RU2555803C2 - Fabrication tooth brushes with universal core - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: this brush comprises rigid plastic core, handle and external moulded element of various shapes to suit particular anatomy of user hand. Proposed process comprises the steps that follow. Plastic ore is moulded in first die. It is withdrawn therefrom. One of multiple second dies is selected with cavity differing from other dies. Plastic core is placed in selected second die to mould the external element around plastic core by injection of material into die cavity. Injected material is mixed chemically with plastic core and external moulded element is cooled down. Note here that said mixed injected material and plastic core form a chemical bond there between. Now, plastic ore is withdrawn along with external moulded element from die cavity.

EFFECT: perfected method.

12 cl, 6 dwg

Description

FIELD OF THE INVENTION

The invention relates generally to the manufacture of dental care devices, and more particularly to methods for manufacturing toothbrushes having a universal core and covering molded elements.

BACKGROUND OF THE INVENTION

Oral care devices, especially toothbrushes, are used by many people for daily care. Such devices typically provide a handle for gripping and manipulating the user as required. However, many handles are simply straight or anatomically made rods of relatively rigid material that are neither comfortable nor easy to handle. In addition, the use of an oral care device can usually occur in wet conditions, which can make the handle slippery.

To provide improved control and greater comfort for the user, toothbrushes with softer elastomeric surfacing on some parts of the handle of the toothbrush are provided, examples of the disclosures of which are given in US patent No. 7458125; 7,240,390 and 7,401,377. Examples of soft coating for a pen for other oral care devices are disclosed in US Pat. Nos. 5,501,597; 6361317 and 7226289.

The problems associated with a handle made of relatively hard material are exacerbated when the toothbrush is electric or otherwise provided with energy due to vibrations caused by the movement of the toothbrush head during use under the influence of electricity. Managing such toothbrushes becomes more problematic when an electric toothbrush is used by children with smaller hands.

Accordingly, there is a need for an oral care device that provides improved control and greater comfort when using the device regardless of the size of the user's hand.

SUMMARY OF THE INVENTION

One aspect of the preferred embodiments includes a method of manufacturing a dental device. A dental device includes a shaft having a plastic core and a covering molded member. The method includes the steps of forming a plastic core in a first mold, removing the plastic core from the first mold, selecting one of the plurality of second molds, each of the plurality of second molds having a different mold cavity, so that the mold cover formed by one of the plurality of second shapes, and the covering molded member formed by another of the plurality of second shapes have different configurations, a plastic core is placed in a selected one of the plurality of second shapes, forming t covering the molded element around the plastic core by injecting material into the mold cavity of a selected one of the plurality of second molds, and removing the plastic core and the covering molded element from the mold cavity.

Another aspect of the preferred embodiments includes a method of manufacturing a dental device. A dental device includes a shaft having a plastic core and a covering molded member. The method includes the steps of providing a first plastic core formed by a first mold, selecting a first of a plurality of second molds, each of the plurality of second molds having a different mold cavity, so that a covering molded member formed of one of the plurality of second molds, and the coating molded member formed by another of the plurality of second shapes, have different configurations, place the first plastic core in the first of the plurality of second shapes, form a first coating the wrapped element around the first plastic core by injecting material into the mold cavity of the first of the plurality of second molds, and the first plastic core and the first covering molded element are removed from the mold cavity. The method also includes the steps of providing a second plastic core formed by the first mold, selecting a second of the plurality of second shapes, placing a second plastic core into a second of the plurality of second shapes, forming a second covering molded member around the second plastic core by injecting material into the cavity the mold is the second of a plurality of second molds and the second plastic core and the second mold cover are removed from the mold cavity.

An additional aspect of the preferred embodiments includes a set of dental devices. The kit includes a first dental device with a first plastic core formed by a first mold and a first covering molded element formed by a first of a plurality of second molds, each of the plurality of second molds having a different mold cavity, so that a covering molded mold formed by one of a plurality of second shapes, and a covering molded member formed by another of the plurality of second shapes have different configurations. The kit also includes a second dental device with a second plastic core formed by the first mold and a second covering molded member formed by a second of the plurality of second molds. The first covering molded element and the second covering molded element have different configurations.

