Note: Descriptions are shown in the official language in which they were submitted.
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METHOD OF MANUFACTURING AN ORAL CARE IMPLEMENT
BACKGROUND OF THE INVENTION
[0001] Oral care implements, especially toothbrushes, are used by many people
on a
daily basis. Typical oral care implements comprise an elongate handle and a
head
connected to one end of the handle. The handle provides a structure by which a
user
grips and manipulates the oral care implement during use. The head typically
comprises one or more elements designed to perform their intended function,
such
as tooth cleaning elements, soft tissue cleaning elements, and/or oral care
agents.
[0002] Toothbrushes are oral care implements having one or more tooth cleaning
elements, which are used to clean teeth by removing plaque and debris from
surfaces of the teeth. Conventional toothbrushes are limited in their ability
to retain
dentifrice for cleaning teeth. During an oral care session, the dentifrice
typically
slips through the tooth cleaning elements, such as tufts of bristles, and away
from
the contact zone of the cleaning elements with the teeth. As a result, the
dentifrice
often is spread around the mouth, rather than being concentrated on the
contact
zone. Therefore, the efficiency of the cleaning process is reduced.
[0003] Over the years, efforts have been made to improve the design of oral
care
implements, in order that they may deliver improved cleaning of users' oral
cavities
during oral care sessions. Such efforts have included the development of heads
carrying structures intended to better retain dentifrice for use in cleaning
and/or
polishing teeth.
[0004] Despite these efforts, a need still exists for an oral care implement
with a head
having a structure for better retaining dentifrice, to enable improved
cleaning
and/or polishing of a user's teeth. A need also exists for an oral care
implement that
is easier to clean after an oral care session.
SUMMARY OF THE INVENTION
[0005] The present invention provides a method of manufacturing an oral care
implement, the method comprising: providing a member and providing a group of
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non-parallel tooth cleaning elements that together define therebetween a
conically-
shaped cavity, wherein the tooth cleaning elements extend through a passage
formed in the member so that respective first portions of the tooth cleaning
elements
are disposed on a first side of the member and respective second portions of
the
tooth cleaning elements are disposed on a second side of the member; and then
fixing together the second portions of the tooth cleaning elements at the
second side
of the member.
[0006] Optionally, the providing comprises: inserting the tooth cleaning
elements
into the passage, so that each of the tooth cleaning elements has a first
portion on the
first side of the member and has a second portion on the second side of the
member,
and then arranging the tooth cleaning elements so that together the tooth
cleaning
elements define therebetween the conically-shaped cavity.
[0007] Optionally, the method comprises inserting a plurality of picks of the
tooth
cleaning elements into the passage. Optionally, the inserting comprises
disposing
the plurality of picks in the passage at respective different orientations.
[0008] Optionally, the method comprises inserting the plurality of picks in
the
passage from respective different directions.
[0009] Optionally, the inserting comprises disposing at least some of the
tooth
cleaning elements in the passage at a different orientation to others of the
tooth
cleaning elements.
[0010] Optionally, the method comprises inserting all the tooth cleaning
elements
into the passage with all the tooth cleaning elements being substantially
parallel to
one another.
[0011] Optionally, the arranging comprises moving at least some of the tooth
cleaning elements relative to others of the tooth cleaning elements to cause
the tooth
cleaning elements to define therebetween the conically-shaped cavity.
Optionally,
the arranging comprises moving the at least some of the tooth cleaning
elements
relative to the others of the tooth cleaning elements by introducing the first
portions
of the tooth cleaning elements into a mold.
[0012] Optionally, the arranging comprises allowing at least some of the tooth
cleaning elements to move relative to others of the tooth cleaning elements to
cause
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the tooth cleaning elements to define therebetween the conically-shaped
cavity.
Optionally, the arranging comprises introducing the first portions of the
tooth
cleaning elements into a mold and allowing the tooth cleaning elements to
conform
to the shape of the mold, for example under the influence of gravity.
[0013] Optionally, the fixing comprises melting together the second portions
of the
tooth cleaning elements to form a melt matte at the second side of the member.
[0014] Optionally, the fixing comprises fixing the second portions of the
tooth
cleaning elements to the member.
[0015] Optionally, the method comprises bringing into contact with one another
plural tooth cleaning elements of the group so that an apex of the cavity is
defined
by the plural tooth cleaning elements.
[0016] Optionally, the cavity has an apex on the second side of the member.
[0017] Optionally, the cavity has an apex in the passage.
[0018] Optionally, the cavity has the shape of a full cone.
[0019] Optionally, the cavity has the shape of a truncated cone, such as a
frusto cone.
[0020] Optionally, the cavity has the shape of a right cone.
[0021] Optionally, the cavity has the shape of a circular cone or of an
elliptical cone
or of a pyramid.
[0022] Optionally, the cavity has an opening defined by distal ends of a
plurality of
the tooth cleaning elements, and wherein the cavity reduces in cross-sectional
area as
distance into the cavity from the opening increases.
[0023] Optionally, the group of non-parallel tooth cleaning elements together
define
a wall around the cavity, the wall having a proximal end adjacent the member
and a
distal end distal from the member, the distal end of the wall being defined by
distal
ends of a plurality of the tooth cleaning elements. Optionally, the wall is a
continuous wall. Optionally, the wall is free of gaps therein. Optionally, a
thickness
of the wall measured from an interior side of the wall facing the cavity to an
opposite exterior side of the wall is less at the distal end of the wall than
at the
proximal end of the wall. Optionally, the wall tapers in thickness from the
proximal
end of the wall to the distal end of the wall.
[0024] Optionally, the group of tooth cleaning elements comprises a tuft of
bristles.
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[0025] Optionally, some or all of the group of tooth cleaning elements are
tapered
bristles.
[0026] Optionally, the passage is a tapered passage.
