Ear cleaning appliance and method of manufacture
A disposable ear cleaning appliance comprising an elongated stem having a hollow cavity which opens outwardly from one end thereof, and a plurality, preferably four, flexible lengths of thermoplastic monofilament. These lengths of monofilament are joined at their outboard ends and extend therefrom to define a bulbous shape. At their respective outboard ends, the thermoplastic monofilaments are bonded by heat and pressure, for example, to form a flattened region which serves to partially stiffen the individual monofilaments adjacent the bonded region and for a relatively short distance therefrom. Thus when the monofilaments are bent into a bulbous configuration by applying pressure against their respective inboard ends to gather the inboard ends into a bundle, the individual monofilaments are placed in compression and tend to retain their bulbous configuration. The accumulated inboard ends of the several monofilaments are gathered into a bundle in which the monofilaments lie side by side in close packed relationship. This bundle of ends is inserted into the hollow cavity at the end of the stem and anchored therein as by sonic welding, adhesive or other suitable bonding technique.
1. An appliance for ear cleaning comprising
an elongated hollow tube defining a stem having at least one open end,
a plurality of lengths of monofilament, each having an outboard end and an inboard end,
a mass of thermoplastic bonding each of said outboard ends of said monofilaments to one another with the respective ones of said plurality of lengths of said monofilaments at locations disposed substantially 90 degrees apart about the periphery of said mass and with each of said lengths of monofilament extending laterally away from said mass of thermoplastic, said mass of thermoplastic extending laterally thereof onto each of said outboard ends of said lengths of monofilament thereby imparting enhanced resistance to bending of each of said plurality of lengths of monofilaments within that region adjacent their respective outboard ends which are bonded to said mass, leaving the unbonded remainder of each of said plurality of lengths of monofilaments free to bend along their unbonded lengths,
each of said plurality of lengths of monofilaments being bent along its length to the extent that each of said inboard ends of each of said plurality of lengths of monofilament are gathered together in side-by-side, closely-packed, relationship, whereby each of said plurality of lengths of monofilament are bent toward a common location thereby causing said unbonded remainder of each length of monofilament to bend against the aforesaid resistance with concomitant outwardly bulging of said unbonded remainder of each length of monofilament,
said gathered inboard ends of said lengths of monofilaments being received with said at least one open end of said stem,
means bonding said gathered inboard ends of said lengths of monofilaments within said at least one open end of said stem, thereby defining a bulbous configuration of said plurality of lengths of monofilaments.
2. The appliance of claim 1 wherein said stem of about 6 cm in length.
3. The appliance of claim 1 wherein said stem is formed of polypropylene.
4. The appliance of claim 1 wherein each of said plurality of lengths of monofilament each is of between about 18 and 25 gauge.
5. The appliance of claim 1 wherein said plurality of lengths of monofilament are defined by first and second lengths of monofilament which intersect each other at their respective midpoints and at mutually perpendicular directions and are bonded to one another at their junction of intersection with said bond extending laterally from said respective midpoints and alone a portion of the length of each of said plurality of lengths of monofilament.
6. The appliance of claim 5 wherein said intersecting monofilaments are bonded by a mass of thermoplastic which extends laterally away from said junction of intersection and along each of said monofilaments within the region thereof adjacent said juncture of intersection.
7. The appliance of claim 6 wherein said mass of thermoplastic is defined by melting and solidification of said intersecting monofilaments at said juncture of intersection of said intersecting monofilaments.