In some embodiments, the method also includes the step of chemically mixing the injected material with a plastic core and cooling the coating molded member, whereby the chemically bonded material and the plastic core form a chemical bond. Within this exemplary aspect, the injected material preferably has a temperature at which the plastic core is softened to chemically bond the core with the injected material. In a further aspect of the preferred embodiments, the method also includes installing electrical functional elements in a plastic core, the electrical functional elements including an electric functional unit and an electric power unit configured to connect to a power source to provide electrical energy function block. In yet another aspect of the preferred embodiments, the dental device includes a head member and a constriction 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 cleaning head. The injected material may be, for example, an elastomer, although the invention is not limited to a particular material.

Further applications of the present invention will become apparent from the detailed description below. It should be understood that the detailed description and specific examples, although showing a preferred embodiment of the invention, are for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and accompanying drawings, in which:

FIG. 1 is a top view of an exemplary embodiment of a toothbrush made in accordance with preferred embodiments of the invention;

FIG. 2 is a second top view of the toothbrush of FIG. one;

FIG. 3 is a side sectional view taken along line III-III of FIG. 2;

FIG. 4 is a top view of another exemplary embodiment of a toothbrush made in accordance with preferred embodiments;

FIG. 5 is a second top view of the toothbrush of FIG. four; and

FIG. 6 is a side sectional view taken along line VI-VI of FIG. 5.

DETAILED DESCRIPTION

The following description of the preferred embodiment (s) is essentially just an example and in no way limits the invention, its use or use.

Unless otherwise indicated, all numbers, quantities, and geometric elements presented herein and elsewhere in the description should be understood to include significant approximations of the term presented. For example, the term “planar” should be understood to include generally or approximately planar configurations.

The drawings illustrate an oral care device or a toothbrush device in the form of a toothbrush having an improved handle and head with bristles or other tooth engaging elements. Although the links are related to a toothbrush having an improved handle, the same handle can be used in other oral care devices, for example toothpicks for interdental spaces, tools for cleaning interdental spaces, plaque scrapers, cleaners / massagers for tongue and soft tissues and the like. It should also be understood that other embodiments may be used and that structural and functional modifications may be made without departing from the scope of the present invention.

Although the invention is not limited to a specific embodiment, exemplary aspects of the invention include a toothbrush having a handle with a hard plastic core that is chemically bonded to the thermoplastic elastomer coating molded member during the “molding over” process, wherein the coated molded element forms an area for gripping the user's hand while using a toothbrush. The resulting covering molded grip may have different external forms for different types of users (eg, adults, children, boys, girls, men, women), while various forms are adapted to match the anatomy of the hand of the target user. For example, boys and girls may prefer different designs of the covering molded element, and likewise, men and women or adults and children may prefer different designs of the covering molded element, specially made for the respective sizes, strength and pressure applied by the hands of the respective users.

Preferred embodiments improve the control and user comfort of the toothbrush by providing a convenient elastomeric coating around the handle of the toothbrush that is sized and shaped suitable for the user's hand. An additional advantage is provided when the toothbrush is an electric toothbrush. It is well known that electric / acoustic toothbrushes vibrate during use. This vibration can cause discomfort to the user, especially when the user holds the hard handle of a vibrating toothbrush. By providing a convenient elastomeric grip around the handle of the toothbrush, and not just selected portions thereof, the elastomeric covering molded element of the preferred embodiments provides a convenient and reliable grip of the toothbrush, while reducing user vibration, since vibration is absorbed by the elastomeric coating. Accordingly, an additional benefit of the invention is to reduce the harm caused to the brush by the wrist and forearm of the user, due to the absorption of vibrations by the elastomeric covering molded element and resulting from the reduction of vibration of the joints of the user.

In FIG. 1-3 illustrates an exemplary embodiment of a toothbrush 10 made according to the invention. Toothbrush 10 includes a handle core 12, a head 14, and a tapered region 18 connecting them. The handle core 12, the constricted region 18 and the head 14 may be integrally formed or, alternatively, formed separately and attached along the constricted region 18 located between the head and the core of the pen and connecting these two elements into one unit. The head 14 has a main portion 20 having a surface or side 22 for mounting bristles to which a plurality of bristles 16 can be attached, preferably by insertion into the holes 24 (FIG. 3) distributed in the main portion 20 on the side 22.

