Replaceable Toothbrush Connector for Clean, Secure Head Attachment
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Solution Overview
Problem
Existing manual toothbrush designs face challenges in cost-efficiency and ease of manufacturing, with complex connector geometries leading to cleaning issues and increased waste, while current connector solutions are not intuitive or consumer-friendly, and are difficult to manufacture and clean.
Innovation Solution
A method for manufacturing an oral care implement with a handle and head that uses injection molding for the handle, connector, and head, featuring a spring-loaded ball-snap element for secure attachment and detachment, and a simple, easy-to-clean connector design with chamfered surfaces to prevent fluid accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complex anchor/engaging mechanism with recesses is used to provide strong connection between head and handle, then the connection strength is improved, but the device becomes difficult to clean and manufacture
Solution Approach 1:
The connector is divided into separate functional elements: a cylindrical body portion that inserts into the handle hollow portion, and a separate coupling element with engagement features. This segmentation allows each component to be manufactured independently using simple injection molding, avoiding the complexity of integrated anchor mechanisms while maintaining connection strength through the coupling element's engagement features.
Solution Approach 2:
The complex engaging mechanism is extracted from the connector body and placed as a separate coupling element. The connector itself is simplified to a basic cylindrical form, while the engagement functionality is concentrated in the separate coupling element that can be easily attached. This extraction simplifies the main connector geometry for easier manufacturing and cleaning.
2Strength
If a complex anchor/engaging mechanism with recesses is used to provide strong connection between head and handle, then the connection strength is improved, but the device becomes difficult to clean
Solution Approach 1:
By segmenting the connector into a simple cylindrical body and a separate coupling element, the design eliminates recesses and complex geometries that trap cleaning fluids. The cylindrical body portion has smooth external surfaces that are easy to clean, while the coupling element's engagement features are designed to not create cleaning difficulties, allowing users to easily clean all surfaces without disassembly.
Solution Approach 2:
The complex engaging mechanism is extracted from the connector body, leaving it as a simple cylindrical form with smooth surfaces that are easy to clean. The engagement functionality is separated into a distinct coupling element, ensuring that the main connector geometry does not create cleaning difficulties while still providing strong connection through the coupling element.
3Device complexity
If small plastic hooks are used in the connector, then the attachment mechanism is simplified, but the hooks relax over time requiring active pushing back by the user
Solution Approach 1:
The spring element automatically maintains engagement pressure on the coupling element without requiring user intervention. When the head is attached to the handle, the spring element self-actuates to press the coupling element into engagement, and when detached, it automatically returns to its initial state. This self-service mechanism eliminates the need for users to actively push back relaxed hooks, making the operation intuitive and effortless.
Solution Approach 2:
The connector employs a dynamic spring element that automatically adjusts its position based on the attachment state. The spring element provides continuous engagement pressure when attached and automatically returns to its initial position when detached, creating a dynamic system that adapts to user actions without requiring manual intervention to maintain engagement.
4Adaptability or versatility
If engaging parts are provided in the brush refill, then the connection mechanism is complete, but additional manufacturing costs and complexity are incurred
Solution Approach 1:
The connection mechanism is segmented into two parts: a simple cylindrical connector body manufactured from basic plastic material, and a separate coupling element that can be manufactured independently. This segmentation allows each component to be produced using cost-effective injection molding processes, avoiding the need for complex integrated designs or expensive materials, while still providing complete connection functionality through the coupling element's engagement features.
Solution Approach 2:
The engaging parts are extracted from the main connector body and placed in a separate coupling element. This extraction allows the main connector to be manufactured as a simple cylindrical form using basic materials and standard injection molding processes, minimizing manufacturing costs. The engagement functionality is concentrated in the separate coupling element, which can be manufactured independently and attached as needed.
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 solution enables a cost-efficient, easy-to-manufacture, and user-friendly oral care implement with a secure and intuitive head attachment mechanism, reducing waste and improving hygiene by preventing fluid accumulation and allowing for easy head replacement, while maintaining a high-quality feel and balance.
Implementation Method 1
spring-loaded ball-snap element for secure attachment and detachment
Implementation Method 2
fixing the connector, preferably by gluing, welding and/or press-fitting
Implementation Method 3
fixing the connector, preferably by gluing, welding and/or press-fitting
Data Source
AI summary
A method for manufacturing an oral care implement comprising a handle, a connector, and a head repeatedly attachable to and detachable from the handle via the connector. The method includes the steps of injection molding of at least a part of the handle having a distal end and a proximal end opposite thereto and comprising a hollow portion; injection molding of at least a part of the connector having an outer lateral surface and a recess therein, the recess forming a cavity within the connector; injection molding of at least a part of the head; inserting the connector into the hollow portion of the handle and fixing the connector therein by gluing, welding, and/or press-fitting.