Communication Element for Attachment of Oral Care Device and Method of Manufacturing the Same

Abstract

According to one aspect, a method 100 for manufacturing a communication element for an attachment assembly of an oral care device is provided, the method having a step 102 of creating an antenna assembly and a step 110 of attaching the antenna assembly to a cold formed metal ring. The step 102 of creating the antenna assembly has a step of forming a base 104 of the antenna assembly using an injection molding process, a step 106 of positioning the antenna on the base, and a step 108 of forming a cover over the base and the antenna using an injection molding process.

Description

Technical Field

[0001] The present invention relates to a communication element for an attachment of an oral care device and a method for manufacturing the same.

Background Art

[0002] More particularly, although not exclusively, the present invention relates to a communication element having an antenna assembly and a cold-formed metal ring coupled to the antenna assembly.

Summary of the Invention

Problems to be Solved by the Invention

[0003] Previously, the manufacture of communication elements involved manufacturing an antenna using a semi-automated coil winding method, which is labor-intensive and can cause damage to the antenna due to handling of the antenna. Subsequently, the chip can be soldered to the antenna by hand, which is also a labor-intensive process and requires high precision due to the small size of the chip, and errors are likely to occur. Past methods may further include covering the antenna and chip with an epoxy material to fix the elements. However, fixing the elements in this way requires care, and as a result, it can be a time-consuming process because the epoxy material is temperature-sensitive, has two parts that need to be mixed in a specific ratio, and handling of the liquid epoxy material is difficult. A further drawback of using epoxy materials relates to the negative environmental footprint of the epoxy. Past methods may further include manufacturing a metal ring using an alloy from, for example, the ZAMAK alloy family, which is formed using molten material, which requires a lot of energy for melting. Also, the metal ring thus formed may need to be coated with another material to improve the rust prevention properties of the ring. Past methods may further include adhering an epoxy-coated antenna to the metal ring, which requires the application of a certain amount of adhesive and sometimes heat to melt the adhesive. Since the adhesive is liquid, care is required when performing this process. Further drawbacks associated with the use of adhesives include that the adhesive may have a long drying time and / or may need to be dried in an oven, it may be sticky, and problems such as incorrect application of the adhesive can make handling and / or modification of the communication element difficult.

[0004] Accordingly, it is desirable to improve the manufacturing method of communication elements so that the amount of energy and thus the cost associated with the manufacture of communication elements can be reduced, and more reliable communication elements can be manufactured in a more automated manner. It is also desirable to manufacture communication elements using more environmentally friendly materials.

[0005] US2021 / 297113A1 describes a wireless communication system including a first unit, a coil antenna, a conductive ring, a second unit, and a wireless communication tag.

[0006] US2006 / 267853A1 describes an antenna coil including a hollow-core type flat coil body and a coil support member disposed between the coil body and a substrate so that the coil body is supported on the substrate surface.

Means for Solving the Problems

[0007] A communication element can form part of an oral care device, for example, to provide communication between an attachment assembly to which the communication element can be attached and a base portion of the oral care device. Another purpose of such an element is to provide an appropriate inertia ratio between the attachment assembly and the base portion of the oral care device so that stable operation of the oral care device is achieved and the oral care device can provide good results (e.g., a satisfactory cleaning result).

[0008] The manufacture of communication elements for an attachment assembly of an oral care device has conventionally been an expensive, time-consuming, and labor-intensive process, which requires a large amount of energy consumption and may require manual work for certain elements. Furthermore, conventional manufacturing methods of communication elements require strict conditions for processing due to the materials used and the processes implemented. Therefore, an object of the present invention described in this document is to overcome these drawbacks and provide more reliable and high-quality communication elements in a more automated manner, which is achieved in particular by utilizing injection molding and cold forming processes.

[0009] According to a first specific aspect, a method for manufacturing a communication element for an attachment assembly of an oral care device is provided. The method includes creating an antenna assembly by using an injection molding process to form a base of the antenna assembly, placing an antenna on the base, and using an injection molding process to form a cover over the base and the antenna. The method further includes attaching the antenna assembly to a cold-formed metal ring.

