Light-emitting Oral Care Implement with Hollow Head Chamber
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Solution Overview
Problem
Existing methods for manufacturing toothbrushes with integrated light sources require additional post-processing steps, increasing costs and discomfort due to the need for thicker handles or separate light accommodations, which compromises user comfort and maneuverability.
Innovation Solution
A method where the toothbrush head and handle are molded separately, allowing for a hollow toothbrush head with a chamber to house a light source and cleaning elements, enabling efficient integration of light-emitting components without increasing thickness, using ultrasonic welding for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the toothbrush head is made thicker to accommodate a light source, then the light source can be integrated, but user comfort and maneuverability decrease
Solution Approach 1:
The light source is nested within a hollow chamber formed inside the toothbrush head structure. The chamber is created by forming the head plate and handle separately, then joining them to enclose the light source and reflective membrane within the existing external dimensions of the toothbrush head, avoiding any increase in overall thickness.
Solution Approach 2:
Instead of adding thickness in the vertical dimension to accommodate the light source, the design utilizes the internal three-dimensional space within the existing head structure. The light source is positioned in a chamber that exploits the depth and internal volume of the head plate rather than increasing external dimensions.
2Adaptability or versatility
If post-processing steps are added to incorporate a light source, then the light source can be integrated, but manufacturing cost and time increase
Solution Approach 1:
The light source and reflective membrane are positioned within the hollow chamber during the molding process itself, before final assembly. The chamber is formed as part of the head plate structure, allowing the light source to be integrated in a single molding operation rather than requiring subsequent post-processing steps to create openings or modify the structure.
Solution Approach 2:
The formation of the hollow chamber and the positioning of the light source are combined into the head plate molding process. The head plate is molded with an integrated hollow chamber that inherently accommodates the light source, merging the structural formation and light source integration into one manufacturing step.
3Adaptability or versatility
If the toothbrush head is made hollow to house light source, then light integration is achieved, but structural strength may be compromised
Solution Approach 1:
The head plate is formed as a thin-walled hollow structure that maintains sufficient structural strength through its geometry and material properties. The head plate acts as a shell structure that encloses the light source while maintaining the necessary mechanical strength for normal toothbrush use, leveraging the strength-to-weight ratio of thin-walled constructions.
Solution Approach 2:
The toothbrush is divided into separate components (head plate, handle, cleaning elements) that are molded and assembled independently. The head plate is formed as a separate hollow structure that can be optimized for both light source accommodation and structural strength, then joined to the handle through ultrasonic welding, allowing each component to be optimized for its specific function.
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 approach allows for a cost-effective, comfortable, and efficient integration of light sources within toothbrushes, enhancing cleaning efficacy and providing therapeutic benefits while maintaining a slim profile, and can be applied to various oral care implements.
Implementation Method 1
a reflective or refractive membrane positioned within the chamber
Implementation Method 2
a reflective or refractive membrane positioned within the chamber
Implementation Method 3
the head plate is ultrasonically welded to the handle
Data Source
AI summary
An oral care implement comprises a head with a plurality of cleaning elements, the head comprising a chamber. The oral care implement may include a reflective or refractive membrane positioned within the chamber. A light source may also be positioned within the chamber such that light from the light source is directed at the reflective or refractive membrane. The oral care implement may also include a head plate with a plurality of tooth cleaning elements coupled thereto, the head plate positioned over the chamber. The light from the light source may be emitted through the head plate. In some embodiments the oral care implement may be a toothbrush. In other embodiments the oral care implement may be non-toothbrush type implements that include a body forming a chamber within which the lighting components are positioned.