Personal care appliance

Portable, electrically driven, handheld sonic personal skin/hair care device includes a housing and a drive assembly to which is coupled a treatment member. The treatment member may include active ingredients incorporated during manufacturing that safely resist and inhibit the growth of mold, mildew and bacteria. The drive assembly includes a stator assembly, armature assembly, mounting member attached to the housing, elongated pivot arm having a first end directly coupled to the armature assembly and a second end directly coupled to the mounting member, and mounting arm having first and second ends, the first end being directly coupled to the armature assembly and the second end being directly coupled to the treatment member such that the stator, when energized, causes oscillation of the armature in an arcuate manner about a pivot point located at the mounting member in turn causing the treatment member to oscillate relative to the housing.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to personal care appliances, such as a power skin care brush, that are used to care for, clean and otherwise treat skin and hair, and, in particular, to a portable, electrically driven, handheld device that may he used to care for, clean and otherwise treat skin and hair.

2. Description of the Related Art

Handheld personal care appliances used to care for, clean or otherwise treat the skin or hair (e.g., to clean, massage and/or apply creams, cleansing solutions or other substances to the skin or hair) are known and have gained increasing popularity. Such devices are most often used to provide daily hygienic skin care, in particular care for the facial skin. These devices usually include a small handheld casing having an internal motor and a self-contained power source (such as a battery) for producing a particular movement/action of a workpiece (e.g., a brush or pad), which in turn produces desired functional results. Examples of such appliances include power skin brushes and power toothbrushes, among others. Such personal care appliances have motor arrangements which produce either rotational movement or oscillating (back and forth) movement.

While many such devices are known, there is room for improvement in the field of personal care appliances such as handheld skin and hair treatment devices. Hence, it is desirable to have a personal care appliance having a drive assembly which is powerful (stronger and faster), energy efficient, quiet and durable. It would also be further desirable to according to an aspect of the present invention described herein, incorporate into the workpiece during the manufacturing stage active ingredients that are safe for use on the skin and resist and inhibit the growth of mold, mildew, fungus and/or bacteria on the workpiece keeping the workpiece cleaner and healthier for a longer period of time. By helping prevent the growth of microorganisms, stain and odor control is also achieved.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a personal care appliance that (i) employs a new and improved mechanism for producing oscillating action of a workpiece, such as a brush or pad, which is powerful (stronger and faster), energy efficient, quiet and durable, and (ii) utilizes a workpiece incorporating active ingredients in the manufacturing stage that are safe for use on the skin and resist and inhibit the growth of mold, mildew, fungus and/or bacteria on the workpiece to maintain the workpiece cleaner and healthier for a longer period of time. By helping prevent the growth of microorganisms, stain and odor control is also achieved.

In one embodiment, a personal care appliance is provided that includes a housing, a drive assembly provided in the housing, and a workpiece member coupled to and driven by the drive assembly. On one specific exemplary implementation, the workpiece member includes active ingredients incorporated during the manufacturing stage that safely resist and inhibit the growth of mold, mildew, fungus and/or bacteria. The drive assembly includes a stator assembly, an armature assembly adjacent the stator assembly and responsive to the stator action to move through a path, a mounting member attached to the housing of the personal care appliance, an elongated pivot arm having a first end directly coupled to the armature assembly and a second end directly coupled to the mounting member such that the armature in operation oscillates in an arcuate manner about a pivot point located at the mounting member, and a mounting arm having a first end and a second end, the first end being directly coupled to the armature assembly. The stator, when energized, is structured to cause the armature to oscillate (which oscillation, as described above, is in an arcuate manner about a pivot point located at the mounting member). The workpiece member is coupled to the second end of the mounting arm such that oscillation of the armature assembly causes the workpiece member to oscillate relative to the housing.

