Pacifier Overmolded Mouth Shield and Frame Interface
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Solution Overview
Problem
Pacifiers are susceptible to accumulating dust, debris, or other contaminants due to gaps between components, compromising cleanliness and hygiene.
Innovation Solution
A pacifier design featuring a continuous interface between the mouth shield and frame secured by an overmold, eliminating gaps and enhancing hygiene through a seamless bond between silicone and thermoplastic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional mechanical connection methods are used between frame and mouth shield, then assembly is simpler, but gaps form that accumulate dust and debris
Solution Approach 1:
The patent merges the frame and mouth shield into a single integrated component using an overmold process. The thermoplastic frame is molded, then a second material (silicone or thermoplastic elastomer) is overmolded onto it to form the mouth shield, creating a seamless continuous interface that eliminates gaps where contaminants could accumulate.
Solution Approach 2:
The patent employs composite materials by combining thermoplastic (for the frame) with silicone or thermoplastic elastomer (for the mouth shield). This composite construction allows the overmold process to create a strong, gap-free bond between dissimilar materials, achieving both structural integrity and hygiene requirements.
2Reliability
If an overmold process is used to create a continuous interface, then cleanliness and hygiene are improved, but manufacturing complexity increases
Solution Approach 1:
The overmold process performs the bonding action during the molding operation itself, rather than as a separate post-assembly step. The second material is applied and cured while the frame is still in the mold, creating the continuous interface as part of the primary manufacturing process.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (screws, clips, adhesives applied after assembly) with a chemical bonding approach through the overmold process. The curable material chemically bonds the frame and mouth shield together, eliminating the need for separate mechanical fastening operations.
3Object-affected harmful factors
If gaps are eliminated between frame and mouth shield, then contaminant accumulation is reduced, but structural complexity increases
Solution Approach 1:
The patent extracts the gap interface that traditionally exists between separate frame and mouth shield components. By removing this gap through the overmold process, the design eliminates the harmful space where dust and debris would accumulate, while the complexity is managed through process integration rather than additional structural elements.
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 design reduces contamination accumulation, facilitates automation in manufacturing, and maintains structural integrity under use, promoting cleanliness and aesthetic appeal.
Implementation Method 1
allowing the curable material to cure in the mouth shield cavity into a mouth shield at least partially secured to the frame by an overmold
Implementation Method 2
a mouth shield secured to the frame at least partially by an overmold
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C
AI summary
A pacifier may include a frame and a mouth shield secured to the frame at least partially by an overmold. An interface between the mouth shield and the frame may be continuous. A method for making a pacifier may include securing a frame in a shield mold defining a mouth shield cavity. The method may further include introducing a curable precursor material into the shield mold. The method may further include overmolding at least a portion of the curable material across at least a portion of the frame in the mold. The method may further include allowing the curable material to cure in the mouth shield cavity into a mouth shield at least partially secured to the frame by an overmold. An interface between the mouth shield and the frame may be continuous.