[0010] In some embodiments, the method may further include forming the cold-formed metal ring using a cold-forming process.

[0011] The cold-forming process can, in some embodiments, include a stamping process.

[0012] In some embodiments, the injection molding process used to form the cover can include an overmold injection molding process.

[0013] Attaching the antenna assembly to the cold-formed metal ring can, in some embodiments, include using a snap-fit mechanism.

[0014] In some embodiments, the method can further include forming the antenna using an air coil winding process.

[0015] According to a second aspect, a communication element for an attachment assembly of an oral care device is provided. The communication element includes an antenna assembly, which includes an injection-molded base, an antenna disposed on the base, and an injection-molded cover positioned over the base and the antenna. The communication element further includes a cold-formed metal ring coupled to the antenna assembly.

[0016] The cold-formed metal ring can, in some embodiments, be made of steel.

[0017] According to a third aspect, an attachment assembly for an oral care device is provided. The attachment assembly has a communication element as defined herein.

[0018] In some embodiments, the attachment assembly may have a brush head, a tongue cleaner, or an oral irrigation attachment.

[0019] According to a fourth aspect, an oral care device is provided. The oral care device has a base portion and an attachment assembly as defined herein.

[0020] In some embodiments, the antenna assembly further has a chip attached to the antenna, and the chip is configured to enable communication between the communication element and the base portion of the oral care device.

[0021] The chip has, in some embodiments, a radio frequency identification (RFID) chip or a near field communication (NFC) chip. According to a fifth aspect, a computer-implemented method for facilitating the manufacture of a communication element for an attachment assembly of an oral care device is provided. The method includes operating an injection molding device to form a base of the antenna assembly, operating a positioning device to position the antenna on the base, operating the injection molding device to form a cover over the base and the antenna, and operating a coupling device to couple the antenna assembly to a cold-formed metal ring.

[0022] According to a sixth aspect, a system for manufacturing a communication element for an attachment assembly of an oral care device is provided. The system has a base forming device configured to form a base of the antenna assembly using an injection molding process, an antenna positioning device configured to position the antenna on the base, a cover forming device configured to form a cover over the base and the antenna using an injection molding process, and a coupling device configured to couple the antenna assembly to a cold-formed metal ring.

[0023] These and other aspects will become apparent from the embodiments described below and will be described with reference to the embodiments.

Brief Description of the Drawings

[0024]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Modes for Carrying Out the Invention

[0025] Hereinafter, exemplary embodiments will be described with reference to the following drawings, which are merely exemplary.

[0026] According to a first aspect, the present invention provides a method of manufacturing a communication element for an attachment assembly of an oral care device. FIG. 1 is a flowchart of an example of such a method 100. The method 100 has, in step 102, a step of creating an antenna assembly by forming a base of the antenna assembly using an injection molding process in step 104. The base can be manufactured using any type of injection molding process, such as insert molding, overmold molding, etc. In some examples, the injection molding can have one or more of the steps of melting a plastic resin, pushing the resulting liquid plastic resin into a mold, and cooling the liquid plastic resin so that the resin solidifies. The injection molding can use, for example, a material including a thermoplastic material. Thermoplastic materials that can be used in the injection molding process described herein can include acrylonitrile butadiene styrene, polyoxymethylene, polypropylene, etc.

[0027] The step of creating the antenna assembly further has, in step 106, a step of placing the antenna on the base. In some examples, the antenna can have an antenna coil (e.g., a coil of wire forming the antenna). In some examples, the antenna is placed on the base by a machine. In some examples, the antenna can be placed around a rim protruding from the base, which helps to fix the antenna to the base. In other words, the rim can support or hold the antenna on the base. For example, the antenna is pushed onto the rim of the antenna assembly. In some examples, the rim helps to prevent damage or deformation of the antenna. In some examples, the position of the rim on the antenna assembly can define the position of the antenna relative to the antenna assembly and thus the position of the antenna relative to any product (e.g., an oral care device) to which the antenna assembly can be attached. The rim may also assist in a subsequent step of forming a cover over the base. The antenna can be manufactured from a metallic material. For example, the antenna can be manufactured from copper, etc.

