Patent Publication Number: US-11389980-B1

Title: Personal care appliance

Description:
FIELD OF THE INVENTION 
     The present invention relates to personal care appliances and more particularly to smart shaving razors capable of detecting the presence of a replaceable cartridge. 
     BACKGROUND OF THE INVENTION 
     Personal care appliances may include a durable component, such as a handle that is reused and a replaceable component, such as a cartridge that needs to be replaced after a certain amount of uses. Examples of personal care appliances may include, but are not limited to facial cleanser devices, toothbrushes and shaving razors. Replaceable cartridges may last for a month, or even longer. Thus, consumers typically lose track of how many times they have used the replaceable cartridges. Furthermore, performance of the replaceable cartridges may gradually decrease over time. Accordingly, the consumer may be less likely to perceive any performance changes that would indicate a new cartridge is needed. 
     A shaving razor or other personal care appliance may count the number of usages and feedback this information to the consumer. For some devices the manufacturer may recommend exchanging an attachment (e.g., cartridge) after a certain time of usage as some attachments decrease their functionality over the time and replacing helps to retain the performance and additional benefits of the device. 
     Some personal care appliances may provide a sensor for detecting the presence of a replaceable cartridge which resets an internal counter. However, these are not passive systems and require light emitter(s) (e.g., light emitting diodes or LEDs). Drawbacks of optical detection systems is that they can confuse the presence of a cartridge with just a low ambient light condition, which may be typical of a dimly lit bathroom early in the morning or late at night. Other drawbacks of present cartridge detection systems include resetting the usage count without additional feedback from the consumer thus leading to potential unintended resets. 
     Accordingly, there is a need to provide a personal care appliance that is capable of sensing the presence of an attachment (e.g., cartridge) in in all reasonably assumable illumination settings including low ambient light without the need for LEDs and accurately track attachment usage. 
     SUMMARY OF THE INVENTION 
     The invention features, in general, a personal care appliance with a handle having a coupler at a first end. A control circuit is positioned within the handle. A consumer user interface is operably connected to the control circuit. A digital counter is operably connected to the control circuit. An optical sensor is mounted to the coupler that sends an electrical output signal to the control circuit. A cartridge is removably mounted to the coupler. The cartridge has an opaque surface covering the optical sensor and blocking ambient light from reaching the optical sensor when mounted to the coupler. The control circuit determines an attachment status of the cartridge by comparing the electrical output signal to one or more predetermined thresholds or by detecting a change over time in the electrical output signal of the optical sensor. 
     The invention features, in general, a personal care appliance with a handle having a coupler at a first end. A control circuit is positioned within the handle. An optical sensor is positioned on the coupler and electrically connected to the control circuit. The optical sensor sends an electrical output signal to the control circuit. A cartridge is removably mounted to the coupler. The cartridge has an opaque surface covering the optical sensor and blocking ambient light from reaching the optical sensor. The coupler does not have a light emitter. 
     The invention also features, in general, a method of resetting a digital counter for a personal care appliance by sending an electrical output signal from an optical sensor to a control circuit. The electrical output signal is compared to a predetermined value with the control circuit or a change in the electrical output signal from the optical sensor is detected over time. A signal is sent to a consumer user interface by the control circuit based on the electrical output signal and the predetermined value or based on the change in the electrical output signal from the optical sensor. The digital counter is reset based on an input signal from the consumer user interface. 
     The invention also features, in general, a method of resetting a digital counter for a personal care appliance by sending an electrical output signal from an optical sensor to a control circuit. The electrical output signal is compared to a predetermined value with the control circuit or detecting a change over time in the electrical output signal from the optical sensor. A signal is sent to a smart device by the control circuit based on the electrical output signal and the predetermined value or based on the change over time in the electrical output signal from the optical sensor. The digital counter is reset based on an input signal the smart device. 
     The invention also features, in general, a method of resetting a digital counter for a personal care appliance by sending an electrical output signal from an optical sensor to a control circuit. The electrical output signal is compared to at least one predetermined value with the control circuit or a change over time in the electrical output signal from the optical sensor is detected by the control circuit. A signal is sent from the control circuit to a cloud based on the electrical output signal of the optical sensor. A signal is sent from the cloud to a smart device or a consumer user interface on a personal care appliance. The digital counter is reset by sending a signal from the smart device or the consumer user interface to the digital counter. 
     The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. It is understood that certain embodiments may combine elements or components of the invention, which are disclosed in general, but not expressly exemplified or claimed in combination, unless otherwise stated herein. Other features and advantages of the invention will be apparent from the description and drawings, and from the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as the present invention, it is believed that the invention will be more fully understood from the following description taken in conjunction with the accompanying drawings. 
