2210. In one embodiment, the second end portion 2212 of the first handle portion 2210 and the second end portion 2232 of the second handle portion 2230 may be aligned in the axial direction.

[0066] Hinge 2250 may be located between a first side 2213 of the first handle portion 2210 and a second side 2234 of the second handle portion 2230. Hinge 2250 includes a hinge axis EE, which is parallel to a first longitudinal axis CC of the first handle portion 2210 and a second longitudinal axis DD of the second handle portion 2230. Figure 9 B and Figure 9As shown in Figure C, the second handle portion 2230 is configured to fold, rotate, or pivot relative to the first handle portion 2210 at hinge 2250 about hinge axis EE to form a handle 2500 of the personal care appliance. The second handle portion 2230 can fold about hinge 2250 to at least partially cover the first handle portion 2210. The first handle portion 2210 and the second handle portion 2230 can then be joined or connected together using any of the techniques described above (e.g., ultrasonic welding, adhesives, interlocking connecting elements, additional materials at the interface).

[0067] In the illustrated embodiment, hinge 2250 extends only along a portion of the first side 2213 of the first handle portion 2210 and the second side 2234 of the second handle portion 2230. In other embodiments, hinge 2250 may extend along a greater length or the entire length of the first side 2213 of the first handle portion 2210 and the second side 2234 of the second handle portion 2230.

[0068] Therefore, except for the location of the hinge 2250 and the second handle portion 2230 of the injection-molded component 2100, the personal care appliance 2000 is similar to the personal care appliance 1000. The first handle portion 2210 and the second handle portion 2230 may have a shape similar to the first handle portion 210 and the second handle portion 230. Specifically, the first handle portion 2210 and the second handle portion 2230 may include recesses such that the recesses together define a hollow cavity similar to the first handle portion 210 and the second handle portion 230 of the injection-molded component 200 of the personal care appliance 1000. Once the second handle portion 2230 is folded around the hinge 2250, the handle 2500 may have a shape similar to that of the foregoing embodiment. Therefore, except for the location of the hinge 2250, Figure 7 and Figure 9 The cross-sectional view can be applied Figures 10A-10C .

[0069] As used throughout, "range" is used as an abbreviation to describe each value within the range. Any value within the range can be chosen as the endpoint of the range. Furthermore, all references cited herein are incorporated herein in their entirety. In the event of any conflict between the definitions in this disclosure and those in the cited references, this disclosure shall prevail.

[0070] While specific examples of implementing the present invention have been described, those skilled in the art will understand that many variations and arrangements of the systems and techniques described above are possible. It should be understood that other embodiments may be employed, and structural and functional modifications may be made, without departing from the scope of the invention. Therefore, the spirit and scope of the invention should be interpreted broadly as set forth in the appended claims.

Claims

1. A method for manufacturing a personal care device, the method comprising: An injection-molded component is formed including a handle portion, the handle portion including a first handle portion, a second handle portion, and a movable hinge connecting the first handle portion to the second handle portion; The handle portion is folded at the movable hinge such that the first handle portion at least partially covers the second handle portion to form a handle of the defined hollow cavity of the personal care device; as well as The first handle portion and the second handle portion are connected together.

2. The method according to claim 1, wherein, The handle portion of the injection-molded component is injection-molded into a single workpiece comprising the first handle portion, the second handle portion, and the movable hinge.

3. The method according to claim 1 or claim 2, wherein, When the first handle portion and the second handle portion are connected together, the handle portion is prevented from unfolding at the movable hinge.

4. The method according to any one of claims 1 to 3, wherein, Connecting the first handle portion and the second handle portion together includes ultrasonically welding the first handle portion and the second handle portion together.

5. The method according to any one of claims 1 to 3, wherein, Connecting the first handle portion and the second handle portion together includes molding additional material along the interface of the first handle portion and the second handle portion to lock the first handle portion and the second handle portion together.