The handle core 12 is a generally cylindrical or tubular rigid plastic rod extending from the body portion 46 of the narrowed region 18 to the lower portion 26 of the toothbrush 10 at its distal end. Without limitation to a specific embodiment, the toothbrush 10 is an electric or acoustic toothbrush having a lower end cap 28 attached to the handle core 12, preferably by friction fit. The end cap 28 is configured to be removed from the core of the handle in the region of its lower portion 26 to provide access to the cylindrical channel for a power source (eg, battery). The end cap 28 preferably has a flat border (for example, a rim, wall, side, surface) 30, allowing the toothbrush 10 to stand upright when mounted on a flat horizontal surface.

In FIG. 3, the handle core 12 has a tubular appearance and accommodates electrical functional elements 32 that are mounted in an elongated shaft of the handle core 12 and a narrowed region 18. It is understood that the handle core 12 is not limited to a cylindrical or tubular shape. For example, the handle core 12 may have other suitable shapes, for example, a plurality of suitable polygons. Electrical functional elements 32 include an electric functional unit 34 (for example, a vibrating element including an electric motor 36 connected to an eccentric element 38) and an electric power unit 40 of the conductive lines 42 configured to connect the electric motor 36 and the power source 44 (e.g. battery, rechargeable battery, connector with electrical outlet). In some embodiments, electrical functional elements 32 may include one or more piezoelectric elements. In some embodiments, electrical functional elements 32 may include, if necessary, more or less components. In the illustrated embodiment, the switch 52 on the front side 54 of the toothbrush 10 is operatively connected to the electric function block 34 to connect or interrupt the power from the power source 44 to the electric function block 34, depending on the position of the switch 52, to the contact or from the contact with an electric power supply 40.

The core 12 of the handle is a rigid plastic rod containing a rigid polymer material. Rigid polymeric material gives strength and reliability to the areas of the toothbrush 10 or the dental tool, which is subjected to loads and the forces arising from the gripping of the toothbrush 10 and the use of the toothbrush 10 in accordance with its dental purpose. Strength and reliability do not allow breakage or deformation of these sections of the toothbrush 10 under load.

In preferred embodiments, the rigid polymeric material may include any rigid thermoplastic material. Suitable rigid thermoplastics include polycarbonates, acrylonitrile butadiene styrene, polyamides, acetals, polysulfones and polypropylene. Rigid polymeric material may also include hard chemically or thermoset polymer material. In addition, providing stiffness, strength and durability of the chemically or thermoset polymer material also provides the benefits of autoclaving.

Examples of rigid chemically or thermoset polymers include epoxy resins, phenolic resins, acrylates, urethanes, and polyesters.

As can be seen in FIG. 1-3, the toothbrush 10 includes a thermoplastic elastomer (TPE) covering molded grip 50, a handle surrounding the handle core 12, by which a human hand is supposed to hold the toothbrush 10 during use. Without limiting the particular design, the molded grip 50 is preferably mounted on the hard plastic handle core 12 by placing the handle core 12 in a suitable shape that insulates the toothbrush 10 on the body portion 46 and in the lower portion 26 of the shaft. A suitable TPE material is then injected into a mold cavity of a suitable shape, as one skilled in the art will understand.

The coating molded grip 50 of the thermoplastic elastomer is chemically bonded to the hard plastic handle core 12 during the “over-molding” process, in which a coating molded grip 50 is formed around the handle core 12. The elastomeric coating molded grip 50 and the handle core 12 are chemically bonded during the process over molding to form an elastomeric coating molded grip 50 by injecting an elastomer that is hot enough to chemically mix with core core 12 handles. In particular, the elastomer is injected at a temperature high enough to soften or melt the outer wall 48 of the plastic core 12 of the handle, sufficient to chemically mix the outer wall with the hot elastomeric material injected to form a coating molded member. As the elastomer cools, the chemical mixture is maintained, creating a chemical bond to hold together the rigid plastic core 12 of the handle and the covering molded grip 50 of the thermoplastic elastomer.

The cover molded grip 50 preferably has a shape convenient for the user to grip the toothbrush 10. It should be understood that the invention is not limited to the shape of the coated molded grippers 50 and 60 (FIGS. 4-6), but that the cover molded grip 50, 60 can be of any shape providing the target user with a comfortable grip for use in a dental procedure. Essentially, the covering molded grip 50, 60 can be formed by conventional means to obtain a shape close to the total size and shape of the user's hand, regardless of the age or gender of the user. In addition, the covering molded grip 50, 60 may include various configurations, for example various colors, patterns, design options, graphic motifs, etc. In addition, in some embodiments, the mold cavity by which the coating molded gripper 50, 60 is molded can be adjusted to produce the coated molded gripper 50, 60 of various shapes, sizes, colors, patterns, design options, graphic motifs, etc. .