[0028] The step of creating the antenna assembly further includes, at step 108, forming a base and a cover over the antenna using an injection molding process. In some embodiments, the injection molding process used to form the cover can have an overmold injection molding process. Overmolding is an injection molding process that includes molding a first material over a second material to form one product. Thus, forming the cover of the antenna assembly is advantageous for several reasons, including that multiple parts (e.g., the base and cover of the antenna assembly) can be combined in a seamless manner, improving the durability and / or strength of the product and thus the quality and reliability of the product. For example, the cover can be configured to protect the antenna from impact and / or prevent a substance (e.g., water) from contacting the antenna. In some examples, based on the materials used during the overmolding process, the antenna assembly can exhibit improved shock absorbency (e.g., when using a resin with rubber during the overmolding process). In some examples, the overmold can use a thermoplastic material. For example, a highly flowable thermoplastic resin such as polypropylene (e.g., polypropylene random copolymer) can be used in the overmold. The advantages of using polypropylene include, for example, the chemical resistance, elasticity, fatigue resistance, and electrical resistance of polypropylene.

[0029] Method 100 further includes, at step 110, attaching an antenna assembly to the cold-formed metal ring. In some embodiments, attaching the antenna assembly to the cold-formed metal ring may involve using a snap-fit mechanism. Using a snap-fit mechanism to attach the antenna assembly to the metal ring can enable the two elements (i.e., the antenna assembly and the metal ring) to be easily, reliably, and / or securely connected. In some examples, the metal ring can have protrusions and / or grooves that allow the antenna assembly to be securely connected to the metal ring. For example, the antenna assembly can be configured to fit onto the protrusions of the metal ring (see, e.g., FIG. 3). In some examples, the metal ring has grooves, and the antenna assembly can have corresponding protrusions such that when the antenna assembly is attached to the metal ring, the protrusions of the antenna assembly fit into the grooves of the metal ring. In some examples, the antenna assembly can be adhered to the cold-formed metal ring, screwed onto the cold-formed metal ring, etc.

[0030] Figure 2 is a flowchart of a further example of a method 200 for manufacturing a communication element for an attachment assembly of an oral care device. Method 200 has the steps of method 100. In some embodiments, method 200 may further include, at step 202, forming a cold formed metal ring using a cold forming process. The cold forming process can, in some embodiments, have a stamping process. The stamping process, in some examples, has cutting a piece of material from a sheet of material (e.g., a plate). In some examples, the stamping process may have forming a specific shape from the sheet material (e.g., a piece of material cut out from the sheet material). In some examples, when the metal ring is formed, a cut-out portion (see, e.g., cut-out portion 316 in FIG. 3) is cut from the cold formed metal ring 304. In other examples, a cut-out portion (e.g., cut-out portion 316 in FIG. 3) may be formed during the stamping process. The metal ring may have one or more cut-out portions. The advantage of using a cold forming process to form the metal ring is that heating is not required, thus reducing the energy required for manufacturing the metal ring and simplifying the manufacturing equipment required for manufacturing the metal ring (e.g., equipment for handling molten metal material is not required). Other advantages of cold forming the metal ring include obtaining a better surface finish and / or better reproducibility, and minimizing the problem of contamination, etc.

[0031] In some embodiments, method 200 may further have, at step 204, forming an antenna using an air coil winding process. Thus, the antenna can have an air coil. Advantageously, the air coil winding can be fully automated, thereby minimizing any handling of the antenna and thus also minimizing the possibility of damage to the antenna. An air coil is a coil of a material that does not have a magnetic core (e.g., a bundle or winding of copper wire).

