Battery Chassis Stroke Limiter for Power Toothbrush Durability
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Solution Overview
Problem
Power toothbrushes face challenges in durability and manufacturing costs due to complex designs and multiple components, which can lead to damage from axial shocks and increased assembly time, and existing frame designs are expensive and costly.
Innovation Solution
The use of elastomeric materials for multi-function components attached to a plastic injection-molded frame to absorb vibrations and axial shocks, with features like tolerance compensation leaves and battery hardstops to protect internal components, and a modular design for simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple component parts are used to hold and protect internal functional parts, then the device can withstand motor motion and provide protection, but manufacturing costs and assembly time increase
Solution Approach 1:
The patent combines multiple functions into a single integrated frame assembly that holds, secures, and protects internal functional parts including the battery, motor, and printed circuit board. This consolidation reduces the number of separate component parts while maintaining structural support and protection capabilities.
Solution Approach 2:
The frame assembly serves multiple functions simultaneously: it provides structural support for internal components, absorbs axial and lateral shocks, isolates vibrations from the motor, and protects sensitive electronics. This multi-functionality eliminates the need for separate dedicated components for each function.
2Reliability
If more component parts are used to absorb axial shocks and protect components, then device durability improves, but manufacturing costs and assembly time increase
Solution Approach 1:
The frame assembly integrates shock absorption and vibration isolation functions directly into its structure through elastomeric material components, eliminating the need for separate shock absorbers or protective components. This single integrated solution reduces manufacturing complexity and assembly steps.
Solution Approach 2:
The patent uses elastomeric materials within the frame assembly to provide shock absorption and vibration isolation properties. These elastomeric components are molded as part of the frame structure, combining protective functionality with structural support in a cost-effective manner.
3Strength
If existing frame designs are used, then structural support is provided, but manufacturing costs are high
Solution Approach 1:
The frame assembly is designed as a modular unit that can be manufactured separately and then integrated with other toothbrush components. This segmentation allows for optimized manufacturing processes and reduces overall production costs while maintaining structural integrity.
Solution Approach 2:
The patent employs elastomeric materials and specific geometric features in the frame assembly that provide structural support through material properties and design geometry rather than through complex mechanical structures, reducing manufacturing costs.
4Ease of operation
If the motor is used for vibration creation, then brushing function is achieved, but vibrations are transmitted to the user through the handle
Solution Approach 1:
The elastomeric material components within the frame assembly act as intermediaries between the motor and the handle, absorbing and dissipating vibration energy before it can be transmitted to the user. These materials serve as vibration isolation elements that decouple the motor's vibration from the handle structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances durability by isolating vibrations and shocks, reducing material and assembly costs, and simplifying the manufacturing process while maintaining effective vibration transmission for a better user experience.
Implementation Method 1
The majority of the vibration energy is directed into the elastomeric material where it dissipates before reaching the housing where it can be transferred to the user
Implementation Method 2
if the device is dropped, the weight of the battery can cause damage to other mechanical or electrical components, or the holding structure and frame, or even to the batteries themselves. By isolating the batteries within various elastomeric components that have features to absorb the axial shock and motion
Data Source
AI summary
A battery chassis with stroke limiter (70) for a power toothbrush (10) configured to improve the durability of a power toothbrush (10) and to simplify the assembly process. The battery chassis stroke limiter (70) provides a secure housing for the battery (80), while tolerance compensation leaves (71, 72), and battery hardstops (75, 76, 77) provide for drop mitigation protection and shock protection, as well as vibration mitigation.