Method for manufacturing sheet for use in tongue plaque cleaner

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Solution Overview

Problem

Conventional tongue plaque cleaners may damage the tongue due to hooking on lingual papillae, and they face challenges in forming sufficient arc-shaped thread members for effective plaque removal, especially with limited density and difficulty in cutting small-diameter loops.

Innovation Solution

A method involving heating a sheet material with looped thread members below the melting point and cutting a part of each loop to form first and second thread members with an arc portion, ensuring efficient plaque removal without tongue damage, suitable for mass production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If looped thread members are used in tongue plaque cleaner, then plaque removal capability is improved, but tongue damage risk increases due to hooking on lingual papillae

Engineering Contradiction:

Improveplaque removal capabilityVSAvoidtongue damage risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The thread members are pre-formed with arc portions and hook shapes during manufacturing, and the sheet is pre-cut along predetermined cut lines to create the desired thread member shapes before use. This preliminary shaping ensures that the thread members have the correct geometry for effective plaque removal while minimizing tongue damage risk.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The thread members are designed with non-uniform properties: they have arc portions with specific curvatures and hook shapes at certain locations, while other portions remain linear. This local variation in geometry allows different parts of the thread member to perform different functions - the arc portions for effective plaque scraping and the hook shapes for controlled engagement with lingual papillae.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If thread members are formed by hair implantation, then manufacturing is simplified, but the number of thread members per unit area is limited to maximum 70 units/cm2

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthread member density

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent replaces the biological hair implantation process with a mechanical cutting process. Looped thread members are created through mechanical means (such as knitting or weaving), and then precisely cut along predetermined lines to form the final thread member shapes. This substitution allows for much higher density arrangements while maintaining manufacturing efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Shape

If cuts are made in looped thread members to form hook shapes, then arc-shaped thread members are created, but the cutting process becomes complex for small-diameter loops

Engineering Contradiction:

Improvethread member arc shapeVSAvoidcutting process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The cutting process is segmented into predetermined cut lines that are designed to pass through specific regions of the looped thread members. By dividing the cutting path into discrete segments or lines, the complexity of cutting small-diameter loops is reduced, and consistent arc shapes can be achieved through standardized cutting procedures.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If simple cutting is performed on looped thread members, then manufacturing is simplified, but the thread members lack sufficient arc portions for effective plaque scraping

Engineering Contradiction:

Improvecutting simplicityVSAvoidarc portion sufficiency

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The sheet is pre-cut along predetermined cut lines during the manufacturing process to create the desired arc shapes and hook forms in the thread members. This preliminary shaping action ensures that when the thread members are eventually separated and used, they already possess the correct geometry for effective plaque scraping, eliminating the need for additional shaping operations.

Inventive Principle:

Principle #10Preliminary action

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

The method enables efficient removal of tongue plaque without damaging the tongue, achieving reliable and cost-effective production of tongue plaque cleaners with enhanced thread member density and shape for effective cleaning.

Implementation Method 1

heating a sheet material having multiple looped thread members protruding from one surface of the sheet material, at a temperature below the melting point of the thread members

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS11542647B2Method for manufacturing sheet for use in tongue plaque cleaner

Publication Date: 2023.01.03 SHIKIEN CO LTD

AI summary

Provided is a method for manufacturing a sheet for use in a tongue plaque cleaner, capable of reliably cutting loops of thread members provided at a given density, and forming thread members each having a shape with an arc portion sufficient enough to scrape off tongue plaque, through steps that are simple, low-cost and suitable for mass production. A method for manufacturing a sheet 1 for use in a tongue plaque cleaner for scraping off tongue plaque, includes: a step of heating a sheet material having multiple looped thread members 2 protruding from one surface of the sheet material, at a temperature below the melting point of the thread members 2; and a step of forming first thread members 3, 8 and second thread members 4, 9 by cutting loops of the thread members 2 heated.