In FIG. 4-6, a second example of preferred embodiments is shown, wherein the toothbrush 100 is substantially similar to the toothbrush 10 discussed above. In particular, the toothbrush 100 shown in FIG. 4-6 is identical to the toothbrush 10 shown in FIG. 1-3, with the exception of the external shape of the cover molded grip 60. The cover molded grip 60 is mounted on a hard plastic handle core 12 and chemically connected to the handle core 12, as discussed above with respect to the cover molded grip 50. That is, the handle core 12 is preferably placed in a suitable shape that insulates the toothbrush 100 at the body portion 46 and the lower portion 26 of the shaft of the handle core 12. However, a suitable mold is otherwise made to form a coating molded grip 60 different from the covering molded grip 50. In other words, the cavity of the mold forming the covering molded grip 60 has a different shape from the cavity of the mold forming the covering molded grip 50, shape, size, color, pattern, design options and / or graphic motif. Regardless of the configuration of the mold cavity, the elastomer is injected at a temperature high enough to soften or melt the outer wall 48 of the plastic core 12 of the handle, sufficient to chemically bond the outer wall and the hot elastomeric material of the injected coating mold. The cover molded grip 60 has an alternative shape for convenient grip by a user having a gender and age different from those of a person or group of people for whom the first exemplary toothbrush is intended.

According to preferred embodiments, both the toothbrush 10 and the toothbrush 100 are preferably made in the same way. For example, the plastic core 12 of the handle is molded in a first shape in the form of a rod, which is removed from the first shape after molding. The second mold used to make one of the coating molded grippers 50 or 60 is selected from a plurality of second molds, each of the plurality of second molds having a mold cavity distinct from the others, such that a covering molded member (e.g., covering molded gripper 50), formed by one of the plurality of second shapes, and a covering molded member (e.g., covering the molded grip 60) formed by another of the plurality of second shapes, have various configurations. The plastic handle core 12 is placed in a selected one of a plurality of second shapes. Then, a covering molded member (e.g., a covering molded grip 50 or a covering molded grip 60) is formed around a plastic handle core 12 by injecting material into a selected mold cavity, and a plastic handle core 12 and a corresponding covering molded grip (e.g., a covering molded grip 50, covering molded grip 60) are removed from the selected mold cavity.

In some embodiments, a kit may be provided comprising a first dental device having a first plastic core 12 and covering the molded grip 50, and a second dental device having a second plastic core 12 and covering the molded grip 60. In such a set, although the plastic core 12 dental devices may be the same, the covering molded grips 50, 60 may have different configurations.

In preferred embodiments, the coated molded grip 50, 60 comprises a thermoplastic elastomeric (TPE) material. The elastomeric material provides increased comfort and provides good grip on the handle of the toothbrush / dental tool that the user grips during manual brushing. Alternatively, the elastomeric material may include an elastomeric chemically or thermoset polymer material for the added benefit of autoclaving. Examples of thermoplastic elastomers include ethylene propylene rubber, polyolefin elastomers, and synthetic rubber. Examples of suitable elastomeric chemical curing or thermosetting polymers include silicone rubber, natural rubber, synthetic rubber, and low hardness urethanes. To ensure optimum comfort as well as better controllability, the elastomeric material of the surface of the coating molded grip preferably has a durometer-measured hardness in the range A11-A50 of Shore hardness, although materials whose hardness is outside this range can be used. More preferred is the range measured by the durometer hardness, comprising A25-A40 shore hardness.

Although the invention has been described in detail and with reference to specific examples, it will be apparent to those skilled in the art that various changes and modifications can be made to it without departing from its meaning and scope. For example, end cap 28 is preferably attached to the core of handle 12 by a threaded snap connection or other friction engagement, but can alternatively be attached by non-friction means, such as adhesive or magnets, within the scope of the invention. Without further elaboration, the foregoing illustrates the invention so fully that other persons can, by using current or future knowledge, easily adapt the invention for use in a variety of service environments.

When used throughout the document, ranges are used as abbreviations for describing any and every value within a range. Any value within the range can be selected as the end of the range. In addition, all cited documents cited herein are hereby incorporated by reference in their entirety. In the event of a conflict between the definition given in this disclosure and the definition given in the cited source, the present disclosure takes precedence.