         FIG. 1  is a top perspective view of one possible embodiment of a personal care appliance having an attached cartridge. 
         FIG. 2  is an enlarged perspective view of a proximal end portion of the personal care appliance with the cartridge detached. 
         FIG. 3  is a perspective view of an electronic subassembly of the personal care appliance of  FIG. 1 . 
         FIG. 4  is a cross section view of the personal care appliance, taken generally along the line  4 - 4  of  FIG. 1   
         FIG. 5 . is a block diagram that depicts a method of resetting a digital counter according to one or more embodiments shown and described herein. 
         FIG. 6 . is a block diagram that depicts another method of resetting a digital counter according to one or more embodiments shown and described herein. 
         FIGS. 7A-7C  are top perspective views of the personal care device of  FIG. 1  with having display notifications. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIGS. 1 and 2 , one possible embodiment of the present disclosure is shown illustrating a personal care appliance  10 . The personal care appliance  10  may include a handle  12  having a coupler  14  at a first end  16  of the handle. A cartridge  18  may be removably mounted to the coupler  14 . The cartridge  18  may include one or more blades  20  for shaving. Although the personal care appliance  10  shown is a shaving razor, it is understood the personal care appliance may also include toothbrushes or other cosmetic devices having a replaceable cartridge. The handle  12  may include an optical sensor subassembly  22 . The optical sensor subassembly  22  may have at least one optical sensor (not shown) positioned within a pocket  24  of a housing  26 . The at least one optical sensor (not shown) may be mounted to a printed circuit board  28  (e.g., a flexible printed circuit board) that extends from the coupler to a cavity within the handle  12 . It is understood that in certain embodiments, the printed circuit board  28 , as well as other electrical components may be positioned outside of the handle  12  and sealed from water ingress. A consumer user interface  25  may be operably connected to a control circuit (not shown). In certain embodiments, the consumer user interface  25  may be positioned on the handle  12 . The consumer user interface (e.g., a touch screen) may provide information to the user and receive input from the user regarding the function of the personal care appliance  10 . It is understood that the consumer user interface  25  may also be physically separated from the handle  12 , such as on a smart device (e.g., a phone or watch) or computer in the form of an app or a push notification requesting an input from the user. In such situations the control circuit (not shown) may still be operably connected to the user interface  25  when the handle  12  is a connected handle that is wirelessly or wire connected to the smart device or computer having the consumer interface. The communication between handle  12  and user interface  25  may happen directly (e.g., peer-to-peer) or via an intermediate cloud service. 
     The cartridge  18  may define an opening  30  dimensioned to receive the coupler  14 . As will be explained in greater detail below, the opening  30  may be defined by an opaque surface  32  that covers the pocket  24  (e.g., in a planar direction) and the optical sensor (not shown) when the cartridge  18  is properly mounted to the coupler  14 . It is understood that tolerances may still allow for small gaps, thus it is understood the pocket  24  may not be completely covered. The opaque surface  32  may prevent any ambient light from reaching the optical sensor and may also prevent light from reflecting light towards the optical sensor (not shown). When the cartridge  18  is removed from the coupler  14 , ambient light may reach the optical sensor  38 . 
     Referring to  FIG. 3 , a perspective view of an electronic subassembly  34  of the personal care appliance  10  of  FIG. 1  is illustrated. The electronic subassembly  34  may be positioned within the handle  12  of  FIG. 1 . The electronic subassembly  34  may include a control circuit  36  (e.g., a microcontroller). The control circuit  36  may be in electrical communication with the printed circuit board  28 , which is in electrical communication with an optical sensor  38  mounted to the printed circuit board  28 . The optical sensor  38  may produce one or more electrical output signals. For example, the optical sensor may produce an electrical output signal when ambient light is blocked from reaching the optical sensor  38  (e.g., the cartridge  18  is mounted to the coupler  14 , as shown in  FIG. 1 ). The optical sensor  38  may also produce the electrical output signal when ambient light is received by the optical sensor  38  (e.g., the cartridge  18  is separated from the coupler  14 , as shown in  FIG. 2 ). It is understood that the electrical output signal may change over time and as the cartridge  18  is mounted to the coupler  14  and removed from the coupler  14 . 