6. The method according to any one of claims 1 to 3, wherein, The first handle portion includes a first connecting element, and the second handle portion includes a second connecting element, wherein connecting the first handle portion and the second handle portion together includes engaging the first connecting element of the first handle portion with the second connecting element of the second handle portion to lock the first handle portion and the second handle portion together.

7. The method according to any one of claims 1 to 6, wherein, After connecting the first handle portion and the second handle portion together, the hollow cavity is completely enclosed within the handle of the personal care device.

8. The method according to any one of claims 1 to 7, further comprising: The first handle portion includes a first end and a second end, the first handle portion extending along a longitudinal axis between the first end and the second end; The second handle portion includes a first end and a second end, the second handle portion extending along the longitudinal axis between the first end and the second end; and The movable hinge is located between the second end of the first handle portion and the first end of the second handle portion, such that folding the handle portion at the movable hinge includes folding the second handle portion relative to the first handle portion about a hinge axis perpendicular to the longitudinal axis.

9. The method according to any one of claims 1 to 7, further comprising: The first handle portion includes a first end, a second end, and a first side and a second side extending between the first end and the second end, the first handle portion extending along a first longitudinal axis between the first end and the second end; The second handle portion includes a first end, a second end, and a first side and a second side extending between the first end and the second end, the second handle portion extending between the first end and the second end along a second longitudinal axis parallel to the first longitudinal axis; and The movable hinge is located between a first side of the first handle portion and a second side of the second handle portion, such that folding the handle portion at the movable hinge includes folding the second handle portion relative to the first handle portion about a hinge axis parallel to the first longitudinal axis and the second longitudinal axis.

10. The method according to any one of claims 1 to 9, further comprising: The injection-molded component includes a head portion integrally formed with the handle portion; as well as The dental cleaning element is attached to the head portion of the personal care device.

11. The method according to any one of claims 1 to 9, further comprising: The head portion, which is separate from and different from the handle portion, is injection molded. The dental cleaning element is attached to the head portion of the personal care device; as well as The head portion is detachably attached to the handle portion.

12. The method according to any one of claims 1 to 11, wherein, The first handle portion extends along a first axis and includes a first U-shaped transverse cross-sectional shape, and wherein the second handle portion extends along a second axis and includes a second U-shaped transverse cross-sectional shape, the first handle portion defining a first portion of the hollow cavity, and the second handle portion defining a second portion of the hollow cavity.

13. A method of manufacturing a personal care device, the method comprising: The handle portion of the personal care device comprises: First handle section; Second handle section; and A hinge that connects the first handle portion to the second handle portion; The second handle portion is folded relative to the first handle portion around the hinge such that the second handle portion at least partially covers the first handle portion, and the first handle portion and the second handle portion define a hollow cavity; and The first handle portion is connected to the second handle portion to form the handle of the personal care device.

14. The method according to claim 13, wherein, The first handle portion and the second handle portion are made of rigid plastic material, and the hinge is made of elastomeric material.

15. The method according to any one of claims 13 to 14, wherein, The handle portion includes: The first handle portion is injection molded in the first mold cavity; The second handle portion is injection molded in the second mold cavity; and The first handle portion and the second handle portion are placed in a third mold cavity, and the hinge is injection molded in the third mold cavity so that the first handle portion and the second handle portion are connected together at the hinge.

16. The method according to any one of claims 13 to 15, wherein, The first handle portion extends along a longitudinal axis, and wherein folding the second handle portion relative to the first handle portion around the hinge includes folding the second handle portion around a hinge axis perpendicular to the longitudinal axis.

17. The method according to claim 13, wherein, The first handle portion, the second handle portion, and the hinge are integrally formed during the injection molding process, such that the handle portion is a single injection-molded component, and wherein the hinge is a movable hinge.

