Multi-Component Oral Care Handle with Mechanical Interlocking
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Solution Overview
Problem
Existing oral care implements, such as toothbrushes, face limitations in design flexibility and cost-effectiveness due to the requirement for two plastic materials to chemically bond during injection molding, resulting in bulky or strength-compromised handles.
Innovation Solution
A multi-component handle structure for oral care implements is developed, comprising a core structure of transparent hard plastic, an elongated handle body of opaque hard plastic, and a grip cover of resilient material, which mechanically interlock without chemical bonding, allowing for greater design flexibility and ergonomic features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two plastic materials are used to form a multi-component handle with chemical bonding during injection molding, then design flexibility and grip functionality are improved, but material selection is restricted and manufacturing complexity increases
Solution Approach 1:
The handle is divided into multiple components (core structure, handle body, grip cover) that are manufactured separately and then assembled through mechanical interlocking rather than chemical bonding. This segmentation allows each component to be optimized independently with different materials and designs, resolving the contradiction between design flexibility and manufacturing complexity.
2Ease of operation
If two plastic materials are used to form a multi-component handle with chemical bonding during injection molding, then grip functionality is improved, but the handle becomes bulky or strength is compromised
Solution Approach 1:
The handle components are nested within each other (core structure within handle body, grip cover over handle body) forming a compact multi-layer structure. This nesting approach provides enhanced grip functionality through multiple material layers while maintaining a sleek profile and preserving overall structural strength, avoiding the bulky appearance that would result from simple side-by-side component placement.
3Adaptability or versatility
If mechanical connection is used instead of chemical bonding, then material selection freedom is improved, but the connection between components must rely on inter-fitting or shrinking methods
Solution Approach 1:
Different local regions of the handle components are designed with specific geometric features (protrusions, recesses, interference fit zones) that enable mechanical interlocking. This localized quality approach allows various materials to be connected through precisely engineered contact areas, providing material selection freedom while maintaining simple and reliable connections without requiring complex assembly mechanisms.
Data Source
AI summary
A method of forming a handle for an oral care implement. The method may include first forming a core structure out of a first hard plastic. Next, an elongated handle body may be formed out of a second hard plastic, whereby during formation the elongated handle body is made to partially surround the core structure, while leaving opposing surfaces of the core structure exposed. Finally, a grip cover may be formed out of a resilient material and positioned over at least a portion of the elongated handle body. The oral care implement handle formed by the method may include a handle having an elongated handle body and a core structure. The elongated handle body may have openings in opposing surfaces. The core structure may be partially surrounded by the elongated handle body while protruding from the openings.