     The optical sensor  38  may be able to distinguish between a close to zero lux condition, in which the cartridge  18  is mounted to the coupler  14  and the opaque surface blocks ambient light and a low lux condition (e.g., 1 lux) in which the cartridge  18  is not mounted to the coupler  14 , but the personal care appliance  10  is in a dimly lit room. It is understood it may be difficult to achieve an absolute dark condition, even with the cartridge  18  mounted to the coupler  14 . Accordingly, the optical sensor  38  may send the electrical output signal to the control circuit  36  that corresponds to a reading from about zero lux to about 0.5 lux. The control circuit  36  may compare the electrical output signal to one or more predetermined threshold values. For example, the electrical output signal may be compared to a predetermined valued stored by the control circuit  36  that represents ambient light being blocked from the optical sensor. In certain embodiments, a first predetermined value may represent a condition of the cartridge  18  attached to the coupler  14 . If the electrical output signal is less than the first predetermined value, the control circuit  36  may determine the cartridge  18  is attached to the coupler  14 . If the electrical output signal is greater than or equal the first predetermined value, then the control circuit  36  may determine the cartridge  18  has been removed from the coupler  14 . As will explained in greater detail below, the control circuit  36  may send various signals depending if it determines the cartridge  18  is attached or removed from the coupler  14 . 
     In certain embodiments, the first predetermined value may not be determined by the manufacturer. For example, the control circuit  36  may run a diagnostic test to have the consumer determine the correct light level for the first predetermined value. The consumer user interface  25  ( FIG. 1 ) may ask the consumer to remove the cartridge  18 . The consumer may confirm via the consumer user interface  25  ( FIG. 1 ) the cartridge  18  ( FIG. 1 ) has been removed. The control circuit  36  may then have the optical sensor  38  send the electrical output signal, which may be stored by the control circuit  36 . The consumer user interface  25  may then ask the consumer to attach the cartridge  18  to the coupler  14  ( FIG. 1 ). The consumer may confirm via the consumer user interface  25  the cartridge  18  is attached ( FIG. 1 ). The control circuit  36  may then have the optical sensor  38  send the electrical output signal again, which may be stored by the control circuit  36 . If the consumer starts using the personal care appliance  10  ( FIG. 1 ) in different lighting conditions, then the consumer may run the diagnostic test again, but under the new lighting conditions. 
     Referring to  FIG. 4 , a cross section view of the personal care appliance  10 , taken generally along the line  4 - 4  of  FIG. 1  is illustrated.  FIG. 4  shows the cartridge  18  mounted to the coupler  14 . The coupler  14  may be positioned within the opening  30  ( FIG. 2 ) with the opaque surface  32  positioned over (i.e., covering) the optical sensor  38 . The pocket  24  may be dimensioned to receive the optical sensor  38 . The optical sensor  38  may be positioned towards a lower portion  40  of the pocket  24  away from a top surface  42  of the coupler  14  that is adjacent to the opaque surface  32 . 
     The optical sensor  38  may include an over molded light guide  44 . The light guide  44  may facilitate guiding ambient light to the optical sensor  38  and may also prevent the optical sensor  38  from being damaged either physically (e.g., from being dropped) or chemically (e.g., by chemicals typically found in personal hygiene appliances). The light guide  48  may comprise a transparent or translucent material, which only influences the transmission of ambient light to the optical sensor  38  to an irrelevant extent. For example, materials may include silicone, thermoplastic elastomers, various curable liquid adhesives and/or polycarbonate. A softer material, such as silicone having a shore A durometer of about 5 to about 70, more preferably in the 30-50 range, may also provide improved sealing characteristics against water ingress and allow for less stringent assembly tolerances (e.g., assembly of the light guide  44  within the pocket  24 ). The light guide  44  may completely surround the optical sensor  38  (e.g., side surfaces and top surface). The light guide  44  may be inserted or positioned within the pocket  24  such that a top surface  46  is flush with the top surface  42  of the coupler  14 . In certain embodiments, the optical sensor  38  may be recessed (e.g., by about 0.1 mm to about 3.0 mm). A small recess or flush surface may help to accommodate tolerance variations or to prevent any ambient light from reaching the optical sensor when the cartridge  18  is mounted to the coupler  14 . 
