Classifications

• • A—HUMAN NECESSITIES
  • A46—BRUSHWARE
  • A46B—BRUSHES
  • A46B5/00—Brush bodies; Handles integral with brushware
  • A46B5/02—Brush bodies; Handles integral with brushware specially shaped for holding by the hand
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/16—Making multilayered or multicoloured articles
• • A—HUMAN NECESSITIES
  • A46—BRUSHWARE
  • A46D—MANUFACTURE OF BRUSHES
  • A46D3/00—Preparing, i.e. Manufacturing brush bodies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/16—Making multilayered or multicoloured articles
  • B29C45/1675—Making multilayered or multicoloured articles using exchangeable mould halves
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/16—Making multilayered or multicoloured articles
  • B29C45/1676—Making multilayered or multicoloured articles using a soft material and a rigid material, e.g. making articles with a sealing part
• • A—HUMAN NECESSITIES
  • A46—BRUSHWARE
  • A46B—BRUSHES
  • A46B2200/00—Brushes characterized by their functions, uses or applications
  • A46B2200/10—For human or animal care
  • A46B2200/1066—Toothbrush for cleaning the teeth or dentures
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
  • A61C17/00—Devices for cleaning, polishing, rinsing or drying teeth, teeth cavities or prostheses; Saliva removers; Dental appliances for receiving spittle
  • A61C17/16—Power-driven cleaning or polishing devices
  • A61C17/22—Power-driven cleaning or polishing devices with brushes, cushions, cups, or the like
  • A61C17/32—Power-driven cleaning or polishing devices with brushes, cushions, cups, or the like reciprocating or oscillating
  • A61C17/34—Power-driven cleaning or polishing devices with brushes, cushions, cups, or the like reciprocating or oscillating driven by electric motor
  • A61C17/3409—Power-driven cleaning or polishing devices with brushes, cushions, cups, or the like reciprocating or oscillating driven by electric motor characterized by the movement of the brush body
  • A61C17/3481—Vibrating brush body, e.g. by using eccentric weights
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
  • B29C45/16—Making multilayered or multicoloured articles
  • B29C45/1671—Making multilayered or multicoloured articles with an insert
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/42—Brushes
  • B29L2031/425—Toothbrush