[0032] Figure 3 shows an example of a communication element 300 for an attachment assembly of an oral care device, its elements, and how the elements are attached. The communication element 300 has an antenna assembly 302 and a cold-formed metal ring 304 coupled to the antenna assembly. The antenna assembly 302 has an injection-molded base 306, an antenna 308 disposed on the base, and an injection-molded cover 310 disposed on the base and on the antenna. In some examples, the base 306 may be referred to as a carrier ring. In some examples, the cover 310 can cover (span across) the entire antenna 308. In other examples, the cover 310 can cover a portion of the antenna 308. In some examples, the base 306 can be circular. In some examples, the base 306 can have a non-circular shape such as an ellipse or a square. In some examples, the base 306 can be in an annular form. In some examples, the base 306 can have a rim. For example, if the base 306 is annular in shape, the rim may project from the inner circumference 314 of the base. In some examples, the rim can extend around all or part of the circumference or outer perimeter of the base 306. In some examples, a chip 312 can be connected to the antenna 308. In some examples, the chip can be connected to the antenna using a soldering process, a welding process, or the like. The cover 310 can be positioned over part or all of the chip 312. In some examples, the base 306 can have a groove, such that the groove can accommodate the chip 312. In some examples, the groove may also be referred to as a pocket (where the chip 312 fits). For example, the groove can hold the chip 312 in a predetermined position and / or protect the chip. In some examples, the groove can be configured to protect the connection (e.g., soldering or welding connection) between the antenna 308 and the chip 312. In some examples, the metal ring 304 has a circular shape. In other examples, the metal ring 304 can have an ellipse, a square, or the like. In some examples, the metal ring 304 is in an annular shape.In some examples, the metal ring 304 can have the same or a similar shape as the base. In some examples, the metal ring 304 can have a cutout portion 316. The cutout portion 316 can be shaped such that the metal ring and thus the communication element can fit together with an adjacent element (e.g., when the communication element is attached to an attachment assembly of an oral care device). For example, the metal ring and thus the communication element can form part of an attachment assembly of an oral care device, where the cutout portion of the metal ring can be configured to connect to an adjacent element of the attachment assembly.

[0033] In some examples, the metal ring 304 has a protrusion 318. The antenna assembly 302 is configured to fit onto the protrusion 318 of the metal ring, thereby enabling connection between the antenna assembly and the metal ring. In some examples, the metal ring 304 can have more than one protrusion as opposed to a single protrusion 318. FIG. 4 shows an illustrative view of an example cold-formed metal ring 400 having four protrusions 404 and a cutout portion 402. Advantageously, weight reduction of the metal ring can be achieved using a metal ring having more than one protrusion as opposed to a single protrusion (such as shown by protrusion 318 in FIG. 3). In some examples, the low weight of the metal ring and thus the communication element can be beneficial when the communication element is attached to an attachment assembly of an oral care device. For example, the frequency of vibration of the brush head may require that the attachment assembly be within a defined weight range so that the frequency of the brush head of the oral care device is within a defined (e.g., desired) frequency range.

[0034] In some embodiments, the attachment assembly can have a brush head, a tongue cleaner, or an oral irrigation attachment.

[0035] In some embodiments, the cold-formed metal ring 304 comprises steel. In some examples, the cold-formed metal ring 304 can comprise stainless steel, which advantageously can reduce corrosion of the metal ring. In other examples, the metal ring 304 may be formed of a metal such as iron, copper, brass, or a metal alloy.

[0036] In some embodiments, the antenna assembly 302 can further comprise a chip 312 attached to the antenna 308, the chip being configured to enable communication between the communication element 300 and a communication element disposed in the base portion of the oral care device. In some examples, the chip 312 is attached to the antenna 308 using laser soldering or the like. In some examples, the chip 312 can have one or more solder pads (e.g., on the upper surface of the chip). The solder pads can have solder. By placing the end of the antenna (e.g., the loose end of the antenna coil) on the solder pad of the chip 312, the antenna can be attached to the chip. In some examples, each end of the antenna coil can be placed on the solder pad of the chip 312. For example, each end of the antenna can be placed on a different solder pad on the chip 312. Thereafter, one or more pins (e.g., a molten pin) can press the end of the antenna against the solder pad of the chip. As a result of the molten pin pressing down on the end of the antenna, the antenna and / or the solder pad is heated, and as a result, the antenna can be fixed to the chip. For example, the heat caused by the molten pin pressing down on the antenna causes a portion of the solder pad to melt, and when the molten portion of the solder pad solidifies, a bond is formed between the antenna and the solder pad (and thus the chip 312). This method is sometimes referred to as a thermocompression bonding method.