In another embodiment, a personal care appliance is provided that includes a housing, a drive assembly provided in the housing, the drive assembly including a stator assembly and an armature assembly adjacent the stator assembly, wherein the stator, when energized, is structured to cause the armature to oscillate, and a workpiece member coupled to the armature assembly such that oscillation of the armature assembly causes the workpiece member to oscillate relative to the housing, wherein the workpiece member incldues one or more components made with an antimicrobial material that is both (i) safe for use on the skin, and (ii) resists and/or inhibits the growth of mold, mildew, fungus and/or bacteria.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

As used herein, the statement that two or more parts or elements are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or elements, so long as a link occurs.

As used herein, “directly coupled” means that two elements are directly in contact with each other.

As used herein, “fixedly coupled” or “fixed” means that two elements are coupled so as to move as one while maintaining a constant orientation relative to each other.

As used herein, the word “unitary” means a part is created as a single piece or unit. That is, a part that includes pieces that are created separately and then coupled together as a unit is not a “unitary” part or body.

As employed herein, the statement that two or more parts or elements “engage” one another shall mean that the parts exert a force against one another either directly or through one or more intermediate parts or elements.

FIG. 1Ais a front elevational view,FIG. 1Bis a side elevational view, andFIG. 1Cis a rear elevational view of a handheld personal care appliance2according to an exemplary embodiment of the present invention. In the illustrated embodiment, personal care appliance2includes a two-pan main housing4having a first (front) portion6and a second (rear) portion8coupled to the first portion6. Also, main housing4includes a handle portion10provided at a first end thereof and structured to enable the user to grip and hold personal care appliance2, and an attachment portion12provided at a second end thereof and structured to mount and hold a workpiece member in a manner that permits the workpiece member to he oscillated for use in skin and/or hair care, cleaning and treatment as described in detail herein. In addition, in the exemplary embodiment, handle portion10is provided with non-slip overlay portions11A and11B that are coupled to the surface of handle portion10. Non-slip overlay portions11A and11B are made of a material, such as rubber, and include a plurality of protruding members (e.g., bumps)13to aid in securely gripping and holding personal care appliance2.

In the illustrated, non-limiting embodiment, workpiece member is a circular brush head assembly14having a base member15, a plurality of bristles16arranged on and extending from base member15in a circular pattern, and a locking ring17structured to secure brush head assembly14in place. It will be appreciated, however, that other types of workpiece members may be used in place of bush head assembly14, such as, without limitation, a pad member assembly or massage head assembly.

Because of the presence of microbes such as bacteria and fungi in all walks of human life, there is a constant interaction between microbes and humans. This is especially so in the workpiece member, where skin cells left on the bristles16from the exfoliating effects of the brush head or other workpiece member provide a food source for microorganisms, which when combined with moisture and light, provide a breeding ground for the growth of mold, mildew and fungus, as well as, microbes, pathogens and bacteria, such asE. coliandStaph, and other microorganisms. Tests have shown that on unprotected surfaces, bacteria can double in number every 20 minutes.

Thus, in one non-limiting exemplary embodiment, the components of the workpiece member including, without limitation, the bristles16are made with active ingredients during the manufacturing stage that are both (i) safe for use on the skin, and (ii) resist and inhibit the growth of mold, mildew, fungus and/or bacteria on the workpiece member, keeping the workpiece member cleaner and healthier for a longer period of time. By helping prevent the growth of microorganisms, stain and odor control is also achieved.

Such active ingredients may include, for example and without limitation, silver ion technology (wherein silver ions are incorporated as an additive at the time of manufacture, or applied as a coating after manufacture), which forms a safe protective antimicrobial surface to resist and inhibit bacterial growth by up to 99.94%. Such active ingredients may further include, without limitation, essential plant oils (e.g., cinnamon oil, clove oil, eucalyptus oil, oregano oil, lavender oil, leleshwa oil, lemon oil, lemon myrtle oil, mint oil, neem oil, nigella sativa (black cumin) oil, peppermint oil, sandalwood oil, ironwort oil, tea tree oil, and thyme oil), and essential minerals, or bacteria resistant polymers (e.g., a polymer that reduces the ability of pathogenic bacteria to attach to the polymer).