Definitions

• the invention relates generally to manufacturing of dental care implements, and more particularly, to methods of manufacturing toothbrushes having common core and overmolds.
• Oral care implements are in use by many people on a daily basis.
• a handle is usually provided to be grasped and manipulated by the user as needed.
• many handles are simply linear or anatomically corrected rods of relatively rigid material which are neither comfortable, nor given to easily manipulation.
• use of an oral care implement may commonly occur under wet conditions, which can cause the handle to be slippery.
• toothbrushes are being provided with softer elastomeric padding over parts of the toothbrush handle, with exemplary teachings provided in U.S. Patent Nos. 7,458,125; 7,240,390; and 7,401,377.
• soft handle coverings for other oral care implements are taught in U.S. Patent No. 5,501,597; 6,361,317; and 7,226,289.
• One aspect of the preferred embodiments includes a method of manufacturing a dental implement.
• the dental implement includes a shaft having a plastic core and an overmold.
• the method includes forming a plastic core in a first mold, removing the plastic core from the first mold, selecting one of a plurality of second molds, with each of the plurality of second molds having a different mold cavity such that an overmold formed by one of the plurality of the second modes and an overmold formed by another one of the plurality of second molds have different configurations, placing the plastic core into the selected one of the plurality of second molds, forming an overmold about the plastic core by injecting a material into the mold cavity of the selected one of the plurality of second molds, and removing the plastic core and overmold from the mold cavity.
• the dental implement includes a shaft having a plastic core and an overmold.
• the method includes providing a first plastic core formed from a first mold, selecting a first one of a plurality of second molds, each of the plurality of second molds having a different mold cavity such that an overmold formed by one of the plurality of the second molds and an overmold formed by another one of the plurality of second molds have different configurations, placing the first plastic core into the first one of the plurality of second molds, forming a first overmold about the first plastic core by injecting a material into the mold cavity of the first one of the plurality of second molds, and removing the first plastic core and the first overmold from the mold cavity.
• the method also includes providing a second plastic core formed from the first mold, selecting a second one of a plurality of second molds, placing the second plastic core into the second one of the plurality of second molds, forming a second overmold about the second plastic core by injecting a material into the mold cavity of the second one of the plurality of second molds, and removing the second plastic core and the second overmold from the mold cavity.
• a further aspect of the preferred embodiments includes a dental implement kit.
• the kit includes a first dental implement with a first plastic core formed of a first mold, and a first overmold formed of a first one of a plurality of second molds, each of the plurality of second molds having a different mold cavity such that an overmold formed by one of the plurality of the second molds and an overmold formed by another one of the plurality of second molds have different configurations.
• the kit also includes a second dental implement with a second plastic core formed of the first mold, and a second overmold formed of a second one of a plurality of second molds. The first overmold and the second overmold have different configurations.
• the method also includes chemically blending the injected material with the plastic core, and cooling the overmold with the chemically blended injected material and the plastic core forming a chemical bond therebetween.
• the injected material preferably has a temperature that softens the plastic core for chemically blending the core with the injected material.
• the method also includes arranging electrically functional elements within the plastic core, the electrically functional elements including an electrically operated functional unit and an electric supply unit connectable to an energy source for energizing the electrically operated functional unit.
• the dental implement includes a head member and a neck located between the head member and the plastic core, and the method may further include attaching a plurality of bristles to the head member to form a brush head.
• the injected material may be, for example, an elastomer.
• FIG. 1 is a top plan view of an exemplary embodiment of a toothbrush constructed in accordance with the preferred embodiments of the invention
• FIG. 2 is a second top plan view of the toothbrush shown in Fig. 1;
• FIG. 3 is a side sectional view taken along line III-III of Fig. 2;
• FIG. 4 is a top plan view of another exemplary embodiment of a toothbrush constructed in accordance with the preferred embodiments;
• Fig. 5 is a second top plan view of the toothbrush shown in Fig. 4; and [0017] Fig. 6 is a side sectional view taken along line VI- VI of Fig. 5.
• the figures illustrate an oral care or dental implement in the form of a toothbrush having an improved handle and a head with bristles or other tooth engaging elements. While reference is made to a toothbrush with an improved handle, other oral care implements, such as inter-proximal picks, flossing tools, plaque scrapers, tongue and soft tissue cleansers/massagers, and the like, may use the same handle. It should also be understood that other embodiments may be utilized and that structural and functional modifications may be made without departing from the scope of the present invention.
• the exemplary aspects of the invention include a toothbrush with a rigid plastic core handle that is chemically bonded to a thermoplastic elastomer overmold during an overmolding process, with the overmold defining a gripping region for a user's hand during use of the toothbrush.
• the resulting overmold grip may have different exterior shapes for different types of users (e.g., adults, children, boys, girls, men, women) with the different shapes altered to anatomically fit the targeted user's hands.