[0037] In some embodiments, the chip 312 comprises a radio frequency identification (RFID) chip or a near field communication (NFC) chip.

[0038] In some examples, communication between the communication element 300 and the base portion of the oral care device (e.g., using an RFID chip or an NFC chip) can enable the identification of the attachment assembly by the base portion of the oral care device. The base portion of the oral care device can be configured to control the operation of the attachment assembly, such as the vibration speed of the brush head. As a result of the communication between the communication element 300 and the base portion of the oral care device, the base portion can be configured to change settings related to the operation of the attachment assembly. Thus, different attachment assemblies can be attached to the base portion of the oral care device, where each of the attachment assemblies is caused to operate in a different manner based on the identification of the attachment assembly by the base portion of the oral care device.

[0039] In some examples, the communication between the communication element 300 and the base portion of the oral care device can be used to improve the safety of the oral care device. The base portion can have a handle portion, which can have a drive assembly that vibrates the drive shaft through a specific angle. The base portion can have a battery or the like. For example, the base portion can be configured to be inoperable (e.g., the motor of the base portion cannot receive power) until the attachment assembly is attached to the base portion.

[0040] According to a third aspect, an attachment assembly for an oral care device is provided, the attachment assembly having the communication element 300 described herein. FIG. 5 shows a schematic view of an example of an attachment assembly 500 for an oral care device according to various embodiments. The attachment assembly 500 has the communication element 300. In some examples, the attachment assembly can have a head portion 504 that can include a brush head, a tongue cleaner, etc. In some examples, the attachment assembly 500 can have a connection portion (not shown) configured to connect the attachment assembly to the base of the oral care device. The connection portion can include any suitable connection mechanism for attaching the attachment assembly 500 to the base of the oral care device. Such connection mechanisms will be known to those skilled in the art. However, it should be understood that in other embodiments, the head portion 504 and / or the connection portion can be omitted.

[0041] According to a fourth aspect, an oral care device is provided, the oral care device having a base portion and an attachment assembly as described herein. FIG. 6 is a schematic view of a further example of an oral care device 600 according to various embodiments. The oral care device 600 has a base portion 602 and an attachment assembly. The attachment assembly can have the attachment assembly 500 described above. The attachment assembly 500 can be connected or attached to the base portion 602, for example, using a connection portion that can interact with a complementary connection mechanism of the base portion 602. The attachment assembly can be attached to the end of a drive shaft 604.

[0042] According to a fifth aspect, there is provided a computer-implemented method 700 for facilitating the manufacture of a communication element 300 for an attachment assembly of an oral care device. Method 700 has, at step 702, the step of operating an injection molding device to form a base 306 of an antenna assembly. The injection molding device can be used for mass production of manufactured parts (e.g., the base of the antenna assembly). The injection molding device can supply a plastic resin to a screw unit. The screw unit may be configured to heat the resin to a liquid state. When the resin becomes liquid, the resin can be injected (e.g., pressed) into an injection molding die cavity under high pressure (e.g., 1000 bar, 1000 bar or more, 1500 bar, etc.). Next, a cooling process is performed, whereby the liquid resin becomes solid (e.g., freezes). Once the resin has solidified, the mold is pushed out of the molding cavity. For example, ejector pins can be used to push the injection molded product (e.g., the base) out of the mold.

[0043] Method 700 further has, at step 704, the step of operating a positioning device to position an antenna 308 on the base. The positioning of the antenna on the base can be performed automatically, for example, using robotic handling. For example, a mechanical gripper can be connected to an arm, and the gripper is configured to pick up the antenna and place it on the base.

[0044] Method 700 further has, at step 706, the step of operating the injection molding device to form a cover 310 over the base and the antenna.

