HK1197878A - Method of making an electromechanical personal care device - Google Patents

Description

Method of manufacturing a personal care electromechanical device

Technical Field

The present invention relates to a low cost hand-held personal care electromechanical device having a one-piece housing and a unitary insert including a frame and electromechanical elements disposed thereon. The invention also relates to methods of manufacturing and assembling the devices, and kits of interchangeable components incorporating such devices.

Background

Hand-held personal care electromechanical devices are known. Many of these devices have mechanisms that transmit motion, such as vibration, rotation, oscillation, etc., to a body surface, such as a human face, elbows, and/or feet.

U.S. patent 7,918,862 to Hull, jr. et al discloses a water-tight arrangement in conjunction with a switch assembly. This is a typical example of an injection molded clamshell housing that includes structural features that allow electromechanical components to be mounted on the housing. In more detail, the device comprises a housing formed of a stiff lightweight plastic material, which may be formed of two parts and attached along a seam. In addition to this seam between the housing parts, additional openings for the battery compartment and the power switch are formed in the housing. Each of these openings employs a waterproof seal.

Cowie et al, U.S. patent application No.2010/0222719, is directed to a facial care implement having a tubular body that houses electromechanical elements. The tubular body is formed from mating interfitting semi-cylindrical side walls and has a skin disposed thereon. Thus, if the body is to be used in a wet environment, it requires many seams to be sealed or gasketed in order to protect the internal electromechanical elements.

Despite the teachings of the prior art, there is still a need for a skin care device that provides a simple and reliable way of manufacturing, reliable resistance to water damage and the possibility of customization.

Disclosure of Invention

Accordingly, it has been found that separating the housing and electromechanical elements of the hand-held personal care device increases manufacturing flexibility, reduces manufacturing costs, and reduces the likelihood of unwanted ingress of liquid.

In particular, the method of manufacturing a hand-held electromechanical device for mammalian body care comprises the steps of: a) forming a one-piece housing having a single opening defined by an edge; b) assembling an integrated plug-in; c) inserting a unitary insert through a single opening of the housing; d) removably applying a cover having an outer 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. An edge of the one-piece shell surrounds the edge area, and the one-piece shell has a projected area that is substantially larger than the edge area. The unitary insert is sized to be insertable through an opening defined by the edge and has a frame with electromechanical elements interconnected in an electrical circuit disposed thereon. The cover closes the opening of the one-piece housing.

Drawings

FIG. 1 is a perspective view of one embodiment of the device of the present invention.

Fig. 2 is a side elevational view of the housing of fig. 1.

Fig. 3 is a top view of the housing of fig. 1 showing the projected area of the housing.

Fig. 4 is an exploded side elevational view of the device of fig. 1.

Fig. 5 is a detailed view of the one-piece insert of fig. 1 and 4.

FIG. 6 is an exploded side elevational view of an alternative embodiment of a unitary insert having a modified distal end.

Fig. 7 is a perspective view of the cover and housing/insert of fig. 1-5, with the cover separated from the housing/insert and rotated to show the underside of the cover.

Fig. 8 is an exploded perspective view of a cover and housing of an embodiment of the invention having a cover in the form of a plug.

Fig. 9 is a partial cross-section of an embodiment of the present invention having a shaft disposed through the cover.

FIG. 10 is a partial cross-section of a housing and insert of an embodiment of the present invention having a gasket disposed between the insert and the housing.

Fig. 11 is a side elevational view of a preform that may be used to blow mold the one-piece shell of fig. 2.

Fig. 12 is a schematic view of components of a kit including a plurality of unitary inserts and a one-piece shell according to an embodiment of the present invention.

Detailed Description

A review of the above prior art shows that there is still a need for a simple and convenient solution for a waterproof electro-mechanical personal body care device. In particular, the plastic housing is typically a two-piece injection molded clamshell structure. This allows for ease of manufacture with structural elements extending from the inner surface of the housing that forms the mounting face for the electromechanical elements contained therein. However, as electromechanical components change during the evolution of commercial products, either the injection mold must be modified or there are significant structural limitations to the design evolution. Alternatively, the modification of the housing must be designed in connection with the mounting of the electromechanical components. Furthermore, mounting the electromechanical element directly on the housing provides a direct way of transferring unwanted motion to the gripping surface of the housing. Finally, combining multiple plastic pieces together to form a unitary housing requires additional locations to seal the structure from possible ingress of liquids (such as water).