• boys and girls may prefer different overmold designs, just as men and women or adults and children may prefer different overmold designs especially configured for the respective sizes, strength and pressure applied by the hands of the respective users.
• the preferred embodiments improve the control and comfort of the toothbrush for the user by providing a comfortable elastomeric covering about the handle of the toothbrush sized and shaped for the user's hand.
• a further benefit is provided when the toothbrush is an electric toothbrush. It is well-known that electric/sonic toothbrushes vibrate during use. This vibration can cause discomfort to a user, especially when the user is holding a rigid handle of the vibrating toothbrush.
• the elastomeric overmold of the preferred embodiments provides a comfortable and secure grip of the toothbrush while reducing the vibration to the user as the vibration is absorbed by the elastomeric covering. Accordingly, a further benefit of the invention is the reduction of healthcare concerns caused to the hand, wrist and forearm of a user by absorption of the vibrations by the elastomeric overmold and resulting reduction of vibrations to the user's joints.
• Figs. 1-3 illustrate an exemplary embodiment of a toothbrush 10 constructed in accordance with the invention.
• the toothbrush 10 includes a core handle 12, a head 14 and a neck region 18 coupled therebetween.
• the core handle 12, neck region 18 and head 14 may be integrally formed or alternatively formed separately and attached along the neck region 18 located between the head and core handle and coupling the two into a single unit.
• the head 14 has a base portion 20 having a bristle mounting surface or face 22 from which a plurality of bristles 16 may be attached, preferably via insertion into bores 24 (Fig. 3) distributed in the base portion 20 across the face 22.
• the core handle 12 is a generally cylindrical or tubular rigid plastic shaft extending from a shank 46 of the neck region 18 to a bottom 26 of the toothbrush 10 at a distal end thereof.
• the toothbrush 10 is an electrical or sonic toothbrush with a bottom end cap 28 attached to the core handle 12, preferably via a frictional fit.
• the end cap 28 is removable from the core handle at the bottom 26 thereof to expose a cylindrical channel for an energy source (e.g., battery).
• the end cap 28 preferably has a planar boundary (e.g., rim, wall, face, surface) 30 that allows the toothbrush 10 to stand upright when placed on a planar horizontal surface.
• the core handle 12 is shown in tubular form enclosing electrically functioning elements 32 that are arranged within the elongated shaft of the core handle 12 and neck region 18. It is contemplated that the core handle 12 is not limited to a cylindrical or tubular shape.
• the core handle 12 may be of other appropriate shape, such as a variety of suitable polygons.
• the electrically functional elements 32 include an electrically operated functional unit 34 (e.g., vibration member including an electric motor 36 coupled to an eccentric member 38), and an electric supply unit 40 of conductive lines 42 connectible between the electric motor 36 and an energy source 44 ⁇ e.g., battery, rechargeable battery, connector to electrical outlet).
• an electrically operated functional unit 34 e.g., vibration member including an electric motor 36 coupled to an eccentric member 38
• an electric supply unit 40 of conductive lines 42 connectible between the electric motor 36 and an energy source 44 ⁇ e.g., battery, rechargeable battery, connector to electrical outlet.
• the electrically functional elements 32 may include one or more piezoelectric elements. In some embodiments, the electrically functional elements 32 may include more or fewer components as desired.
• a switch 52 at a front side 54 of the toothbrush 10 is operably connectable to the electrically operated functional unit 34 to connect or interrupt power from the energy source 44 to the electrically operated functional unit 34 based on the position of the switch 52, toward or away from contact with the electric supply unit 40.
• the core handle 12 is a hard plastic shaft comprising a rigid polymer material.
• a rigid polymer material provides strength and durability for portions of the toothbrush 10 or dental instrument that will be subjected to stresses and forces associated with gripping the toothbrush 10 and using the toothbrush 10 for its intended dental purpose. Strength and durability will prevent these portions of the toothbrush 10 from cracking or being deformed under stress.
• the rigid polymer material may include any rigid thermoplastic material. Suitable rigid thermoplastics include polycarbonates, acrylonitrile butadiene styrene, polyamides, acetals, polysulfones, and polypropylene.
• the rigid polymer material may also include a rigid chemical cure or thermocure polymer material. Besides providing rigidity, strength, and durability, a chemical cure or thermocure polymer material also provides the advantages of being autoclavable.
• Exemplary rigid chemical cure or thermocure polymers include epoxies, phenolics, acrylates, urethanes and polyesters.
• the toothbrush 10 includes a thermoplastic elastomer (TPE) overmold grip 50 surrounding the core handle 12 where a person's hand is expected to hold the toothbrush 10 during use.
• TPE thermoplastic elastomer
• the overmold grip 50 is preferably assembled onto the rigid plastic core handle 12 by placing the core handle 12 in a suitable mold that seals off the toothbrush 10 at the shank 46 and the bottom 26 of the shaft. A suitable TPE material is then injected into a suitably shaped mold cavity as understood by a skilled artisan.
• the thermoplastic elastomer overmold grip 50 is chemically bonded to the rigid plastic core handle 12 during the overmolding process that forms the overmold grip 50 about the core handle 12.
• the elastomer overmold grip 50 and the core handle 12 are chemically bonded during the overmolding process for the elastomer overmold grip 50 by the injection of the elastomer that is hot enough to chemically blend with the material of the core handle 12.
• the elastomer is injected at a temperature hot enough to cause an outer wall 48 of the plastic core handle 12 to soften or melt sufficiently for chemical blending of the outer wall with the hot elastomeric material of the injection overmold.