[0027] Optionally, the passage has a length between the first and second sides
of the
member of from 0.5 to 2.0 mm.
[0028] Optionally, the member comprises part of a head of an oral care
implement,
and the group of non-parallel tooth cleaning elements extends from a first
surface of
the head.
[0029] Optionally, the member comprises a plate or membrane, and the method
further comprises providing the plate or membrane in a head of an oral care
implement so that the group of non-parallel tooth cleaning elements extends
from a
first surface of the head.
[0030] Optionally, the method comprises providing a soft tissue cleaner to
form at
least part of a second surface of the head, which second surface of the head
is
opposite to the first surface of the head. Optionally, the method comprises
flowing a
material onto the above-mentioned melt matte and allowing the material to
harden,
to form the soft tissue cleaner. Optionally, the method comprises adhering the
soft
tissue cleaner to the above-mentioned melt matte.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] A more complete understanding of the present invention, and the
advantages
thereof, may be acquired by referring to the following description in
consideration of
the accompanying drawings, in which like reference numbers indicate like
features,
and wherein:
[0032] Figure 1 is a perspective view of a first oral care implement
manufactured
according to a first embodiment of the method of the present invention;
[0033] Figure 2 is an enlarged plan view of a head of the implement of FIG. 1;
[0034] Figure 3 is an enlarged perspective view of the head of the implement
of FIG.
1;
[0035] Figure 4 is a partial cross-sectional view of the head taken along line
4-4 in
Figure 2;
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[0036] Figure 5 is a perspective view of a second oral care implement
manufactured
according to a second embodiment of the method of the present invention;
[0037] Figure 6 is an enlarged plan view of a head of the implement of FIG. 5;
[0038] Figure 7 is a perspective view of a third oral care implement
manufactured
according to a third embodiment of the method of the present invention; and
[0039] Figure 8 is an enlarged plan view of a head of the implement of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] The following description of the preferred embodiments is merely
exemplary
in nature and is in no way intended to limit the invention, its application,
or uses.
The description of illustrative embodiments according to principles of the
present
invention is intended to be read in connection with the accompanying drawings,
which are to be considered part of the entire written description. In the
description
of embodiments of the invention disclosed herein, any reference to direction
or
orientation is merely intended for convenience of description and is not
intended in
any way to limit the scope of the present invention. Relative terms such as
"lower,"
//upper," "horizontal," "vertical," "above," "below," "up," "down," "top" and
"bottom" as well as derivative thereof (e.g., "horizontally," "downwardly,"
//upwardly," etc.) should be construed to refer to the orientation as then
described or
as shown in the drawing under discussion. These relative terms are for
convenience
of description only and do not require that the apparatus be constructed or
operated
in a particular orientation unless explicitly indicated as such. Terms such as
"attached," "affixed," "connected," "coupled," "interconnected," and similar
refer to
a relationship wherein structures are secured or attached to one another
either
directly or indirectly through intervening structures, as well as both movable
or
rigid attachments or relationships, unless expressly described otherwise.
Moreover,
the features and benefits of the invention are illustrated by reference to the
preferred
embodiments. Accordingly, the invention expressly should not be limited to
such
preferred embodiments illustrating some possible non-limiting combination of
features that may exist alone or in other combinations of features.
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[0041] In the following description, the method of the invention is used in
the
manufacture of a manually-operated oral care implement, more specifically a
manually-operated toothbrush. However, in other embodiments, the method of the
invention is used in the manufacture of a powered toothbrush wherein one or
more
cleaning elements provided to the head of the implement are drivable so as to
be
moved relative to the handle of the implement. In still further embodiments,
method of the invention is used in the manufacture of other forms of oral care
implements, such as a soft-tissue cleansing implement, or another implement
designed for oral care. It is to be understood that other embodiments may be
utilised, and that structural and functional modifications may be made without
departing from the scope of the present invention.
[0042] As used herein, the term "cone", and derivatives thereof such as
"conical"
and "conically", covers full cones and truncated cones, such as frusto-cones.
As
used herein, the term "apex" of a cavity means a, or the, deepest portion or
point of
the cavity from an open end of the cavity.
[0043] Figures 1 to 4 illustrate an oral care implement 100, in this case a
toothbrush,
manufactured according to a first embodiment of the method of the present
invention. The toothbrush 100 has a body 110 comprising a handle portion 120,
a
head portion 140, and a neck portion 130 that connects the handle portion 120
to the
head portion 140. The head portion 140 is an end portion of the body 110 and
is
provided with a set 200 of cleaning elements for cleaning surfaces in a user's
mouth,
such as surfaces of their teeth.
[0044] The implement 100 has a head 180, comprising the head portion 140 of
the
body 110, the set 200 of cleaning elements, and a soft tissue cleaner 160,
each of
which is described in more detail below. In a variation to this embodiment,
the soft
tissue cleaner 160 is omitted.
[0045] The head portion 140 has a first, proximal end 141 and a second, distal
end
142. The handle portion 120 has a first, proximal end 121 and a second, distal
end
122. The neck portion 130 connects the distal end 122 of the handle portion
120 to
the proximal end 141 of the head portion 140. The neck portion 130 is
generally of a
narrower cross sectional area than at least the distal end 122 of the handle
portion
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120 and, in some embodiments, the neck portion 130 is generally of a narrower
cross
sectional area than all portions of the handle portion 120.
[0046] The handle portion 120 of the body 110 provides the user with a
mechanism
by which he/she can readily grip and manipulate the toothbrush 100, includes
ergonomic features which provide a high degree of control for the user while
maintaining comfort, and may be formed of many different shapes and with a
variety of constructions.
[0047] Generally, the toothbrush 100 extends from a proximal end 101 (which is
also
the proximal end 121 of the handle portion 120) to a distal end 102 (which is
also the
distal end 142 of the head portion 140) along a longitudinal axis A-A.
