Metal Sheet Motion Transmitter for Oral Care
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Solution Overview
Problem
Existing oral care implements with motion transmitter elements face challenges in manufacturing efficiency and cost due to the use of injection molded plastic materials, which require cooling time and are less rigid compared to metal-based solutions.
Innovation Solution
A motion transmitter element made from a punched and bent metal sheet with specific cross-sectional shapes, such as L-shape or U-shape, is used, which is lightweight and rigid, eliminating the need for cooling time in manufacturing and providing mechanical stability through magnetic or mechanical coupling with a drive shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If injection molded plastic materials are used for the motion transmitter element, then manufacturing complexity is reduced, but manufacturing efficiency decreases due to cooling time requirements and rigidity is insufficient
Solution Approach 1:
The patent changes the material parameter from plastic to metal sheet, which fundamentally alters the manufacturing process from injection molding (requiring cooling time) to punching and bending (no cooling required). This parameter change resolves the contradiction by eliminating the cooling time bottleneck while maintaining ease of manufacture through simple sheet metal forming operations.
Solution Approach 2:
The motion transmitter element is formed as a composite structure from a metal sheet with non-flat cross-sectional shapes (L-shape, U-shape, or S-shape sections). This composite geometric structure provides both the manufacturing efficiency of sheet metal forming and the rigidity required for motion transmission, resolving the contradiction between ease of manufacture and productivity.
2Ease of manufacture
If injection molded plastic materials are used for the motion transmitter element, then manufacturing cost is reduced, but rigidity and mechanical stability are insufficient
Solution Approach 1:
The patent applies curvature and non-flat cross-sectional shapes (L-shape, U-shape, S-shape) to the metal sheet portions. These curved and folded geometries provide structural rigidity and mechanical stability while still using relatively inexpensive metal sheet material. The curved sections act as stiffening elements that maintain the element's shape under operational loads.
Solution Approach 2:
The patent changes the material parameter from plastic to metal sheet, which inherently provides superior rigidity and mechanical stability. Combined with the non-flat cross-sectional geometry, this material parameter change resolves the contradiction between material cost and rigidity by using cost-effective metal sheet forming processes to create a structurally superior component.
3Adaptability or versatility
If a multi-component motion transmitter element is used, then manufacturing flexibility is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functional components into a single integrated metal sheet element. The motion transmitter element is formed from one punched and bent metal sheet that simultaneously provides motion transmission, structural support, and coupling functions. This merging reduces device complexity while maintaining manufacturing flexibility through the versatility of sheet metal forming processes.
Solution Approach 2:
The metal sheet is segmented into different functional zones with non-flat cross-sectional shapes at specific locations. These segmented sections (L-shape, U-shape, or S-shape) perform different functions within the single element, providing manufacturing flexibility for assembly while maintaining overall structural simplicity. The segmentation is achieved through punching and folding operations on the metal sheet.
Data Source
AI summary
An oral-care implement having a housing extending along a longitudinal-extension direction, a functional element mounted at the housing for driven motion relative to the housing, a motion-transmitter element disposed within the housing and extending along the longitudinal-extension direction. The motion-transmitter element has a first coupling portion coupled with the functional element. The motion-transmitter element has a metal-sheet portion made from a punched and bent metal sheet. The metal-sheet portion can have at least one section having a non-flat cross-sectional shape in a plane perpendicular to the longitudinal-extension direction, such as an L-shape, or U-shape, or S-shape.