Accordingly, the housing and electromechanical elements have been separated to increase manufacturing flexibility, reduce manufacturing costs, and reduce the likelihood of unwanted ingress of liquids. In particular, a low cost hand-held personal care waterproof electromechanical device has been invented having a one-piece housing and a single opening defined by an edge, a unitary insert sized to be insertable through the opening, and a removable cover arranged and configured to engage the edge. The unitary insert includes a frame having electromechanical elements interconnected in an electrical circuit disposed thereon. The removable cover has an outer surface and is arranged and configured to transmit at least one output of an electromechanical element disposed within the housing.

As used herein the specification and claims, the term "unitary" and variations thereof refer to a collection of parts joined to form a unitary body.

As used herein the specification and claims, the term "edge" and variations thereof refer to an edge of a structure defining an opening, which may be rounded or of other geometric shape.

As used herein in the specification and claims, the term "projection area" and variations thereof refer to the area of projection of a three-dimensional object onto a plane. When comparing two or more projection areas, the projections are on the same plane.

As used herein the specification and claims, the term "removable cover" and variations thereof relate to a cover designed to close and be removable from an opening of a one-piece housing, which cover removal from the opening does not require excessive force and/or does not cause damage to any of the cover, the one-piece insert, and the one-piece housing.

As shown in fig. 1, a first embodiment of the device of the present invention is a hand-held waterproof electromechanical device 10 that may be used for body care of a mammalian individual. The device includes a one-piece housing 20 that houses a one-piece insert 30 and has a cover 40. Preferably, the one-piece housing 20, integral insert 30 and cover 40 are arranged and configured to resist liquid ingress into the device. This may be achieved by the optional use of a gasket, as described below. Thus, the device is better resistant to liquid entering the device. Further, the unitary insert 30 is attached to at least one of the one-piece housing 20 and the cover 40 to provide a more robust device.

As shown in fig. 2, a one-piece housing 20 defines a volume contained by the housing and has a single opening 21 defined by an edge 22. The one-piece housing preferably has an ergonomic shape that is convenient to hold by a human hand. The handheld electromechanical device is lightweight to prevent fatigue of the user during use. Preferably, the mass of the handheld electromechanical device is less than about 450 grams; more preferably, less than about 300 g; and most preferably, less than about 150 g. The one-piece housing 20 has a substantially continuous outer wall to provide a pleasing appearance and eliminate the risk of poor closure of seams between housing components present in a multi-part housing, which seams may provide access for liquids to the device. A single opening greatly reduces the number and linear size of seams in an electromechanical device configuration. It may be desirable to provide a shoulder 23 adjacent to the opening 21. Thus, in this embodiment, the rim 22 may extend from the shoulder 23 to allow the cover 40 to engage and fit onto the rim 22. A gasket 24 may be disposed about the rim 22. As shown in fig. 2 and 10, the gasket 24 is an O-ring and is disposed within a groove 25 that is sized to provide an effective sealing seat for the gasket 24 to prevent liquid from entering the device 10. Although circular openings and corresponding edges are shown in fig. 1-5, it should be appreciated that alternative geometries are possible.

The one-piece shell 20 preferably has an inner surface that is substantially smooth and continuous to facilitate manufacturing and improve mechanical isolation of the unitary insert 30 from the shell 20. The smooth, continuous inner surface also forces the electromechanical components to assemble on the frame of the unitary insert, as discussed in more detail below. As shown in FIG. 3, the one-piece housing 20 has a projection area PA_H(shown by the cross-hatching within the outer bold line defining the projected perimeter) which is substantially larger than the edge region RA (shown by the opposite cross-hatching within the opening), i.e. byThe area surrounded by the rim 22. In this embodiment, the projected area PA is symmetrical on opposite sides of a plane perpendicular to the edge 22, but it is not radially symmetrical about the center of the edge 22. In alternative embodiments, the projected area may be radially symmetric about the center of the opening 21, symmetric across planes perpendicular to the edges, or it may be isotropic (having a structure that is not dictated by the direction from the center or diameter of the opening).

The outer surface of the one-piece shell may be smooth or it may have a surface structure such as a highlighted gripping area 26. The surface structures may be formed during the formation of the one-piece shell, or they may be added subsequently. These surface structures may include, but are not limited to, texture, coloration, information, and the like. The surface structure may be provided by known methods, such as by coating (e.g., printing and/or painting), applying a label or other structure, etching, dyeing, and the like. The texture may be slight, or it may be substantially sufficient to be apparent on the inner surface of the housing. The one-piece housing may be transparent so that the interior can be seen. This is useful for internally using LEDs as status indicators. The housing is preferably rigid, but it may be beneficial to have one or more flexible portions. Alternatively, the one-piece housing may have greater flexibility. Partial or complete flexibility may be useful in combination with a switch that a user can depress by bending the housing (as is equally applicable to the top cover) or having a pump through which the liquid is dispensed. The gasket prevents liquid from entering from the outside, but in another embodiment it can be used to prevent liquid from exiting.