Although the
handle portion 120 is a non-linear structure in the illustrated embodiment,
the
longitudinal axis A-A of the implement 100 is linear in the illustrated
embodiment.
However, the invention is not so limited, and in certain embodiments, the
implement 100 may have a simple linear handle portion 120 that is
longitudinally
aligned along the linear longitudinal axis A-A of the implement 100.
[0048] The head portion 140 is connected to the handle portion 120 via the
neck
portion 130. In this embodiment, the head portion 140, neck portion 130 and
handle
portion 120 are formed as an integral structure using an injection molding
process.
The head portion 140 is substantially immovable relative to the neck portion
130 and
handle portion 120. The head portion 140, handle portion 120 and neck portion
130
are together a single, unitary structure. That is, the body 110 is a unitary
body.
However, in other embodiments, the head portion 140 and the neck portion 130
together may be formed as a separate component from the handle portion 120,
which separate components are operably connected at a later stage of the
manufacturing process by any suitable technique known in the art, including
without limitation thermal welding, sonic welding, a tight-fit assembly, a
coupling
sleeve, adhesion, fasteners, and a snap-fit connection. Whether the head and
neck
portions 140, 130 and the handle portion 120 are constructed as a single piece
or a
multi-piece assembly (including connection techniques) is not limiting of the
present
invention in all embodiments. Furthermore, other manufacturing techniques may
be used in place of and/or in addition to injection molding to create the
handle
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portion 120 and/or the head portion 140 (or components thereof) and/or the
neck
portion 130, such as milling and/or machining.
[0049] In this embodiment, the body 110 comprising each of the head portion
140,
neck portion 130 and handle portion 120 is constructed of a hard,
substantially rigid
material, specifically the hard plastic polypropylene (PP). However, in
variations to
this embodiment, the head portion 140 may instead or additionally be
constructed of
one or more of the following hard materials: polyethylene, polypropylene,
polyamide, polyester, cellulosics, styrene-acrylonitrile (SAN), acrylic,
acrylonitrile
butadiene styrene (ABS) and a thermoplastic. Also, in
variations to this
embodiment, the handle portion 120 and/or the neck portion 130 may instead or
additionally be constructed of one or more of those materials. An optional
thumb
grip 125 is provided on a front side of the handle portion 120, and an
optional rear
grip 127 is provided on a rear side of the handle portion 120 opposite to the
front
side of the handle portion 120. The thumb and rear grips 125, 127 are non-
unitary
with the body 110, and may be formed of any of the materials discussed below
for
the soft tissue cleaner 160.
[0050] The head 180 generally comprises a first surface 183, on a front side
of the
head 180, and a second surface 184, on a rear side of the head 180 opposite to
the
first side and thus opposite to the first surface 183. The first surface 183
and the
second surface 184 of the head 180 can take on a wide variety of shapes and
contours, none of which are limiting of the present invention. For example,
the first
and second surfaces 183, 184 can be planar, contoured or combinations thereof.
The
first surface 183 and second surface 184 are joined by a peripheral or lateral
surface
145 of the head portion 140, which is a peripheral or lateral surface 185 of
the head
180. The cleaning elements of the set 200 are provided at, and extend outward
from,
the first surface 183 of the head 180 for cleaning contact with an oral
surface,
preferably teeth.
[0051] While the set 200 of cleaning elements is particularly suited for
cleaning teeth,
the set 200 of cleaning elements can also be used to clean oral soft tissue,
such as a
tongue, gums, or cheeks instead of or in addition to teeth. As used herein,
the term
"cleaning element" is used in a generic sense to refer to any structure that
can be
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used to clean, massage or polish an oral surface, such as teeth or soft
tissue, through
relative surface contact.
[0052] In this embodiment, the set 200 of cleaning elements comprises the
following
different types of cleaning elements, each of which extends from the first
surface 183
of the head 180 and is discussed in more detail below: groups 210 of non-
parallel
tooth cleaning elements 220, pointed cleaning elements 250, raised cleaning
elements
260, and distal and proximal cleaning elements 270.
[0053] With reference specifically to Figure 4, the groups 210 of tooth
cleaning
elements 220 will be described. In this embodiment, the implement 100 has a
plurality of groups 210 of tooth cleaning elements 220. However, in variations
to
this embodiment, such as is described with reference to Figures 7 and 8 below,
only
one group 210 of non-parallel tooth cleaning elements 220 is provided. For
simplicity, only one of the groups 210 of the first embodiment will be
described in
detail, but it will be understood that each of the groups 210 of the first
embodiment
is of substantially the same construction.
[0054] Each of the non-parallel tooth cleaning elements 220 of the group 210
is a
flexible, nylon bristle that extends from the first surface 183 of the head
180.
Accordingly, the group 210 of non-parallel tooth cleaning elements 220
comprises a
tuft of bristles. The non-parallel nature of the tooth cleaning elements 220
of the
group 210 results from some, or all, of the tooth cleaning elements 220 of the
group
210 not being parallel to others of the tooth cleaning elements 220 of the
group 210.
Each of the tooth cleaning elements 220 has a (optionally tapered) distal end
221
furthest from the first surface 183 of the head 180, an opposite proximal end
222, and
is linear, or substantially linear, between its distal end 221 and the first
surface 183 of
the head 180.