18. The method according to any one of claims 13 to 17, wherein, The personal care device mentioned is a toothbrush.

19. The method according to any one of claims 13 to 18, wherein, Attaching the first handle portion to the second handle portion includes at least one of the following: The first handle portion is ultrasonically welded to the second handle portion; or Additional material is injection molded along the interface between the first handle portion and the second handle portion to lock the first handle portion and the second handle portion together; or The first connecting element of the first handle portion is engaged with the second connecting element of the second handle portion to lock the first handle portion and the second handle portion together.

20. A personal care appliance, comprising: Injection-molded parts include: The handle portion includes: First handle section; The second handle section; and A movable hinge connects the first handle portion to the second handle portion.

21. The personal care appliance according to claim 20, wherein, The injection-molded component is a single-piece structure.

22. The personal care appliance according to any one of claims 20 to 21, wherein, The second handle portion is configured to fold relative to the first handle portion around the movable hinge to form a handle with a hollow cavity defined between the first handle portion and the second handle portion.

23. The personal care appliance according to any one of claims 20 to 22, further comprising: The first handle portion includes a first end and a second end; The second handle portion includes a first end and a second end; Each of the first handle portion and the second handle portion extends along a common longitudinal axis between the first end and the second end; The movable hinge is located between the second end of the first handle portion and the first end of the second handle portion, and the movable hinge has a hinge axis perpendicular to the common longitudinal axis; and The second handle portion is configured to fold relative to the first handle portion at the movable hinge about the hinge axis to form the handle of the personal care device.

24. The personal care appliance according to any one of claims 20 to 22, further comprising: The first handle portion includes a first end, a second end, and a first side and a second side extending between the first end and the second end, the first handle portion extending along a first longitudinal axis between the first end and the second end; The second handle portion includes a first end, a second end, and a first side and a second side extending between the first end and the second end. The second handle portion extends between the first end and the second end along a second longitudinal axis parallel to the first longitudinal axis. The second handle portion extends side by side with the first handle portion in the axial direction. The movable hinge is located between a first side of the first handle portion and a second side of the second handle portion, and the movable hinge has a hinge axis parallel to the first longitudinal axis and the second longitudinal axis; and The second handle portion is configured to fold relative to the first handle portion at the movable hinge about the hinge axis to form the handle of the personal care device.

25. The personal care appliance according to any one of claims 20 to 24, further comprising: The first handle portion extends along a first axis and has a first U-shaped transverse cross-sectional shape; The second handle portion extends along the second axis and has a second U-shaped transverse cross-sectional shape; and The second handle portion is configured to rotate relative to the first handle portion about the movable hinge to form a handle with a hollow cavity.

26. The personal care appliance according to any one of claims 20 to 25, further comprising: The first handle portion includes a first surface and a second surface opposite to the first surface, the second surface including a first recess; The second handle portion includes a first surface and a second surface opposite to the first surface, the second surface including a second recess; and The second handle portion is configured to rotate relative to the first handle portion about the movable hinge, such that the second surface of the first handle portion and the second surface of the second handle portion contact each other at the interface, and the first recess and the second recess form a hollow cavity.

27. The personal care appliance according to any one of claims 20 to 26, further comprising: The head portion, which is connected to the handle portion; as well as Multiple dental cleaning elements are attached to and extend from the head portion.

28. The personal care appliance according to claim 27, wherein, The first handle portion includes a first end and a second end, wherein the head portion is coupled to the first end of the first handle portion, and the second handle portion is coupled to the second end of the first handle portion via the movable hinge.

29. The personal care appliance according to any one of claims 20 to 28, wherein, The injection-molded component includes a longitudinal axis, wherein the first handle portion extends along the longitudinal axis between a first end of the first handle portion and a second end of the first handle portion, and wherein the second handle portion extends from the second end of the first handle portion in the direction of the longitudinal axis.

30. The personal care appliance according to any one of claims 20 to 29, wherein, The personal care device mentioned is a toothbrush.

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