Two-Step Injection Molding for Oral Care Implement Grip and Cleaning
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Solution Overview
Problem
Existing oral care implements lack comfort and robustness, and current manufacturing methods are complex, necessitating a simpler method to create a more comfortable and durable oral care implement.
Innovation Solution
A method involving a two-step injection molding process where a resilient first material is applied to the handle and head of an oral care implement, followed by the injection of a second resilient material to form oral care elements, potentially including a soft tissue cleaner, ensuring a robust and comfortable design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate manufacturing steps are used to create different components (handle, head, oral care elements), then functional versatility is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the handle portion, head portion, and oral care elements into a single unitary structure formed by one-step injection molding. The first material forms the handle and head portions, while the second material forms the oral care elements, all in a single manufacturing process. This eliminates the need for separate manufacturing steps and assembly operations, resolving the contradiction between functional versatility and manufacturing complexity.
Solution Approach 2:
The single molded structure serves multiple functions: the handle portion provides grip and structural support, the head portion provides the cleaning surface, and the integrated oral care elements perform cleaning functions. All these functions are achieved through one manufacturing process, demonstrating multi-functionality that resolves the contradiction between versatility and complexity.
2Ease of operation
If resilient materials are used for comfort (grip feature, soft plastic elements, yieldable bumpers), then ease of operation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses two different resilient materials in a single injection molding process: a first resilient material for the handle and head portions providing grip comfort, and a second resilient material for the oral care elements providing soft contact. This composite material approach achieves comfort for both handling and oral care functions while maintaining manufacturing simplicity through one-step processing.
3Ease of manufacture
If a one-step injection molding process is used to form all components, then ease of manufacture is improved, but manufacturing precision and functional differentiation may be compromised
Solution Approach 1:
The patent applies different materials with different properties to different regions of the same molded part: the first resilient material is used for the handle and head portions where grip comfort is needed, while the second resilient material is used for the oral care elements where soft contact with oral surfaces is required. This local differentiation of material properties achieves functional precision within a simple one-step manufacturing process.
Data Source
AI summary
A method of manufacturing an oral care implement comprising: (a) providing a body comprising a handle portion and a head portion, the head portion having a hole extending there through from a first side to a second side; (b) providing a layer of first material on the handle portion and the head portion to form a subassembly comprising a handle section, comprising the handle portion and a first portion of the layer of first material, and a head section, comprising the head portion and a second portion of the layer of first material; and (c) then injection molding a second material onto the head section to form one or more oral care elements of the second material on the head section and a member of the second material in the hole, which member is unitary with the one or more oral care elements.