[0055] The tooth cleaning elements 220 define therebetween a cavity 230. That
is, the
cavity 230 is located between the tooth cleaning elements 220 and is bound by
the
tooth cleaning elements 220. More specifically, the tooth cleaning elements
220
together define a wall 240 around the cavity 230, the wall 240 having a
proximal end
242 adjacent the first surface 183 of the head 180 and a distal end 241 distal
from the
first surface 183 of the head 180, the distal end 241 being defined by distal
ends 221
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of a plurality (optionally all) of the tooth cleaning elements 220. The wall
240
surrounds the cavity 230. In the present embodiment, in which the tooth
cleaning
elements 220 of the group 210 are packed closely together so that each of the
tooth
cleaning elements 220 of the group 210 contacts at least one other of the
tooth
cleaning elements 220 of the group 210, the wall 240 is a continuous wall 240
around
the cavity 230. Preferably the wall 240 extends for 360 degrees around the
cavity
230. Preferably the wall 240 is free of gaps therein.
[0056] In this embodiment, the distal end 241 of the wall 240 has a
substantially
linear side profile. In this embodiment, the distal end 241 of the wall 240 is
substantially planar. Moreover, the distal end 241 of the wall 240 is
substantially
parallel to the first surface 183 of the head 180. In other embodiments, the
distal end
241 of the wall 240 could be non-planar and/or non-parallel to the first
surface 183 of
the head 180. In still further variations to this embodiment, the distal end
241 of the
wall 240 may have an alternative side profile, such as a non-linear profile,
an S-
shaped profile, a wavy profile, a serrated profile, a U-shaped profile, a V-
shaped
profile, or a pointed profile.
[0057] A thickness T of the wall 240 measured from an interior side 243 of the
wall
240 facing the cavity 230 to an opposite, exterior side 244 of the wall 240 is
less at the
distal end 241 of the wall 240 than at the proximal end 242 of the wall 240.
That is,
the thickness T2 of the wall 240 at the distal end 241 of the wall 240 is less
than the
thickness Ti of the wall 240 at the proximal end 242 of the wall 240. The
maximum
thickness Ti of the wall 240 is at the proximal end 242 of the wall 240, while
the
minimum thickness T2 of the wall 240 is at the distal end 241 of the wall 240.
The
thickness of the wall 240 decreases linearly (i.e. at a regular rate) between
the
proximal end 242 of the wall 240 and the distal end 241 of the wall 240. That
is, the
wall 240 tapers in thickness from the proximal end 242 of the wall 240 to the
distal
end 241 of the wall 240. Moreover, a cross sectional area of the wall 240 at
the distal
end 241 of the wall 240 is substantially equal to a cross sectional area of
the wall 240
at the proximal end 242 of the wall 240. Furthermore, at any point between the
distal
end 241 and the proximal end 242 of the wall 240, the thickness of the wall
240 is
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substantially constant around a full perimeter of the cavity 230. The wall 240
is
preferably rotationally symmetrical.
[0058] The cavity 230 has an opening 232 at the distal end 241 of the wall 240
and an
apex 231 at a position in the cavity 230 furthest from the distal ends 221 of
the tooth
cleaning elements 220 of the group 210, i.e. furthest from the opening 232 of
the
cavity 230. In this embodiment, the apex 231 is formed at the point (see
Figure 4)
where plural of the tooth cleaning elements 220 of the group 210 are in
contact with
one another. The significance of the cavity 230 having an apex 231, and more
specifically an apex 231 formed by the tooth cleaning elements 220 rather than
by
some other element, such as part of the first surface 183 of the head 180,
will be
explained below.
[0059] In this embodiment, the apex 231 is within a hole 186 in the head 180,
and the
group 210 of non-parallel tooth cleaning elements 220 extends from within the
hole
186. The hole 186 has an axis H-H and a cross-sectional area orthogonal to the
axis
H-H. The cross-sectional area of the hole 186 varies along the axis H-H. In
particular, the hole 186 is a tapered hole 186, whereby the cross-sectional
area
reduces as distance into the hole 186 from the first surface 183 increases. In
other
embodiments, the hole 186 is not tapered.
[0060] In this embodiment, the cavity 230 is conically-shaped, with an axis C
of the
cone being the imaginary straight line that passes through the apex 231 and
about
which the opening 232 has rotational symmetry. More specifically, in this
embodiment the cavity 230 has the shape of a right circular full cone, whereby
the
opening 232 is circular and substantially planar, and the axis C of the cone
passes
through the opening 232 at right angles to the plane of the opening 232. In a
variation, the opening 232 may instead by elliptical (and optionally
substantially
planar), so that the cavity has the shape of an elliptical cone, optionally a
right
elliptical cone. In further variations to this embodiment, the cavity 230 may
instead
take the shape of an oblique circular or elliptical cone, in which the axis C
is not at
right angles to the plane of the opening 232. In other embodiments, the
opening 232
could take a still different shape, such as a square or rectangle, in which
case the
cavity 230 would have the shape of a pyramid (note that a pyramid is a cone
with a
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polygonal base). In still other embodiments, instead of having the shape of a
full
cone, the cavity 230 could instead have the shape of a truncated cone, such as
a
frusto-cone, n which case the apex 231 would not be a point as such, but
instead
would be an area preferably formed by material of plural of the tooth cleaning
elements 220 of the group 210.
[0061] Preferably, a distance between two diametrically-opposed cavity-facing
points on the wall 240 (which points would be located at or adjacent the
opening
232) is at least 10 times the width of any one of the tooth cleaning elements
220. In
other words, preferably a width of the opening 232 is at least 10 times the
width of
any one of the tooth cleaning elements 220. More preferably, this multiple is
at least
20 times, and most preferably, this multiple is at least 30 times or at least
40 times.
Preferably, the distance is at least 5 times the thickness T2 of the wall 240
at the distal
end 241 of the wall 240, and most preferably the distance is at least 10 times
the
thickness T2 of the wall 240 at the distal end 241 of the wall 240.
[0062] Preferably, the internal angle a of the conical cavity, i.e. the angle
at the apex
231 of the cavity 230, is at least 20 degrees. More preferably, the angle a is
at least 25
degrees, or at least 30 degrees. Preferably, the angle a is less than 45
degrees, and
more preferably the angle a is less than 40 degrees, or less than 35 degrees.