Fig. 4 shows an exploded side elevation view of the fig. 1 device illustrating the relationship between the one-piece housing 20, the unitary insert 30, and the cover 40, while fig. 5 provides additional details of the unitary insert 30 and its constituent elements. In addition, the unitary insert 30 includes a frame 31 having electromechanical elements interconnected in an electrical circuit disposed thereon. The frame 31 has a proximal portion 32 and an oppositely disposed distal portion 33. A flange 34 or other attachment surface is located at proximal end 33 for attaching to or engaging edge 22 or other portion of housing 20 near opening 21 to secure integral insert 30 to housing 20. The electromechanical elements are mounted on or disposed in recesses in the frame 31. For example, in the embodiment shown in fig. 4 and 5, the insert 30 includes an electric motor 35 and a power source (such as a battery 36 interconnected with electrical wires or other electrical conduits in the circuit). The circuit may be opened and closed by a switch, elements of which may be positioned on the cover, as discussed in further detail below.

The unitary insert 30 is sized to be inserted through the opening 21 and is substantially contained within the one-piece housing 20. In the embodiment of FIGS. 1-5, the unitary insert 30 has a projected area PA surrounded by the rim 22 (see FIG. 4)_I. It should be noted that this projected area does not include any portion of the mounting flange 34 that would be secured to the rim 22 by an interference fit or by overlapping a portion of the rim 22. In other words, the one-piece insert 30 may be inserted into the opening 21 with a single linear motion (without interference). In an alternative embodiment shown in FIG. 6, the unitary insert 30' has a projected area PA_I'which extends outside the opening due to the lateral extension of the distal portion 33'. The one-piece insert 30' may be inserted into the opening 21 by: the distal portion 33' is first inserted through the opening 21; pivoting the unitary insert 30' to align with the remainder of the unitary insert, the remainder having a projected area surrounded by an edge; and inserting the remainder of the unitary insert 30' through the rim 21.

A removable cover 40 engages the edge 22 to close the opening 21. In the embodiment of fig. 1-5, the removable cover 40 is a top cap arranged and configured to removably engage over the rim 22. The cap also engages a gasket 24 disposed about the rim 22 to prevent liquid from entering the device 10. This sealing engagement protects the electromechanical elements from damage, including short circuits that may be caused by water or other liquids when penetrating into the interior of the housing 20. In the embodiment of fig. 1-5 and 7, as well as the embodiment of fig. 10 described in more detail below, the top cover has an inner surface 41 disposed toward the unitary insert 30 that closes the opening 21, and an outer surface 42 disposed away from the opening 21. In addition, the top cover has a sidewall 43 that surrounds the rim 22 and engages the gasket 24. The outer surface 42 may itself be a body care surface, or it may be a platform or other structure upon which an optional body care element 44 may be disposed, either directly on the outer surface 42 or on the outer surface 42 through an optional coupler 44a such as disclosed in commonly assigned U.S. serial No. 12/770,994 filed on 30/4/2010 by Hull. Such optional body care elements may be applied directly onto optional coupler 44a or onto the outer surface, or there may be attachment mechanisms, such as hook and loop systems or adhesives, clamps, snaps, and the like.

In the preferred embodiment shown in fig. 1-5, the cover cooperates with the insert to form the switch. This is shown in more detail in fig. 7. The unitary insert 30 has a first electrical conductor 37a disposed on its proximal surface 32a, and the inner surface 41 of the cap has a second electrical conductor 37 b. The top cover preferably engages the rim 22 by means of a bayonet connector mechanism having one or more pins provided on the frame and a matching "L" slot provided in the inner wall 43 of the top cover. The cap and/or the rim are formed of a sufficiently resilient material that allows the cap and rim to be removably locked together. In this embodiment, the "L" slot extends to allow the top cover to rotate between (1) "open" position in which the second electrical conductor 37b on the top cover connects the first electrical conductor 37a disposed on the proximal surface 32a of the unitary insert 30 with the battery 36 to close the electrical circuit, and (2) "closed" position in which the second electrical conductor 37b on the top cover is rotated to open the electrical circuit by disengaging either or both of the first electrical conductor 37a and the battery 36 on the unitary insert 30.