• the chemical blend remains creating a chemical bond for holding the rigid plastic core handle 12 and the thermoplastic elastomer overmold grip 50 together.
• the overmold grip 50 is preferably shaped for comfortable handing by the user of the toothbrush 10. It is understood that the invention is not limited to the shape of the overmold grips 50 and 60 (Figs. 4-6), but that the overmold grip 50, 60 may be formed in any shape that provides the intended user with a comfortable grip for use during the dental procedure. As such, the overmold grip 50, 60 may be formed by conventional means to a shape targeted towards the general size and shape of a user's hand regardless of the age or gender of the user. In addition, the overmold grip 50, 60 may include various configurations, such as different colors, patterns, designs, motifs, etc. Further, in some embodiments, the mold cavity that molds the overmold grip 50, 60 may be adjustable to produce overmold grip 50, 60 of the various shapes, sizes, colors, patterns, designs, motifs, etc.
• Figs. 4-6 depict a second example of the preferred embodiments with a toothbrush 100 substantially similar to the toothbrush 10 discussed above.
• the toothbrush 100 shown in Figs. 4-6 is identical to the toothbrush 10 shown in Figs. 1-3 except for the exterior shape of the overmold grip 60.
• the overmold grip 60 is assembled onto the rigid plastic core handle 12 and chemically bonded to the core handle 12 as discussed above for the overmold grip 50. That is, the core handle 12 is preferably placed in a suitable mold that seals off the toothbrush 100 at the shank 46 and the bottom 26 of the core handle 12 shaft.
• the suitable mold is configured differently to form the overmold grip 60 which is different than the overmold grip 50.
• the mold cavity of the mold that forms the overmold grip 60 has a different shape, size, color, pattern, design and/or motif than the mold cavity of the mold that forms the overmold grip 50.
• the elastomer is injected at a temperature hot enough to cause the outer wall 48 of the plastic core handle 12 to soften melt sufficiently for chemical blending of the outer wall and the hot elastomeric material of the injected overmold.
• the overmold grip 60 is formed in an alternative shape for comfortable handling by a user having a different gender or age than the targeted person or group of the first exemplary toothbrush.
• either of the toothbrushes 10, 100 is preferably made by the same method.
• the plastic core handle 12 is molded in a first mold as a shaft that is removed from the first mold subsequent the molding.
• a second mold used for manufacturing one of the overmold grips overmold grips 50 or 60 is selected from a plurality of the second molds, with each of the plurality of second molds having a different mold cavity such that an overmold (e.g., overmold grip 50) formed by one of the plurality of the second modes and an overmold (e.g., overmold grip 60) formed by another one of the plurality of second molds have different configurations.
• the plastic core handle 12 is placed into the selected one of the plurality of second molds. Then an overmold (e.g., overmold grip 50 or overmold grip 60) is formed about the plastic core handle 12 by injecting a material into the selected mold cavity, and the plastic core handle 12 and the respective overmold grip (e.g., overmold grip 50, overmold grip 60) is removed from the selected mold cavity.
• an overmold e.g., overmold grip 50 or overmold grip 60
• a kit may be provided that include a first dental implement with a first plastic core 12 and a overmold grip 50, and a second dental implement with a second plastic core 12 and a overmold grip 60.
• the plastic core 12 may be common among the dental implements
• the overmold grips 50, 60 may have different configurations.
• the overmold grip 50, 60 comprises a thermoplastic elastomer (TPE) material.
• TPE thermoplastic elastomer
• the elastomeric material provides increased comfort and gripability to the handle of the toothbrush/dental instrument that is gripped by the user when using the toothbrush manually.
• the elastomeric material may include an elastomeric chemical cure or a thermocure polymer material for the added advantage of autoclavability.
• thermoplastic elastomers include ethylene-propylene rubber, polyolefin elastomers, and synthetic rubber.
• suitable elastomer chemical cure or thermocure polymers include silicon rubber, natural rubber, synthetic rubber, and lower durometer urethanes.
• the elastomeric material of the overmold grip surface preferably has a hardness durometer measurement ranging between A11-A50 Shore hardness, although materials outside this range may be used.
• a more preferred range of the hardness durometer rating is between A25-A40 Shore hardness.
• end cap 28 is preferably attached to the core handle 12 by threaded, snap fit or other frictional engagement, yet may alternatively be attached by non- frictional means such as an adhesive or magnets within the scope of the invention.

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• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Brushes (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)

Applications Claiming Priority (1)

Publications (1)

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ID=44625361

Family Applications (1)

Country Status (9)

Families Citing this family (5)

Family Cites Families (11)

• 2011
  • 2011-03-01 EP EP11707972.3A patent/EP2680720A1/en not_active Withdrawn
  • 2011-03-01 AU AU2011360964A patent/AU2011360964A1/en not_active Abandoned
  • 2011-03-01 WO PCT/US2011/026652 patent/WO2012118489A1/en active Application Filing
  • 2011-03-01 KR KR1020137025760A patent/KR20130141671A/ko active IP Right Grant
  • 2011-03-01 CN CN2011800688035A patent/CN103415229A/zh active Pending
  • 2011-03-01 MX MX2013009902A patent/MX2013009902A/es not_active Application Discontinuation
  • 2011-03-01 CA CA2828376A patent/CA2828376A1/en not_active Abandoned
  • 2011-03-01 RU RU2013143944/12A patent/RU2555803C2/ru not_active IP Right Cessation
• 2012
  • 2012-02-29 TW TW101106472A patent/TW201247142A/zh unknown

Non-Patent Citations (1)

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