In some
embodiments, this angle a is the angle between two diametrically-opposed
cavity-
facing tooth cleaning elements 220 of the group 210.
[0063] In this embodiment, each of the groups 210 of tooth cleaning elements
220
comprises a plurality of flexible, nylon bristles 220. However, in variations
to this
embodiment, the tooth cleaning elements 220 of the group(s) 210 may
additionally or
alternatively comprise any one or more of the following, without limitation:
rigid
bristles, filament bristles, fibre bristles, nylon bristles, spiral bristles,
tapered bristles,
rubber bristles, elastomeric protrusions, flexible polymer protrusions, co-
extruded
filaments, flag bristles, crimped bristles, anti-bacterial bristles and
combinations
thereof and/or structures containing such materials or combinations.
[0064] The tooth cleaning elements 220 of the group(s) 210 can be connected to
the
head 140 using anchor free tufting (AFT). Alternatively, the cleaning elements
220
could be mounted to tuft blocks or sections by extending through suitable
openings
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in the tuft blocks so that the base of the cleaning elements 220 is mounted
within or
below the tuft block. Staple technology may instead be used.
[0065] In AFT, the tooth cleaning elements 220 (bristles or other elements,
such as
elastomeric elements) are arranged to extend through a passage 156 in a member
150, which in this embodiment is a plate but in a variation to this embodiment
is a
membrane. Respective first portions, i.e. free distal ends, 221 of the tooth
cleaning
elements 220 on a first side 153 of the plate 150 perform the cleaning
function.
Respective second portions, e.g. proximal ends, 222 of the tooth cleaning
elements
220 on a second side 154 of the plate 150 are fused, or melted together, by
heat to
form a melt matte 223 and to be anchored in place relative to the plate 150.
The plate
150 is secured to the pre-made head portion 140, such as by ultrasonic
welding.
Alternatively, the material of the head portion 140 is subsequently moulded
over the
member 150 to envelop, or substantially envelop, the member 150.
[0066] Although, as shown in Figure 4, the member 150 is a plate or membrane
that
is a separate entity to the head portion 140, in a variation to this
embodiment the
member 150 is part of the head portion 140 itself, which head portion 140 may
be
unitary with, or otherwise connected to, the handle portion 120 and/or the
neck
portion 130 of the implement 100, and thus is part of the head 180. In either
arrangement, the hole 186 comprises the passage 156 through the member 150.
Preferably, the passage 156 has a length between the first and second sides
153, 154
of the member 150 of from 0.5 mm to 2.0 mm, more preferably from 0.75 mm to
1.5
mm.
[0067] From Figure 4, it can be seen that the apex 231 of the cavity 230 is
disposed in
the hole 186 on the second side 154 of the member 150. However, in a variation
to
this embodiment, the apex 231 is disposed in the passage 156, which is
comprised in
the hole 186. In this embodiment, the passage 156 in the member 150 is a
tapered
passage. However, in other embodiments, this need not be the case.
[0068] At the rear side of the head 180 is disposed the soft tissue cleaner
160,
preferably formed from resilient material. The soft tissue cleaner 160 is
comprised in
the second surface 184 of the head 180. The soft tissue cleaner 160 comprises
a pad
and a plurality of flexible protrusions 162 protruding from the pad.
Preferably, the
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pad also is of a flexible material and the pad and protrusions 162 are a
unitary
component. Preferably the pad and the protrusions 162 are made of an
elastomer,
such as a thermoplastic elastomer (TPE), or styrene-ethylene/butylene-styrene
(SEBS).
[0069] Some methods of manufacturing an oral care implement 100 according to
the
present invention will now be described. Broadly speaking, each of the methods
comprises: providing a member 150 and providing a group 210 of non-parallel
tooth
cleaning elements 220 that together define therebetween a conically-shaped
cavity
230, wherein the tooth cleaning elements 220 extend through a passage 156
formed
in the member 150 so that respective first portions 221 of the tooth cleaning
elements
220 are disposed on a first side 153 of the member 150 and respective second
portions 222 of the tooth cleaning elements 220 are disposed on a second side
154 of
the member 150, and then fixing together the second portions 222 of the tooth
cleaning elements 220 at the second side 154 of the member 150.
[0070] As shown in Figure 4, the member 150 may be a plate or membrane that is
a
separate entity to a head portion 140 of the implement 100. Alternatively, the
member is part of the head portion 140. The head portion 140 may be unitary
with,
or otherwise connected to, the handle portion 120 and/or the neck portion 130
of the
implement 100.
[0071] The method of manufacture of the implement 100 shown in Figure 1
comprises inserting the tooth cleaning elements 220 (each of which is a
bristle,
optionally a tapered bristle) into the tapered passage 156, so that each of
the tooth
cleaning elements 220 has a first portion 221 on the first side 153 of the
member 150
and has a second portion 222 (in this embodiment, a proximal end) on the
second
side 154 of the member 150, and then arranging the tooth cleaning elements 220
so
that together the tooth cleaning elements 220 define therebetween the
conically-
shaped cavity 230.
[0072] More specifically, in one embodiment, the inserting comprises disposing
a
plurality of (preferably between two and four) picks (i.e. individual
clusters) of
mutually-aligned tooth cleaning elements 220 into the passage 156 with the
picks at
respective different orientations relative to one another. Each of the picks
may be
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inserted into the passage 156 from a different direction to each of the other
picks
with the picks at respective different orientations relative to one another
during the
inserting, or all of the picks may be inserted into the passage 156 from the
same
direction, for example in a direction parallel to the shortest distance
between the first
and second sides 153, 154 of the member 150, with the picks at respective
different
orientations relative to one another during the inserting. Either way, the
inserting
comprises disposing at least some of the tooth cleaning elements 220 in the
passage
156 at a different orientation to others of the tooth cleaning elements 220.