While the preceding paragraphs describe a bayonet coupling between the cover 40 and the insert 30, elements of the bayonet coupling, such as pins and slots, may be positioned on the combination of the housing 20, the integral insert 30, and the cover 40.

Another embodiment may replace the rotary switch formed by the combination of the cover 40 and the insert 30 with a push button switch operated by bending the housing and/or the cover.

In an alternative embodiment shown in fig. 8, the cover is a plug 40 'arranged and configured to be removably engaged within the rim 22'. A gasket 45 (such as an O-ring) may be provided around the plug 40'. In addition, an O-ring may be disposed within a groove that is sized to provide an effective sealing seat for the gasket 45 to prevent liquid from entering the device 10.

In another alternative embodiment shown in fig. 9, the cover 40 "may have an aperture 46 having a shaft washer 47 and a movable shaft 48 disposed therein, and wherein the movable shaft 48 is operatively connected to the insert-mounted motor 35 to transfer motion from the motor 35 to a moving platform 49 having the body care elements 44 disposed thereon outside of the housing 20. Thus, the body-care element 44 may rotate or oscillate against the skin of the user. Other motion outputs are also possible. For example, cams, slides, and/or other translation mechanisms may interact with the moving platform 49.

As mentioned above, it is desirable to construct the body care device 10 to resist liquid ingress to avoid damage to the electronic components contained therein. Thus, the housing 20 sealingly engages at least one of the unitary insert 30 and the cover 40. The use of one or more gaskets 24, 45 between the cover 40 and the housing 20 is described above. In addition to or in lieu of such a gasket, it may be desirable to seal the connection between the housing 20 and the one-piece insert 30. Accordingly, a suitable gasket 38 may be provided between the housing 20 and the one-piece insert 30, as shown in FIG. 10. This gasket 38 may only resist the ingress of liquid into the interior of the housing 20, or it may also act as a damping member to dampen and isolate the motion generated by the electromechanical elements provided on the frame 31 from being transmitted to the housing 20. However, if it is determined that the water resistance is not critical to the operation of the device, one or more of the gaskets may be eliminated.

As can be seen in the overview of the above paragraph, the cover 40 is arranged and configured to transmit at least one output of an electromechanical element disposed within the housing. For example, in the embodiment of fig. 1-5, vibrational motion from the insert 30 may be transmitted through the cover 40 to the outer surface 42. In the embodiment of fig. 9, rotational or oscillating motion from the insert may be transferred through the cover 40 "to the skin contacting element 48 via a moveable shaft 48. In the embodiment of fig. 10, the vibratory motion from the insert 30 may be separated from the housing 20 and transferred directly to the skin contacting element 48.

As described above, the one-piece housing 20 defines a volume that is contained by the housing. When the opening 21 is closed by the cover 40, the volume contained by the one-piece housing is at least about 60% of the total volume contained by the one-piece housing 20 and the cover 40. Preferably, the volume contained by the one-piece housing is at least about 80%, more preferably at least about 90%, of the total volume contained by the one-piece housing 20 and cover 40.

The device of the invention is manufactured in the following way: the method includes forming a one-piece housing, assembling a unitary insert, inserting the unitary insert into the housing, attaching the unitary insert to the one-piece housing, and removably applying a cover to the housing. Further, the one-piece housing defines a volume and has a single opening defined by an edge. The housing also has a substantially continuous outer wall and has a projected area substantially larger than the edge. Preferably, the housing has a shoulder and the rim extends above the shoulder. The rim may also have a gasket disposed therearound. Thus, the device may be manufactured by forming a one-piece housing having an opening defined by an edge and disposing a gasket around the edge.

The one-piece shell may be formed by blow molding a thermoplastic preform to a desired final form. One of ordinary skill in the art will recognize the manner in which the dimensions of the preform are designed to achieve the desired final form. For example, the one-piece shell 20 shown in fig. 2 may be manufactured by blow molding the thermoplastic preform 50 shown in fig. 10. Preform 50 has elements of edge 22, such as a groove 25 molded into it. These elements are retained during the blow molding process.