Claims (12)

1. A method of manufacturing a dental device, and the dental device has a rod with a plastic core and covering the molded element, the method comprises the steps of:
a) form a plastic core in a first form;
b) removing the plastic core from the first mold;
c) one of the plurality of second molds is selected, each of the plurality of second molds having a casting cavity different from the others, so that the covering molded member formed by one of the plurality of second molds and the covering molded member formed by another of the plurality of second molds have various configurations;
d) placing the plastic core in one mold selected from a plurality of second molds;
e) forming a covering molded member around a plastic core by injecting material into a mold cavity of one mold selected from a plurality of second molds; and
f) removing the plastic core and the covering molded member from the mold cavity,
wherein the method further comprises a step in which, after step e), the injected material is chemically mixed with the plastic core and the coating molded member is cooled, while the chemically mixed injected material and the plastic core form a chemical bond with each other. 2. The method according to claim 1, in which the injected material has a temperature at which the plastic core is softened to chemically connect the core with the injected material. 3. The method according to claim 1, further comprising installing electrical functional elements in a plastic core, wherein the electrical functional elements include an electrical functional unit and an electrical power unit configured to connect to a power source to provide electrical functional energy block. 4. The method according to claim 1, in which step d) includes inserting portions of the plastic core into the cavity of the mold, the plastic core being between the embedded sections. 5. The method according to claim 1, in which the plastic core includes a distal end forming a channel extending into the core, and further comprising the step of inserting electrical functional elements into the channel and attaching an end cap to the distal end of the plastic core to close the channel . 6. The method according to claim 1, in which the dental device includes a head element and a narrowing located between the head element and the plastic core, and further comprising the step of attaching a plurality of bristles to the head element to form a cleaning head. 7. The method according to claim 1, in which the injected material is an elastomer. 8. The method according to claim 1, in which the configuration includes one or more of the shapes, sizes, colors, patterns, design options and graphic motifs. 9. A method of manufacturing a dental device having a rod with a plastic core and covering the molded element, the method comprises the steps of:
a) provide a first plastic core formed from a first mold;
b) the first of the plurality of second shapes is selected, each of the plurality of second shapes having a mold cavity different from the others, so that the covering molded member formed by one of the plurality of second shapes and the covering shaped member formed by another of the plurality of second shapes have various configurations;
c) placing the first plastic core in the first of a plurality of second shapes;
d) forming a first covering molded member around the first plastic core by injecting material into the mold cavity of the first of a plurality of second molds;
e) removing the first plastic core and the first covering molded member from the mold cavity;
f) providing a second plastic core formed from a first mold;
g) choose the second of many second forms;
h) placing a second plastic core in a second of a plurality of second shapes;
i) forming a second covering molded member around a second plastic core by injecting material into a mold cavity of a second of a plurality of second molds; and
j) removing a second plastic core and a second covering molded member from the mold cavity,
wherein the method further comprises stages in which:
after step d) the injected material is chemically mixed with the first plastic core and the first coating shaped element is cooled, while the chemically mixed injected material and the first plastic core form a chemical bond between them; and / or
after step i) the injected material is chemically mixed with the second plastic core and the second coating molded element is cooled, while the chemically mixed injected material and the second plastic core form a chemical bond between them. 10. The method according to claim 9, in which the configuration includes one or more of the shapes, sizes, colors, patterns, design options and graphic motifs. 11. A set of dental devices containing:
a first dental device with a first plastic core formed by the first mold, and a first covering molded element formed by the first of the plurality of second molds, each of the plurality of second molds having a mold cavity different from the others, so that the covering molded mold formed of one of the plurality second shapes, and a covering molded member formed by another of the plurality of second shapes have different configurations; and
a second dental device with a second plastic core formed by the first mold and a second covering molded member formed by a second of the plurality of second molds;
wherein the first covering molded element and the second covering molded element have different configurations; and
the first dental device comprises a chemical mixture of a first plastic core and a material of a first covering molded element, which provides a chemical bond holding together the first plastic core and the first covering molded element; and / or
the second tooth device comprises a chemical mixture of a second plastic core and a material of the second covering molded element, which provides a chemical bond holding together the second plastic core and the second covering molded element. 12. The kit according to claim 11, in which the configuration includes one or more of the shapes, sizes, colors, patterns, design options and graphic motifs.

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