The picks
may be inserted into the passage 156 at the same time or successively.
[0073] In a variation to this process, the tooth cleaning elements 220
(whether in
individual picks or as one set) are all inserted into the passage 156 with all
the tooth
cleaning elements 220 being substantially parallel to one another.
[0074] The arranging may comprise moving at least some of the tooth cleaning
elements 220 relative to others of the tooth cleaning elements 220 and
relative to the
member 150 to cause the tooth cleaning elements 220 to define therebetween the
conically-shaped cavity 230, such as by introducing the first portions 221 of
the tooth
cleaning elements 220 into a mold (not shown) and using the mold to move the
tooth
cleaning elements 220. Alternatively, the arranging may comprise allowing at
least
some of the tooth cleaning elements 220 to move relative to others of the
tooth
cleaning elements 220 and relative to the member 150 to cause the tooth
cleaning
elements 220 to define therebetween the conically-shaped cavity 230, such as
by
introducing the first portions 221 of the tooth cleaning elements 220 into a
mold and
allowing the tooth cleaning elements 220 to conform to a shape of the mold,
e.g.
under the influence of gravity.
[0075] In any event, ultimately the tooth cleaning elements 220 extending
through
the passage 156 have respective different orientations relative to one
another. Each
of the tooth cleaning elements 220 of the group 210 extends through the
passage 156
with a distal end 221 thereof on the first side 153 of the member 150 and the
proximal end 222 thereof on the second side 154 of the member 150. The tooth
cleaning elements 220 of the group 210 are positioned so that they contact one
another on the second side 154 of the member 150, and are splayed apart from
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another on the first side 153 of the member 150. Over all, the tooth cleaning
elements 220 define the conically-shaped cavity 230 therebetween. The tooth
cleaning elements 220 may contact one another at their proximal ends 222, or
at
respective points a short distance from their respective proximal ends 222, to
define
the apex 231 of the cavity 230. As discussed above, the cavity 230 of the
implement
100 has the shape of a right circular full cone. In other embodiments,
depending on
the relative orientations of the tooth cleaning elements 220, the cavity 230
may
instead have any of the other shapes discussed above.
[0076] Next, the tooth cleaning elements 220 are fixed at respective different
orientations relative to one another by holding the tooth cleaning elements
220 and
heating up the second portions 222 (i.e. the proximal ends, in this
embodiment) of
the tooth cleaning elements 220 to cause the second portions 222 to melt and
run into
one another. The heat is then removed and the second portions 222 of the tooth
cleaning elements 220 are allowed to cool and harden into one monolithic mass
or
melt matte 223, so that the picks of tooth cleaning elements 220 become fused
together at the second side 154 of the member 150. In some embodiments, the
second portions 222 of the tooth cleaning elements 220 become fixed to the
member
150 during this process.
[0077] Preferably, this process results in the apex 231 of the cavity 230
becoming
formed on the second side 154 of the member 150. However, in other cases, the
apex
231 may become formed within the passage 156. The position of the apex 231 may
change during the fixing process as material of the tooth cleaning elements
220
flows. Where the apex 231 is formed relative to the passage 156 and relative
to the
member 150 as a whole depends upon how close to one another tooth cleaning
elements 220 are held, the length of time for which the heating is carried
out, and the
material of the tooth cleaning elements 220. In any case, the fixed group 210
of non-
parallel tooth cleaning elements 220 together define the wall 240, discussed
above.
As also discussed above, preferably the wall 240 is a continuous wall, and
more
preferably the wall 240 is free of gaps therein. Moreover, while in this
embodiment
the passage 156 is tapered and has a length of between 0.5 and 2.0 mm, in
variations
to this embodiment the passage 156 is not tapered and/or has a different
length.
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[0078] Next, in embodiments where the member comprises a plate or membrane 150
separate from the head portion 140, such as the embodiment described with
reference to Figures 1 to 4, the member 150 including the group(s) 210 of
tooth
cleaning elements 220 is attached to the head portion 140 so that the member
150
becomes provided in the head 180 of the implement 100. This attaching may be
by
one of the methods discussed above. The first side 153 of the member 150
effectively
forms part or all of the first surface 183 of the head 180, so that the group
210 of non-
parallel tooth cleaning elements 220 extends from the first surface 183 of the
head
180. In variations to this embodiment, the member 150 may end up embedded
within the head 180. In alternative embodiments where the member 150 comprises
part of the head portion 140, then this attachment process can be omitted.
[0079] The method of manufacturing the implement 100 shown in Figures 1 to 4
also
includes providing the soft tissue cleaner 160 to form at least part of the
second
surface 184 of the head 180, which second surface 184 of the head 180 is
opposite to
the first surface 183 of the head 180. In some embodiments, the soft tissue
cleaner
160 is in contact with the tooth cleaning elements 220 of the group 210, more
specifically with the proximal ends 222 thereof. The soft tissue cleaner 160
may be a
pre-made entity, for example made of TPE, which is adhered to the head portion
140
and to the tooth cleaning elements 220 of the group 210. Alternatively, the
method
may involve flowing a material, such as a TPE, onto the melt matte 223, and
into any
gaps left between the tooth cleaning elements 220 at or around their proximal
ends
222, and then allowing the material to harden to form the soft tissue cleaner
160. The
soft tissue cleaner 160 thus can be bound to the tooth cleaning elements 220
of the
group 210.
[0080] The oral care implement 100 may be manufactured by a different method.
For example, the hole(s) 186, the passage 156 and the member 150 may be
omitted
altogether. The tooth cleaning elements 220 may be individually provided to
the
first side 183 of the head 180, or a unitary structure including the
individual tooth
cleaning elements 220 may be provided to the first side 183 of the head 180 or
to the
hole 186. Such a unitary structure may be made of TPE.