An actuator mechanism18including a number of buttons is provided on handle portion10for controlling the operation of personal care appliance2(i.e., controlling the starting, stopping and/or speed of the movement of brush head assembly14). In addition, handle portion10also includes a number of indicator lights19for indicating various modes of operation of personal care appliance2.

FIG. 2is a rear elevational view of personal care appliance2in a condition wherein the second portion8of main housing4has been removed.FIG. 3is a side elevational view of personal care appliance2in a condition wherein a front part of the first portion6of main housing4(i.e., the part located at attachment portion12) has been removed.FIGS. 2 and 3allow the internal components of personal care appliance2to be readily viewed. As seen inFIG. 2, a main circuit board20is mounted and held within handle portion10of main housing4. Main circuit board20includes the control electronics which control the operation of personal care appliance2. A rechargeable battery22is coupled to main circuit board20and is adapted to provide power for personal care appliance2.

In addition, as seen inFIGS. 2 and 3, a drive assembly24is mounted and held within attachment portion12of main housing4. Brush head assembly14is structured to be selectively attached to drive assembly24so that, as described in more detail below, drive assembly24is able to move brush head assembly14in an oscillating manner with respect to main housing4.FIG. 4is an exploded side elevational view of drive assembly24and brush head assembly14(without the associated portions of main housing4).

As seen inFIGS. 2-4, drive assembly24includes an electric motor26that is coupled to main circuit board20and rechargeable battery22by wires28. Motor26includes a stator assembly30and an armature assembly32. Stator assembly30includes an E-core member34having first and second outer legs and a center leg in between the outer legs, and a stator coil36wrapped around the center leg of E-core member34. Armature assembly32includes a main body portion38and first and second magnets40A,40B spaced apart from one another and coupled to a first side of main body portion38. First and second magnets40A,40B are oriented such that the poles of first and second magnets40A,40B face in opposite directions (e.g., the N pole of magnet40A faces stator assembly30and the S pole of magnet40B faces stator assembly30).

Drive assembly24further includes a pivot arm42having a first end44directly coupled to a second side of main body portion38(opposite the first side thereof). In the exemplary embodiment, pivot arm42is a thin, elongated piece of metal such as, without limitation steel. Drive assembly24also includes a mounting member46which is coupled to first portion6of main housing4. In the exemplary embodiment, mounting member46is made of a plastic material, such as, without limitation, a thermoplastic, by a molding process. As seen inFIG. 2, mounting member includes a base portion48and first and second arms50A and50B extending outwardly and downwardly from base member48such that the end of arms50A and SOB are perpendicular to the longitudinal axis of base member48. A second end52of pivot arm42is directly coupled to base member48. Thus, as seen inFIG. 2, the longitudinal axis of pivot arm42is perpendicular to the longitudinal axis of base member48. In the exemplary embodiment, an end portion of second end52of pivot arm42is molded inside base portion48such that end portion of second end52of pivot arm42is fixed inside and not moveable relative to base portion48. As described herein, only the portion of pivot arm42that is located outside of base portion48is moveable relative to base portion48.

First and second constraining members54A and54B are attached to respective ones of the arms50A and50B and extend in a direction that is perpendicular to the longitudinal axis of pivot arm42. In the exemplary embodiment, constraining members54A and54B comprise springs to constrain and assist (i.e., drive) the movement of pivot arm42when necessary, which is believed to assist with the generation of speed and/or power of the oscillations.

Drive assembly24further includes a mounting arm assembly56for coupling brush head assembly14to drive assembly24. In particular, mounting arm assembly56includes a first end58that is directly coupled to main body portion38of armature assembly32, and a peg member60that is structured to be selectively coupled to brush head assembly14through a central aperture provided in attachment portion12(peg member60is structured to extend through that central aperture to facilitate selective connection of brush head assembly14, or a different skin treatment attachment device, thereto). Thus, as shown inFIG. 4, when assembled, the center of base member15of brush head assembly14will be positioned directly over armature assembly32.

