Multi-Component Oral Care Handle With Mechanical Core Connection
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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, which restricts design options and can result in bulky or strength-compromised handles.
Innovation Solution
A multi-component handle structure comprising a core structure of a first rigid material within a through slot of an elongated handle body made of a second rigid material, with a grip cover of a resilient material applied over the handle body, allowing for mechanical connection without chemical bonding and enhancing ergonomic design and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two plastic materials are used to form a multi-component handle, then design flexibility is improved, but the requirement for chemical bonding during injection molding restricts material selection and design options
Solution Approach 1:
The patent replaces the chemical bonding mechanism with a mechanical connection system. The core structure includes a first component and a second component that connect mechanically through integrated features such as recesses, protrusions, or snap-fit mechanisms, eliminating the need for chemical bonding during injection molding and expanding material selection freedom.
Solution Approach 2:
The handle is divided into distinct modular components (core structure with first component and second component) that can be manufactured separately and assembled through mechanical connection. This segmentation allows independent material selection and manufacturing optimization for each component without being constrained by bonding requirements.
2Adaptability or versatility
If a mechanical connection is used instead of chemical bonding, then material selection freedom is improved, but the design is limited to tubular sleeve configurations that are bulky or sacrifice strength
Solution Approach 1:
The patent employs a nested configuration where the second component is positioned within or around the first component in a layered arrangement. This nesting allows for optimized load distribution and structural integrity while maintaining a compact profile, avoiding the bulkiness of simple tubular designs.
Solution Approach 2:
The patent utilizes composite construction by combining different plastic materials in the first and second components, each selected for specific mechanical properties. The mechanical connection between these composite components is designed to distribute stresses effectively, maintaining or enhancing overall handle strength despite the absence of chemical bonding.
3Ease of manufacture
If a tubular sleeve configuration is used for mechanical connection, then manufacturing is simplified, but the handle becomes bulky or loses strength
Solution Approach 1:
The patent applies local quality by providing structural reinforcement and connection features only in specific critical areas of the handle components, rather than uniformly throughout. This allows the majority of the handle to maintain a compact, ergonomic profile while ensuring strength and stability at the mechanical connection points.
Data Source
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AI summary
An oral care implement having a multi-component handle, and method of manufacturing the same. The invention can be an oral care implement having a handle which comprises at least four components constructed of different materials. The invention may also be an oral care implement having a handle comprising a core structure constructed of a first rigid material and an elongated handle body constructed of a second rigid material, the core structure disposed within a through slot of the elongated handle body; and a grip cover constructed of a resilient material that covers a front surface, a rear surface and a proximal end surface of the elongated handle body. The grip cover may be used to conceal through-holes in the elongated handle body that result from supporting the core structure during the injection molding of the elongated handle body about the core structure.