[0045] Method 700 further has, at step 708, an operation of activating a coupling device to couple an antenna assembly to the cold-formed metal ring 304. This step can be performed in an automated manner, for example, using robotic handling. The antenna assembly can be disposed across the cold-formed metal ring. The antenna assembly and the cold-formed metal ring can be pressed together. The antenna assembly and the cold-formed metal ring can be held together using a snap-fit mechanism.

[0046] Devices 702, 704, 706, 708 may be disposed in a production hall, may have their own frames (e.g., separated from each other), and may operate automatically using individual control systems. Each of devices 702, 704, 706, 708 may have a safety cabinet to ensure the safety of a person in the vicinity of the device. Elements of the invention disclosed herein (e.g., base portion 306) can be passed between devices 702, 704, 706, 708 using an automatic conveying system (e.g., a belt conveyor). In some examples, each of devices 702, 704, 706, 708 can perform its function independently of other devices. For example, an injection molding device can be configured to form a base of the antenna assembly, and then the base is conveyed (e.g., using a belt conveyor) to a positioning device, as a result of which the antenna is disposed on the base. In other examples, a base is formed using an injection molding device, and then at some predetermined time later, an antenna can be attached to the base (e.g., the base can be removed from the injection molding device and later input to a positioning device).

[0047] According to a sixth aspect, a system 800 for manufacturing a communication element 300 for an attachment assembly of an oral care device is provided. The system includes a base forming device 802 configured to form a base 306 of an antenna assembly using an injection molding process, an antenna positioning device 804 configured to position an antenna 308 on the base, a cover forming device 806 configured to form a cover 310 over the base and the antenna using an injection molding process, and a coupling device 808 configured to couple the antenna assembly to a cold formed metal ring 304.

[0048] Another aspect of the invention relates to a computer program product. FIG. 9 is a schematic diagram of a non-transitory computer-readable medium 902 that communicates with a processor 904. In some embodiments, a computer program product is provided that includes a non-transitory computer-readable medium 902 having computer-readable code embodied therein, the computer-readable code being configured to cause a computer or processor, when executed by a suitable computer or processor 904, to perform the steps of the methods disclosed herein.

[0049] The processor 904 can have one or more processors, processing units, multi-core processors, or modules configured or programmed to control the elements of the system 800 in the manner described herein. In a particular implementation, the processor 904 can include a plurality of software and / or hardware modules, each configured to perform or for performing individual or multiple steps of the methods described herein.

[0050] As used herein, the term "module" is intended to include hardware elements such as a processor or an element of a processor configured to perform a particular function, or software elements such as a set of instruction data having a particular function when executed by a processor.

[0051] It should be understood that embodiments of the present invention apply also to a computer program adapted to carry out the invention, in particular a computer program on or in a carrier. The program can be in source code, object code, an intermediate code between source and object code such as a partially compiled form, or any other form suitable for use in implementing a method according to embodiments of the present invention. It should also be understood that such a program can have many different architectural designs. For example, the program code implementing the functions of the method or system according to the present invention can be subdivided into one or more subroutines. Many different ways of distributing functions among these subroutines will be apparent to those skilled in the art. The subroutines can be stored together in one executable file to form a self - contained program. Such an executable file can have computer - executable instructions, for example, processor instructions and / or interpreter instructions (e.g., Java interpreter instructions). Alternatively, one or more or all of the subroutines can be stored in at least one external library file and can be linked statically or dynamically, for example, to the main program at run - time. The main program includes at least one call to at least one of the subroutines. The subroutines can also have function calls to each other. Embodiments regarding computer program products have computer - executable instructions corresponding to at least one respective processing step of the methods defined herein. These instructions can be subdivided into subroutines and / or stored in one or more files that are linked statically or dynamically. Another embodiment regarding computer program products has computer - executable instructions corresponding to at least one respective means of the systems and / or products defined herein. These instructions can be subdivided into subroutines and / or stored in one or more files that are linked statically or dynamically.

