Toothbrush Head With Dual Flexible Wings For Injection Molding
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Solution Overview
Problem
Existing toothbrush designs with flexible heads, often made from polypropylene segments linked by elastomeric material, are difficult to manufacture due to complex arrangements and require specialized mechanisms for maintaining segment spacing, while using a single flexible material for both head and handle complicates the manufacturing process.
Innovation Solution
An oral care implement with a handle, head support, and neck, featuring a recessed head with two sections that allow for injection molding of different materials, where the second head section with flexible wings can be attached to the first section using undercuts or other attachment mechanisms, simplifying the manufacturing process by allowing for separate injection molding steps and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple materials (polypropylene segments and elastomeric material) are used to create flexibility in the toothbrush head, then the ability to adjust to tooth curvature is improved, but the manufacturing complexity increases due to requiring multiple injection molding stations and mechanisms for maintaining segment spacing
Solution Approach 1:
The toothbrush head is divided into multiple segments that can move relative to each other, allowing the head to conform to the curvature of teeth and gums. Each segment is made of flexible material and can independently adjust position to match dental contours.
Solution Approach 2:
The patent combines multiple materials (polypropylene and elastomeric material) into a unified head structure where the elastomeric material acts as both the connecting element between polypropylene segments and the flexible surface that contacts teeth, eliminating the need for separate elastomeric components and simplifying the manufacturing process.
2Reliability
If polypropylene segments are injection molded separately and then assembled with elastomeric material, then material properties are optimized, but the manufacturing process requires complex multi-station injection molding with mechanisms for holding segments
Solution Approach 1:
The polypropylene segments are pre-formed with integrated elastomeric material already attached in the desired configuration, so that when the segments are assembled, the elastomeric material is already in its final position and orientation, eliminating the need for complex holding mechanisms during assembly.
Solution Approach 2:
The elastomeric material serves as an intermediary that is co-molded with the polypropylene segments, acting as both the bonding agent and the flexible surface, thereby simplifying the manufacturing process by reducing the number of separate components that need to be assembled.
3Stability of the object's composition
If a single flexible material is used for both the head and handle, then material consistency is improved, but the manufacturing process becomes more complex
Solution Approach 1:
Different regions of the toothbrush are made from different materials optimized for their specific functions: the head uses flexible materials to conform to teeth, while the handle uses rigid materials for structural support and grip, with each material selected and applied locally to match functional requirements.
Solution Approach 2:
The toothbrush is constructed as a composite structure combining different materials (polypropylene and elastomeric material) in specific configurations, where each material provides properties suited to its location, creating a multi-material product that optimizes both performance and manufacturability.
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
Facilitates a more straightforward manufacturing process for toothbrushes with flexible heads, reducing production complexity and costs while maintaining the flexibility needed to adjust to the curvature of teeth, and enhancing the attachment strength between the head and handle.
Implementation Method 1
The body is injection molded over the head such that the bottom face of the recess attaches to a bottom surface of the first head section and that the side face of the recess attaches to a side surface of the first head section
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
An oral care implement has a body made of a first material. The body has a handle, a head support, and a neck extending between the handle and the head support. The head support has a recess therein, and the recess has a bottom face and a side face. A head has a first head section and a second head section, and supports a plurality of contact elements. The first head section is disposed in the recess and attached thereto, and the second head section is attached to the first head section and unattached to the body.