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[0081] A first benefit of the provision of the conically-shaped cavity 230 is
that it
provides the head 180 with a large volume for retaining toothpaste.
[0082] A second benefit of this structure is that the cavity 230 is easy to
clean of
toothpaste following a teeth cleaning session, since toothpaste captured in
the cavity
230 is entirely or substantially unable to work its way down to the first
surface 183 of
the head 180 where it may become trapped. It is preferable that the cavity 230
has an
apex 231 in the form of a point. In such cases, the toothpaste still less able
to work its
way down to the first surface 183 of the head 180.
[0083] A third benefit of the conically-shaped cavity 230 is that it holds the
majority
of the toothpaste at a position where it will be effective at cleaning the
teeth. This is
particularly the case in embodiments in which the wall 240 is a continuous
wall 240
around the cavity 230, and more particularly the case when the cavity 230 has
an
apex 231 in the form of a point.
[0084] A fourth benefit of the structure is that, in embodiments where the
tooth
cleaning elements 220 are flexible, during a teeth cleaning session the tooth
cleaning
elements 220 are able to bend, flex or rotate (about the point apex 231, when
provided) to come into contact with each other at, or close to, their distal
ends 221.
Thus, the cavity 230 is able to be significantly reduced in volume to cause
toothpaste
held in the cavity 230 to be completely, or substantially completely, expelled
from
the cavity 230 onto the teeth during a teeth cleaning session. As a result,
the
toothpaste becomes positioned at a contact zone of the tooth cleaning elements
220
with the teeth, thus enabling improved cleaning and/or polishing of a user's
teeth
using the toothpaste.
[0085] As discussed above, the set 200 of cleaning elements comprises pointed
cleaning elements 250 that extend from the first surface 183 of the head 180
and have
respective pointed distal ends 251. In each pointed cleaning element 250, the
pointed distal end 251 is that part of the pointed cleaning element 250
furthest from
the first surface 183 of the head 180. In some embodiments each pointed
cleaning
element 250 is an elastomeric component. However, in the present embodiment,
each pointed cleaning element 250 comprises a group of bristles, wherein each
of the
bristles has a distal end furthest from the first surface 183 of the head 180,
and
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wherein the distal ends of the bristles together define a pointed distal end
251 of the
pointed cleaning element 250. The distal ends of some or all of the bristles
themselves may be any shape, including flat, rounded or tapered. The distal
ends
251 of the pointed cleaning elements 250 are further from the first surface
183 of the
head 180 than the distal ends 221 of the non-parallel tooth cleaning elements
220
making up the groups 210. Due to their shape and height relative to the groups
210
of non-parallel tooth cleaning elements 220, the pointed cleaning elements 250
are
particularly effective at cleaning between a user's teeth.
[0086] As is best shown in Figure 2, the head 180 has a first end 181 and a
second
end 182. An axis extends between the first and second ends 181, 182, which
axis is
parallel to the longitudinal axis A-A of the implement 100 and extends along
the
longitudinal middle of the head 180. Plural ones of said pointed cleaning
elements
250 are disposed on the head 180 spaced along this axis. More particularly,
the
implement 100 comprises a plurality of said pointed cleaning elements 250, and
a
plurality of said groups 210 of non-parallel tooth cleaning elements 220.
The
pointed cleaning elements 250 alternate with the groups 210 of non-parallel
tooth
cleaning elements 220 between the first end 181 and the second end 182 of the
head
180. That is, between any two of the pointed cleaning elements 250, there is
provided a pair of laterally-spaced groups 210 of the non-parallel tooth
cleaning
elements 220.
[0087] As discussed above, the set 200 of cleaning elements comprises raised
cleaning elements 260 that extend from the first surface 183 of the head 180.
Each of
these cleaning elements 260 has a convex distal end 261 which is that part of
the
raised cleaning element 260 furthest from the first surface 183 of the head
180. In
some embodiments each raised cleaning element 260 is an elastomeric component.
However, in the present embodiment, each raised cleaning element 260 comprises
a
group of bristles, wherein each of the bristles has a distal end furthest from
the first
surface 183 of the head 180, and wherein the distal ends of the bristles
together
define a convex distal end 261 of the raised cleaning element 260. The distal
ends of
the bristles themselves may be any shape, including flat, rounded or tapered.
The
distal ends 261 of the raised cleaning elements 260 are further from the first
surface
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183 of the head 180 than the distal ends 221 of the non-parallel tooth
cleaning
elements 220 making up the groups 210, and approximately the same distance
from
the first surface 183 of the head 180 as the distal ends 251 of the pointed
cleaning
elements 250. Due to their shape and height relative to the groups 210 of non-
parallel tooth cleaning elements 220, the raised cleaning elements 260 are
particularly effective at sweeping away plaque and debris from surfaces in a
user's
mouth.
[0088] As is best shown in Figure 2, plural ones of said raised cleaning
elements 260
are disposed longitudinally spaced along the lateral edges of the first
surface 183 of
the head 180. The raised cleaning elements 260 alternate with the groups 210
of non-
parallel tooth cleaning elements 220 between the first end 181 and the second
end
182 of the head 180, so that pairs of the raised cleaning elements 260 are
longitudinally positioned on the head 180 in alignment with ones of the
pointed
cleaning elements 250, so that the raised cleaning elements 260 flank the
pointed
cleaning element 250 on their lateral sides.
[0089] As discussed above, the set 200 of cleaning elements comprises distal
and
proximal cleaning elements 270 that extend from the first surface 183 of the
head 180.
