Methods of making electromechanical personal care device

Abstract

A method of making a handheld, electromechanical device useful in mammalian body-care includes the steps of: a) forming a one-piece housing having a single opening defined by a rim; b) assembling a unitary insert; c) inserting the unitary insert through the single opening of the housing; d) removably applying a cover having an exterior surface to close the opening of the one-piece housing; and e) attaching the unitary insert to at least one of the one-piece housing and the removable cover. The rim of the one-piece housing circumscribes a rim area, and the one-piece housing has a projected area that is substantially larger than the rim area. The unitary insert is dimensioned to be insertable through the opening defined by the rim, and it has a frame having disposed thereon electromechanical elements interconnected in an electrical circuit. The cover closes off the opening of the one-piece housing.

What is claimed is: 
     
         1 . A method of assembling a handheld, electromechanical device useful in mammalian body-care, the method comprising:
 a) providing a one-piece housing having a single opening defined by a rim;   b) providing a unitary insert dimensioned to be insertable through the opening defined by the rim, the unitary insert comprising a frame having disposed thereon electromechanical elements interconnected in an electrical circuit;   c) inserting the unitary insert through the single opening of the housing;   d) removably applying a cover having an exterior surface to close the opening of the one-piece housing; and   e) attaching the unitary insert to the cover prior to removably applying the cover to close the opening.   
     
     
         2 . The method of  claim 1 , further comprising sealingly engaging at least two of the cover, frame and one-piece unitary housing to resist the ingress of liquids into the one-piece housing. 
     
     
         3 . The method of  claim 1 , wherein providing the one-piece housing comprises providing a one-piece housing formed by subjecting a thermoplastic preform to a blow-molding process. 
     
     
         4 . The method  claim 1 , wherein providing a one-piece housing comprises providing a one-piece housing formed by rotomolding a polymeric material. 
     
     
         5 . The method of  claim 1 , wherein the one-piece housing has a projected area that is symmetrical on opposite sides of a plane perpendicular to the opening. 
     
     
         6 . The method of  claim 1 , wherein the unitary insert has a projected area that is circumscribed by the single opening, and inserting the unitary insert through the single opening involves a single, linear motion. 
     
     
         7 . The method of  claim 1 , wherein the unitary insert has a projected area that extends outside of the opening, and inserting the unitary insert through the single opening comprises aligning a distal portion of the unitary insert with the opening, inserting the distal portion through the opening, pivoting the unitary insert to align a remaining portion of the unitary insert that has a projected area that is circumscribed by the rim, and inserting the remaining portion of the unitary insert through the rim. 
     
     
         8 . The method of  claim 1 , further comprising providing a damping member between the unitary insert and the one-piece housing to inhibit the transfer of motion therebetween. 
     
     
         9 . The method of  claim 1 , wherein the removable cover is arranged and configured to transmit at least one output of the electromechanical elements disposed within the one-piece housing through the exterior surface of the cover. 
     
     
         10 . The method of  claim 9 , wherein the cover further comprises an aperture having a gasket and a moveable shaft disposed therein, and wherein the moveable shaft is operatively connected to the motor to transfer motion from the motor to a skin-contacting element disposed outside of the one-piece housing. 
     
     
         11 . The method of  claim 1 , wherein the removable cover comprises a cap, and the step of removably applying the cover comprises removably engaging the cap over the rim. 
     
     
         12 . The method of  claim 1 , wherein the removable cover comprises a plug, and the step of removably applying the cover comprises removably engaging the plug within the rim. 
     
     
         13 . The method of  claim 12 , further comprising arranging a gasket about the plug. 
     
     
         14 . The method of  claim 1 , further comprising arranging a gasket about the unitary insert between the unitary insert and the one-piece housing. 
     
     
         15 . A method of assembling a handheld, electromechanical device useful in mammalian body-care, the method comprising:
 a) attaching a unitary insert to a cover having an exterior surface, the unitary insert comprising a frame having disposed thereon electromechanical elements interconnected in an electrical circuit; and   b) removably applying the cover with the unitary insert already attached thereto to the single opening of a one-piece housing to close the opening of the one-piece housing.   
     
     
         16 . The method of  claim 15 , further comprising sealingly engaging at least two of the cover, frame and one-piece unitary housing to resist the ingress of liquids into the one-piece housing. 
     
     
         17 . The method of  claim 15 , wherein the one-piece housing has a projected area that is symmetrical on opposite sides of a plane perpendicular to the opening. 
     
     
         18 . The method of  claim 15 , wherein the unitary insert has a projected area that is circumscribed by the single opening, and inserting the unitary insert through the single opening involves a single, linear motion. 
     
     
         19 . The method of  claim 15 , wherein the unitary insert has a projected area that extends outside of the opening, and inserting the unitary insert through the single opening comprises aligning a distal portion of the unitary insert with the opening, inserting the distal portion through the opening, pivoting the unitary insert to align a remaining portion of the unitary insert that has a projected area that is circumscribed by the rim, and inserting the remaining portion of the unitary insert through the rim. 
     
     
         20 . The method of  claim 15 , further comprising providing a damping member between the unitary insert and the one-piece housing to inhibit the transfer of motion therebetween. 
     
     
         21 . The method of  claim 15 , wherein the removable cover is arranged and configured to transmit at least one output of the electromechanical elements disposed within the one-piece housing through the exterior surface of the cover. 
     
     
         22 . The method of  claim 21 , wherein the cover further comprises an aperture having a gasket and a moveable shaft disposed therein, and wherein the moveable shaft is operatively connected to the motor to transfer motion from the motor to a skin-contacting element disposed outside of the one-piece housing. 
     
     
         23 . The method of  claim 15 , further comprising arranging a gasket about the unitary insert between the unitary insert and the one-piece housing.