In operation, when power is provided to motor26by rechargeable battery22, armature assembly32will be caused to oscillate back and forth in an arcuate path about a pivot point located at mounting member48as a result of the changing magnetic field produced in stator assembly30and the interaction of magnets40A,40B therewith. As a result, brush head assembly14will be caused to oscillate with respect to main housing4. A user may then apply the oscillating bush head assembly14to different areas of skin and/or hair (e.g., the lace, feet, etc.) to provide care and treatment for the skin and/or hair, for example by using, the oscillating brush head assembly to apply a cleansing solution of another substance to the user's skin and/or hair.

In one particular exemplary embodiment, personal care appliance2is structured and configured such that brush head assembly14will be caused to oscillate with respect to main housing4at a rate up to 330 times/second. In addition, in this particular embodiment, rechargeable battery22is structured and configured such that personal care appliance2will operate for about 30-40 minutes on a single charge and such that only about 2 milliamperes is consumed when personal care appliance2is not in use (which prolongs the battery life).

FIG. 5is an exploded side elevational view of a drive assembly62according to an alternative exemplary embodiment of the present invention. Drive assembly62may be used in place of drive assembly24to drive brush head assembly14. As seen inFIG. 5, drive assembly62includes an electric motor64that may be coupled to main circuit board20described herein by wires28. Motor64is similar to motor26and includes a stator assembly66and an armature assembly68. Stator assembly66includes an E-core member70having first and second outer legs and a center leg in between the outer legs, and a stator coil72wrapped around the center leg of E-core member70. Armature assembly68includes a main body portion74and first and second magnets76spaced apart from one another and coupled to a first side of main body portion74. First and second magnets76are oriented such that the poles thereof face in opposite directions.

Drive assembly62further includes a pivot arm78having a first end80directly coupled to a second side of main body portion74(opposite the first side thereof). In the exemplary embodiment, pivot aim78is a thin, elongated piece of metal such as, without limitation steel. Drive assembly62also includes a mounting member82which may be coupled to first portion6of main housing4. Mounting member82includes a base portion84and first and second arms86extending outwardly and downwardly from base member84such that the end alarms86are perpendicular to the longitudinal axis of base member84. A second end88of pivot arm78is directly coupled to base member82. Thus, the longitudinal axis of pivot arm78is perpendicular to the longitudinal axis of base member84. Also, first and second constraining members (like constraining members54A and54B) are attached to respective ones of the arms86and extend in a direction that is perpendicular to the longitudinal axis of pivot arm78. In the exemplary embodiment, an end portion of second end88of pivot arm78is molded inside base portion84such that end portion of second end88of pivot arm78is fixed inside and not moveable relative to base portion84. As described herein, only the portion of pivot arm78that is located outside of base portion84is moveable relative to base portion84.

Drive assembly62also further includes an S-shaped mounting arm90for coupling brush head assembly14to drive assembly62. In particular, S-shaped mounting arm90includes a first portion92, an elongated second portion94coupled to first portion92, and a third portion96coupled to second portion94. As seen inFIG. 5, in the exemplary embodiment, first portion92and third portion96extend in directions that are parallel to one another, and second portion94extends in a direction that is perpendicular to first and third portions92,96. Also in the exemplary embodiment, mounting arm90is a thin, elongated piece of metal such as, without intimation steel. First end92of mounting area90is directly coupled to main body portion74of armature assembly68, and third portion96is structured to be selectively coupled to brush head assembly14through a central aperture provided in attachment portion12(third portion96is structured to extend through that central aperture to facilitate selective connection of brush head assembly14, or a different skin treatment attachment device, thereto). Thus, as shown inFIG. 5, when assembled, the center of base member15of brush head assembly14will be positioned over a midpoint98of pivot arm78.

In operation, when power is provided to motor64, armature assembly68will be caused to oscillate back and forth in an arcuate path about a pivot point provided at mounting member82as a result of the changing magnetic field produced in stator assembly66and the interaction of magnets70therewith. As a result, brush head assembly14will be caused to oscillate with respect to main housing4. A user may then apply the oscillating bush head assembly14to different areas of skin (e.g., the face, feet, etc.) to provide care and treatment for the skin, for example by using the oscillating brush head assembly to apply a cleansing solution to the user's skin.