The distal and proximal cleaning elements 270 are disposed at the first and
second
ends 181, 182 of the head 180. In some embodiments each of the distal and
proximal
cleaning elements 270 is an elastomeric component. However, in the present
embodiment, each distal and proximal cleaning element 270 comprises a group of
bristles, wherein each of the bristles has a distal end furthest from the
first surface
183 of the head 180, and wherein the distal ends of the bristles together
define a
sloped distal end 271 of the distal and proximal cleaning element 270 that has
a peak
furthest from the centre of the first surface 183 of the head 180. The distal
ends of the
bristles themselves may be any shape, including flat, rounded or tapered. The
peaks
of the sloped distal ends 271 are approximately the same distance from the
first
surface 183 of the head 180as the distal ends 251 of the pointed cleaning
elements
250. Due to their shape, peak height and positioning on the head 180, the
distal and
proximal cleaning elements 270 are also effective at cleaning between a user's
teeth.
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The distal cleaning elements 270 also are useable to reach far into the user's
mouth,
to clean effectively their rearmost molars.
[0090] A second implement 100 manufactured according to a second embodiment of
the method of the present invention is shown in Figures 5 and 6. Like elements
shown in Figures 1 to 4 are indicated in Figures 5 and 6 with the same
reference
numerals. In the interests of conciseness, the elements common to the two
embodiments will not be described in detail again with reference to Figures 5
and 6.
All of the above-described possible variations to the first embodiment are
equally
applicable to the second embodiment.
[0091] Whereas in the first embodiment the head 180 had a substantially
elliptical or
lozenge-shape, the head 180 of the implement 100 of the second embodiment has
an
outer shape in plan view similar to the outer edge of a number 8. The head 180
has a
first end 181 and a second end 182. An axis extends between the first and
second
ends 181, 182, which axis is parallel to the longitudinal axis A-A of the
implement
100 and extends along the longitudinal middle of the head 180. The head 180
includes only two groups 210 of non-parallel tooth cleaning elements 220
disposed
on the head 180 spaced along this axis.
[0092] Surrounding each of the two groups 210 is a plurality of wedge-shaped
cleaning elements 280, each of which has a wedge shape in plan view. In some
embodiments each of the wedge-shaped cleaning elements 280 is an elastomeric
component. However, in the present embodiment, each wedge-shaped cleaning
element 280 comprises a group of bristles, wherein each of the bristles has a
distal
end furthest from the first surface 183 of the head 180, and wherein the
distal ends of
the bristles together define a sloped distal end 281 of the wedge-shaped
cleaning
element 280 that has a peak furthest from the centre of the cavity 230. The
distal
ends of the bristles themselves may be any shape, including flat, rounded or
tapered.
[0093] At the longitudinal middle of the head 180, and disposed on the lateral
edges
of the first surface 183 of the head 180, is a pair of triangular-shaped
cleaning
elements 290, each of which has a substantially triangular shape in plan view.
An
inward-facing vertex of each of the triangular-shaped cleaning elements 290
faces an
inward-facing vertex of the other of the triangular-shaped cleaning elements
290. In
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some embodiments each of the triangular-shaped cleaning elements 290 is an
elastomeric component. However, in the present embodiment, each triangular-
shaped cleaning element 290 comprises a group of bristles, wherein each of the
bristles has a distal end furthest from the first surface 183 of the head 180,
and
wherein the distal ends of the bristles together define a pointed distal end
291 of the
triangular-shaped cleaning element 290 that has a peak at the midpoint of the
side of
the triangle opposite from the inward-facing vertex. The distal ends of the
bristles
themselves may be any shape, including flat, rounded or tapered. The distal
ends
291 of the triangular-shaped cleaning elements 290 are further from the first
surface
183 of the head 180 than the distal ends 221 of the non-parallel tooth
cleaning
elements 220 making up the groups 210. Due to their shape and height relative
to
the groups 210 of non-parallel tooth cleaning elements 220, the triangular-
shaped
cleaning elements 290 are particularly effective at cleaning between a user's
teeth.
[0094] A third implement manufactured according to a third embodiment of the
method of the present invention is shown in Figures 7 and 8. Like elements
shown
in Figures 5 and 6 are indicated in Figures 7 and 8 with the same reference
numerals.
In the interests of conciseness, the elements common to the two embodiments
will
not be described in detail again with reference to Figures 7 and 8. All of the
above-
described possible variations to the first and second embodiments are equally
applicable to the third embodiment.
[0095] The head 180 of the third implement 100 manufactured according to the
third
embodiment of the method of the present invention has a substantially
elliptical
outer shape in plan view. The head 180 includes only one group 210 of non-
parallel
tooth cleaning elements 220. The tooth cleaning elements 220 together define
therebetween a cavity 230 that has the shape of an elliptical cone. The group
210 is
disposed on the head 180 with the cavity 230 substantially coaxial with the
elliptical
outer shape of the head 180.
[0096] Surrounding the group 210 is a plurality of wedge-shaped cleaning
elements
280, each of which has a wedge shape in plan view. In some embodiments each of
the wedge-shaped cleaning elements 280 is an elastomeric component. However,
in
the present embodiment, each wedge-shaped cleaning element 280 comprises a
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group of bristles, wherein each of the bristles has a distal end furthest from
the first
surface 183 of the head 180, and wherein the distal ends of the bristles
together
define a sloped distal end 281 of the wedge-shaped cleaning element 280 that
has a
peak furthest from the centre of the cavity 230. The distal ends of the
bristles
themselves may be any shape, including flat, rounded or tapered.
[0097] While the invention has been described with respect to specific
examples
including presently preferred modes of carrying out the invention, those
skilled in
the art will appreciate that there are numerous variations and permutations of
the
above described systems and techniques. It is to be understood that other
embodiments may be utilized and structural and functional modifications may be
made without departing from the scope of the present invention. Thus, the
scope of
the invention should be construed broadly as set forth in the appended claims.
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