Brush Head Section Over-Molding for Anchor-Free Cleaning Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing brush heads for oral care devices, particularly powered toothbrushes, require high material costs and are not adaptable for both manual and electric devices using anchor-free or hot tufting methods.
Innovation Solution
A method involving injection molding of a first thermoplastic insert and over-molding with a softer second thermoplastic material to create a cleaning element carrier, allowing for secure anchoring of cleaning elements without the need for anchors, suitable for both manual and electric toothbrushes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If anchor-free or hot tufting methods are used for powered toothbrushes, then hygiene and bristle pattern variability are improved, but material requirements and costs increase
Solution Approach 1:
The invention divides the brush head into modular components: a reusable insert containing the driving system and coupling elements, and a disposable brush head portion with cleaning elements. This segmentation allows the expensive anchor-free mounting system to be used only in the durable insert, while the disposable portion uses simpler, less material-intensive attachment methods.
Solution Approach 2:
The invention changes the material parameter by using a thermoplastic material for the insert that can be molded to create integrated anchoring structures. The thermoplastic material allows for heat-based anchoring of cleaning elements directly into the insert, providing secure attachment without requiring additional anchor components or excessive materials.
2Object-affected harmful factors
If anchor-free or hot tufting methods are used for powered toothbrushes, then hygiene and bristle pattern variability are improved, but manufacturing complexity increases
Solution Approach 1:
The invention merges multiple functions into the insert: the driving system, the coupling mechanism, and the anchoring structure for cleaning elements are all integrated into a single thermoplastic molded component. This consolidation simplifies manufacturing by reducing the number of separate parts and assembly steps required.
Solution Approach 2:
The insert is designed as a universal component that can be used with different brush head configurations and cleaning element arrangements. The standardized insert design allows the same anchor-free mounting technology to serve multiple product variants, reducing overall manufacturing complexity across the product line.
3Quantity of substance
If traditional anchor tufting methods are used, then material usage is reduced, but bristle pattern precision and hygiene are compromised
Solution Approach 1:
The invention replaces the mechanical anchor system with a thermal bonding system. The thermoplastic insert is heated during molding to melt and bond cleaning elements directly into place, eliminating the need for separate anchor wires or mechanical fastening components, thus reducing material usage while maintaining precision.
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 method reduces material costs and increases versatility by enabling the production of brush heads with a secure, hygienic, and anchor-free mounting system for both manual and electric toothbrushes, ensuring high precision and ease of cleaning.
Implementation Method 1
injecting a first thermoplastic material into an insert-forming mold cavity to form an insert
Implementation Method 2
injecting a second thermoplastic material into said over-molding mold cavity so that the part of the insert and the part of the at least one cleaning element which are located inside said over-molding mold cavity are over-molded by the second thermoplastic material
Implementation Method 3
the insert has a section behind which the cleaning element carrier can engage
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method for producing a brush head section for an oral care device has the following steps: injecting a first thermoplastic material into an insert-forming mold cavity to form an insert; transferring said insert into an over-molding mold cavity, wherein the insert is arranged partially inside and partially outside of said over-molding mold cavity; arranging one end of at least one cleaning element in said over-molding mold cavity; injecting a second thermoplastic material into said over-molding mold cavity so that the part of the insert and the part of the at least one cleaning element which are located inside said over-molding mold cavity are over-molded by the second thermoplastic material, which second thermoplastic material thereby forms a cleaning element carrier, and wherein the hardness of the second thermoplastic material is smaller than the hardness of the first thermoplastic material; and ejecting the resulting brush head section from said over-molding mold cavity.