[0052] The carrier of a computer program can be any entity or device capable of carrying the program. For example, the carrier can include a data storage device such as a ROM, e.g., a CDROM or a semiconductor ROM, or a magnetic recording medium such as a hard disk. Further, the carrier can be a transmissible carrier such as an electrical signal or an optical signal, which can be transmitted via an electrical or optical cable or wirelessly or by other means. When the program is embodied in such a signal, the carrier can be constituted by such a cable or other device or means. Alternatively, the carrier can be an integrated circuit in which the program is embedded, and the integrated circuit is configured to execute the relevant method or is used in the execution.

[0053] Modifications to the disclosed embodiments can be understood and implemented by those skilled in the art who practice the principles and techniques described herein, upon consideration of the figures, the disclosure, and the appended claims. In the claims, the term "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. One processor or other unit can perform the functions of a plurality of items recited in the claims. The mere fact that certain means are recited in mutually different dependent claims does not indicate that a combination of these means cannot be used advantageously. A computer program can be stored or distributed in a suitable medium, such as an optical storage medium or a solid-state medium, supplied together with or as part of other hardware, but can also be distributed in other forms, such as via the Internet or other wired or wireless communication systems. Any reference signs in the claims should not be construed as limiting the scope of the invention.

Claims

1. In a method for manufacturing a communication element for an attachment assembly of an oral care device, The base of the antenna assembly is formed using an injection molding process. An antenna is placed on the base, and The steps include creating an antenna assembly by forming a cover over the base and the antenna using an injection molding process so as to enclose at least a portion of the antenna, A method comprising the step of attaching the antenna assembly to the cold-formed metal ring.

2. The method according to claim 1, further comprising the step of forming the cold-formed metal ring using a cold forming process.

3. The method according to claim 2, wherein the cold forming process includes a stamping process.

4. The method according to any one of claims 1 to 3, wherein the injection molding process used to form the cover comprises an overmolding injection molding process.

5. The method according to any one of claims 1 to 4, wherein the step of attaching the antenna assembly to the cold-formed metal ring is to use a snap-fit ​​mechanism.

6. The method according to any one of claims 1 to 5, further comprising the step of forming the antenna using an air coil winding process.

7. A communication element for an attachment assembly of an oral care device, An antenna assembly, Injection-molded base, The antenna located on the aforementioned base, An antenna assembly including a base and an injection-molded cover positioned on the antenna so as to enclose at least a portion of the antenna, A communication element having a cold-formed metal ring coupled to the antenna assembly.

8. The communication element according to claim 7, wherein the cold-formed metal ring is made of steel.

9. An attachment assembly for an oral care device, wherein the attachment assembly has a communication element as described in claim 7 or 8.

10. The attachment assembly according to claim 9, further comprising a brush head, a tongue cleaner, or an oral cleaning attachment.

11. Oral care device, The base part, An oral care device having the attachment assembly described in claim 9 or 10.

12. The oral care device according to claim 11, wherein the antenna assembly of the attachment assembly further comprises a chip attached to the antenna, the chip enabling communication between the communication element and the base portion of the oral care device.

13. The communication element according to claim 12, wherein the chip has a radio frequency identification (RFID) chip or a near-field communication (NFC) chip.

14. In a computer implementation method for facilitating the manufacture of communication elements for attachment assemblies of oral care devices, The steps include operating an injection molding machine to form the base of the antenna assembly, The steps include: activating the positioning device to position the antenna on the base, The steps include operating an injection molding apparatus to form a cover over the base and the antenna so as to enclose at least a portion of the antenna, A method comprising the steps of operating a coupling device to couple the antenna assembly to the cold-formed metal ring.

15. A system for manufacturing communication elements for attachment assemblies of oral care devices, A base forming apparatus that uses injection molding to form the base of an antenna assembly, An antenna positioning device for positioning the antenna on the base, A cover forming apparatus that uses injection molding to form a cover over the base and the antenna so as to enclose at least a portion of the antenna, A system comprising a coupling device for bonding the antenna assembly to a cold-formed metal ring.

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