Modular Toothbrush Neck-Handle Coupling for Production Efficiency
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Solution Overview
Problem
Manual toothbrushes face challenges in production efficiency due to long cooling times in injection molding and complexity in bristle field design, leading to high costs and reduced cleaning effectiveness, especially in low-price variants.
Innovation Solution
A manual toothbrush design featuring a coupling element that irreversibly connects the neck and handle, using a geometric body with a smaller diameter than the neck and handle, allowing for independent design and manufacturing, and potentially incorporating a circumferential elevation for sealing and flexibility, enabling a strong yet flexible connection and reducing production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding is used to produce toothbrush parts, then manufacturing precision and strength are improved, but production time increases due to long cooling times
Solution Approach 1:
The toothbrush is divided into separate modular components (head, neck, handle) that can be manufactured independently through injection molding and then assembled. This allows parallel production of multiple parts, reducing overall production time while maintaining the precision benefits of injection molding for each component.
2Reliability
If complex bristle fields are designed to improve cleaning effectiveness, then cleaning quality is improved, but device complexity and production complexity increase
Solution Approach 1:
The bristle field is segmented into multiple independent tuft groups arranged in specific patterns. Each tuft or group can be manufactured and attached separately to the brush head, allowing complex cleaning patterns to be achieved through simple, repeatable manufacturing steps rather than complex integrated structures.
Solution Approach 2:
Different regions of the bristle field are designed with locally optimized characteristics - varying tuft lengths, densities, and orientations in different areas to target specific cleaning needs (gums, interdentals, surfaces). This allows high cleaning effectiveness through localized simple structures rather than uniform complexity throughout.
3Adaptability or versatility
If replaceable brush head system is implemented to improve hygiene and reusability, then adaptability and hygiene are improved, but device complexity and production costs increase
Solution Approach 1:
The toothbrush is designed as a segmented system with a reusable handle and replaceable head components. The head can be detached and replaced independently, allowing hygiene maintenance without replacing the entire brush. The coupling mechanism uses simple geometric interlocking features that enable easy attachment and detachment.
Solution Approach 2:
The brush head is extracted as a separate replaceable component from the handle. This allows the head to be discarded after use while retaining the handle for continued use with new heads, improving hygiene and reducing waste while keeping the overall system relatively simple through standardized coupling interfaces.
4Ease of operation
If neck portion is made small and flexible for comfortable handling, then ease of operation is improved, but strength and rigidity are reduced
Solution Approach 1:
The neck portion utilizes composite construction combining materials with different properties - typically a harder material for structural strength and a softer or more flexible material for comfort. This allows the neck to be small and flexible for handling while maintaining sufficient strength through material composition rather than increased size.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A toothbrush comprises a head, a neck portion and a handle, wherein the neck portion and the handle portion are connected to each other via a coupling element. Said connection is constructed as an inseparable connection, meaning that after being combined once neck portion and handle cannot be separated again without destroying the toothbrush. Further, a method for producing such a toothbrush may comprise the following steps: providing a head, a neck portion and handle; providing a coupling element and combining the neck portion to the handle by the coupling element so that an irreversible connection is formed.