The blow molding process provides a one-piece shell having a substantially continuous outer wall and a substantially smooth continuous inner surface. An alternative molding process includes rotational molding. Furthermore, these processes allow the formation of a final housing shape in which the projected areas PA are symmetrical on opposite sides of one or more planes perpendicular to the edge 22, symmetrical about the center of the opening 21, and/or isotropic. In sharp contrast to injection molding, the blow molding process also allows for the easy formation of a desired one-piece shell having a projected area that is substantially larger than the edge. In cases where the one-piece housing material is subjected to conditions that may alter the dimensions of the opening and/or edges (structures critical to the sealing engagement of the components of the device), it may be useful to incorporate structures for maintaining these dimensions during the manufacturing process. For example, the process equipment may include elements that maintain the diameter of the rim after the preform is formed, during the blow molding process, and during the cooling period after the one-piece shell is completed.

The unitary insert further includes a frame having electromechanical elements interconnected in an electrical circuit disposed thereon. The frame may be formed from one or more structural elements, preferably plastic, which may be formed in any useful manner. For example, one or more elements of the frame may be injection molded plastic components that form a mounting surface for a motor or other motion generating device, a battery or other power source, gears, shafts, and the like. The frame may also have electrical connectors disposed thereon and one or more switches or switching elements. The individual components of the one-piece insert are joined together to form the complete one-piece insert. The insert passes through the single opening of the housing and is attached to the housing. As described above, a single linear motion may be used to insert a unitary insert 30 (such as shown in fig. 4) into a one-piece housing 20. Alternatively, as shown in fig. 6, the method may require: aligning the distal portion 33' 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, the remaining portion having a projected area surrounded by an edge; and inserting the remainder of the unitary insert through the rim.

Optionally, a gasket and/or damping member may be provided between the unitary insert and the housing to further protect the electromechanical elements from liquid ingress and/or inhibit the transfer of motion between the unitary insert and the housing.

The method also includes removably applying a cover to the housing to cover the opening thereof. In one embodiment, the cover is a cap and the step of removably applying the cover includes removably engaging the cap over the rim. In another embodiment, the cover is a plug and the step of removably applying the cover includes removably engaging the plug within the rim. If the cover is a plug, the method may include the step of disposing a gasket around the plug.

The unitary insert 30 is attached to at least one of the one-piece housing 20 and the cover 40 to provide a more robust device. This attachment may be permanent, or it may be temporary or removable. Such attachment may be accomplished by known methods including, but not limited to, welding, adhesives, and mechanical fastening (screws, snaps, interference fit, etc.). In several preferred embodiments, the unitary insert is ultrasonically welded to either the cover or the one-piece housing.

The device of the present invention may be used in any desired body care regimen. Known solutions include cleansing, exfoliating, microdermabrasion, massaging, and the like. In embodiments incorporating optional body care elements, the user can select the appropriate body care element, apply it to the outer surface of the cover, apply water to the body care element (if appropriate), initiate movement of the device, and apply the body care element to the desired location. After use, the body care element may be removed and discarded. Thus, the body-care elements may be in the form of pads, brushes, sponges, facial puffs (gathered polymeric material webs), protrusions (for massaging, etc.), and the like.

Another method of the present invention is directed to a method of manufacturing a hand-held electromechanical device and/or allowing a user to select a component of a hand-held mechanical device body care system. The method comprises the following steps: forming a one-piece housing defining a volume and having a single opening defined by an edge; selecting a unitary insert from a plurality of unitary inserts sized to be insertable through an opening defined by an edge; inserting a selected one-piece insert through a single opening of a housing and attaching the insert to a one-piece housing; selecting a cover from a plurality of covers arranged and configured to mate with a selected unitary insert; and removably applying a cover to close the single opening of the housing. Each of the plurality of unitary inserts includes a frame having electromechanical elements interconnected in an electrical circuit disposed thereon. Each of the plurality of different covers is arranged and configured to mate with one or more of the plurality of different unitary inserts.

The one-piece housing may have any shape, or be selected from a plurality of shapes and sizes and surface configurations, so long as it is suitable for handheld consumer applications. Additionally, the plurality of unitary inserts may be selected from a unitary insert supply having different electromechanical elements, sizes, and/or shapes. Thus, a desired unitary insert may provide different motions, different power levels, and other different properties desired by the user. The plurality of covers may be selected from a supply arranged and configured to mate with the plurality of one-piece housings and the unitary insert. These covers may be caps, plugs, etc., as described above.

Thus, the method provides the manufacturer with the flexibility to manufacture customizable and/or multiple hand-held electromechanical devices on a single production line. Alternatively, the method allows for the formation of a kit of body care devices and interchangeable components such that a consumer can assemble a variety of customizable configurations at home.