     Referring back to  FIG. 1  and with additional reference to  FIG. 5 , the personal care appliance  10  may include a digital counter  50  that can be reset.  FIG. 5  illustrates a block diagram is shown depicting one possible embodiment of a method of resetting a digital counter  50 . The digital counter  50  may generate usage data about the personal care appliance  10  ( FIG. 1 ), such as count time (e.g., shaving duration), incidence of usage, or strokes (e.g., shaving strokes). The optical sensor  38  may send the electrical output signal to the control circuit  36 . The control circuit  36  may then compare the electrical output signal to the first predetermined threshold value stored in the control circuit  36 . In certain embodiments, the first predetermined value for the electrical output signal may correspond to an irradiation of the optical sensor  38  of about 0.5 mW/m 2  or to an illumination of about 0.5 lux. In other embodiments, the first predetermined value may correspond to 1.0 mW/m 2  or 1.0 lux. If the electrical output signal is below these values, the cartridge  18  may be attached to the coupler  14 . The consumer user interface  25  may display the status of the cartridge  18  (e.g., displaying words and/or a cartridge symbol). It is understood the consumer user interface  25  may be positioned somewhere on the handle  12  of  FIG. 1 ; however, in lieu of or in addition to, a smart device  52  (e.g., computer, tablet, phone or watch) may also be provided with consumer user interface. 
     When the cartridge  18  is removed, the electrical output signal will be greater than or equal to the first predetermined value. Accordingly, the control circuit  36  may send a signal to the consumer user interface  25  on the handle  12  and/or the smart device  52  prompting a consumer to input a response, noting the cartridge  18  has been removed from the coupler  14 . The consumer user interface  25  and/or the smart device  52  may then send a signal resetting the digital counter  50 . Alternatively, the control circuit may bypass the consumer interface  25  and reset the shave stroke counter. However, this may not be advantageous, as the digital counter  50  may be reset without the consumer&#39;s knowledge when the cartridge  18  is reattached after it was accidentally detached (e.g., during a drop). The consumer user interface  25  and/or smart device  52  allows the user to confirm the status of the cartridge  18 . 
     The control circuit  36  comparing the electrical output signal to the predetermined value may work for a wide range of ambient light conditions. However, it may be possible for such a system to confuse the attachment condition of the cartridge  18  in very bright light conditions where the control circuit  36  sends a signal that the cartridge is attached, but in reality, it is not. Accordingly, the control circuit  36  may in lieu of or in addition to, may detect a change in the electrical output signal over time to compensate for such conditions. The time variable may be determined by the approximate amount of time it takes to detach the cartridge  18  from the coupler  14  plus the time to attach the cartridge  18  to the coupler  14 . 
     If the control circuit detects a drop in the electrical output signal over time, then the control circuit  36  may send a signal to the consumer user interface  25  and/or the smart device  52  prompting a consumer to input a response, noting the cartridge  18  has been removed from the coupler  14 . The consumer user interface  25  and/or the smart device  52  may then send a signal to reset a digital counter  50 . The amount of the change in the electrical output signal over time may also be stored by the control circuit  36  (e.g., as a second predetermined value). 
     Referring to  FIG. 6 , a block diagram is shown depicting another possible embodiment of a method of resetting the digital counter  50 . As previously described for the embodiment disclosed in  FIG. 5 , the optical sensor  38  may send an electrical output signal to the control circuit  36 . The control circuit  36  may then send a signal to the cloud  54 . The cloud  54  may use an algorithm to process the signal from the control circuit  36  along with additional (e.g., usage information provided by the consumer and/or the control circuit  36 ). The cloud  54  may then send a signal to the consumer user inter face  25  and/or the smart device  52  notifying the user and requesting confirmation. The consumer may provide an input to the consumer user inter face  25  and/or the smart device  52  to reset the digital counter  50 . 
     Referring to  FIGS. 7A, 7B and 7C  the consumer user interface  25  of the handle  12  of the personal care appliance  10  may display one or more notifications to the user. For example, the consumer user interface  25  may display a cartridge removal notification  56 , such as an icon, informing the user that the cartridge  18  has been removed, as shown in  FIG. 7A . The consumer user interface  25  may display a cartridge attachment notification  58 , such as an icon, informing the user that the cartridge  18  is successfully attached and is ready for use. The consumer user interface  25  may change the display from the cartridge attachment notification  56  to the cartridge removal notification  56  based on the input from the control circuit  36  ( FIG. 5 ) or the cloud  54  ( FIG. 6 ). When the cartridge  18  is reattached or replaced with a new cartridge  18 , the consumer user interface may display an input request notification  60  of a cartridge replacement condition, such as an icon, requesting confirmation from the user that the cartridge  18  has been replaced. If the consumer inputs the cartridge  18  has been replaced, a signal may be sent to reset the digital counter ( FIGS. 5 and 6 ). 
     The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”. Therefore, the term “about” should be interpreted as being within typical manufacturing tolerances, as well as measuring instrumentation tolerances to those skilled in the art. 
     Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. 
     While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.