As described above, at least two of the one-piece housing, the unitary insert, and the cover are preferably in sealing engagement to resist liquid from entering the one-piece housing. This may be accomplished by disposing a gasket around the rim, around the cover, and/or between the unitary insert and the one-piece housing. Further, the damping member described above may be provided between the one-piece insert and the one-piece housing.

A kit of parts with interchangeable components includes a first component that is a one-piece shell, a second component that is a unitary insert, and a third component that is a cover. The kit includes at least one of each of the first, second and third components, and one of at least two of the components. Thus, the kit may comprise one-piece housing and one-piece inserts and respective covers, or the kit may comprise one-piece inserts and one-piece housings and respective covers. While it is also possible to have a cover and a plurality of one-piece housings and integral inserts, this may be very rare. Finally, the kit may include a plurality of each of the three components.

Figure 12 shows an example of a kit. The kit comprises two integral inserts 101, 102. Each unitary insert 101, 102 has a cover 103, 104, respectively, associated therewith. The one-piece insert/cover combination may be combined with one of four one-piece housings 105, 106, 107, 108 (shown in phantom cross section). However, the unitary insert 101 has a lateral projection 109 on its distal end and this projection interferes with both of the one-piece shells. Thus, the unitary insert 101 can only be used with one-piece housings 105, 107, but not with one-piece housings 108, 109 (as indicated by the arrows connecting the unitary insert and the housings).

The foregoing description and examples are provided to facilitate a complete and non-limiting understanding of the invention disclosed herein. Many modifications and embodiments of the invention can be made without departing from the spirit and scope of the invention, and the invention is therefore defined by the following appended claims.

Claims (19)

1. A method of manufacturing a hand-held electromechanical device for mammalian body care, comprising the steps of:

a) forming a one-piece shell having a single opening defined by an edge, wherein the edge surrounds an edge area and the one-piece shell has a projected area that is substantially larger than the edge area;

b) assembling a unitary insert sized to be insertable through the opening defined by the rim, the unitary insert including a frame having electromechanical elements interconnected in an electrical circuit disposed thereon;

c) inserting the unitary insert through the single opening of the housing;

d) removably applying a cover having an outer 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.

2. The method of claim 1, further comprising the step of sealingly engaging at least two of the cover, frame, and one-piece unitary housing to resist liquid from entering the one-piece housing.

3. The method of claim 1, wherein the one-piece housing has a shoulder and the rim extends from the shoulder.

4. The method of claim 3, further comprising the step of disposing a gasket around the rim.

5. The method of claim 1, wherein the step of forming a one-piece shell comprises subjecting a thermoplastic preform to a blow molding process to form the one-piece shell.

6. The method of claim 1, wherein the step of forming a one-piece housing comprises rotational molding a polymeric material to form the one-piece housing.

7. The method of claim 1, wherein the one-piece housing has projected areas that are symmetrical on opposite sides of a plane perpendicular to the edge.

8. The method of claim 1, wherein the unitary insert has a projected area surrounded by the rim, and the step of inserting the unitary insert through the single opening involves a single linear motion.

9. The method of claim 1, wherein the unitary insert has a projected area that extends outside of the opening, and the step of 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 with a remaining portion of the unitary insert, the remaining portion having a projected area surrounded by the rim; and inserting the remaining portion of the unitary insert through the rim.

10. The method of claim 1, further comprising providing a damping member between the unitary insert and the one-piece shell to inhibit the transfer of motion between the unitary insert and the one-piece shell.

11. The method of claim 1, wherein the removable cover is arranged and configured to transfer at least one output of the electromechanical element disposed within the one-piece housing through the outer surface of the cover.

12. The method of claim 11, wherein the cover further comprises an aperture having a washer and a movable shaft disposed therein, and wherein the movable shaft is operably connected to the motor to transfer motion from the motor to a skin contacting element disposed outside the one-piece housing.

13. 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.

14. 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.

15. The method of claim 14, further comprising the step of disposing a gasket around the plug.

16. The method of claim 1, further comprising the step of disposing a gasket around the unitary insert between the unitary insert and the one-piece shell.

17. The method of claim 1, further comprising the step of providing a surface structure on an exterior surface of the one-piece shell.

18. The method of claim 1, wherein attaching the unitary insert comprises attaching the unitary insert to the one-piece shell after inserting the unitary insert through the opening.

19. The method of claim 1, wherein attaching the unitary insert comprises attaching the unitary insert to the cover before removably applying the cover to close the opening.