1. Field of the Invention
Aspects of the present invention relate to a method of manufacturing a toothbrush in which bristles are set in a toothbrush body without an anchor and a toothbrush manufactured by the method.
2. Description of the Related Art
Generally, when a method used to fasten bristles to a head part of a toothbrush body uses an anchor made of metal, the bristles relatively easily fall out of the head part as compared to when an “anchorless method,” which does not require the use of an anchor, is used. Furthermore, when using the anchor, it is difficult to diversify the shape (length, thickness, color, etc.) of the bristles. Thus, most recent toothbrushes have been manufactured by the anchorless method.
A toothbrush manufactured by the anchorless method may include bristles, a planar head insert in which the bristles are set, and a toothbrush body which has a head part to which the head insert is coupled. The head insert has a plurality of setting holes and a plurality of bristles may be inserted into each setting hole. The operation of inserting the bristles into the setting hole typically includes inserting the lower parts of the bristles into the end of the setting hole using a heating apparatus, which corresponds to the upper surface of the head insert, such that the lower parts of the bristles are disposed on the lower surface of the head insert. Thereafter, the lower parts of the bristles are adhered to the head insert by fusing.
However, the anchorless method setting, which includes setting the bristles in each setting hole, has disadvantages including, for example, that it requires much time and labor when the setting the bristles in the each setting hole is conducted manually and that it cannot ensure the quality of the toothbrush.
To avoid these problems, an automatic system was recently proposed that was revealed to be complicated and very expensive. Moreover, the automatic system typically produces only one kind of toothbrush design. Hence, if a new toothbrush design is developed, part of or the entirety of the system must be changed, thus imposing a huge financial burden.
According to an aspect of the invention, a method of producing a bundle of bristles is provided and includes collecting a plurality of bristles substantially close together and fusing and subsequently hardening ends of the collected bristles to each other by cutting the ends of the collected bristles using a heated cutter to thus produce a bundle of bristles.
According to another aspect of the invention, a method of manufacturing a toothbrush is provided and includes collecting a plurality of bristles substantially close together, cutting ends of the collected bristles using a heated cutter to thereby harden and fuse the cut ends of the collected bristles to each other to thus produce a bundle of bristles, cutting the fused bundle of bristles into a plurality of unit bundles of bristles having a predefined cross-sectional area corresponding to a setting hole of a toothbrush head insert, inserting parts of the bundle of bristles other than the fused parts thereof into the setting hole such that the fused parts of the bundle of bristles is disposed on a lower surface of the head insert, adhering the fused parts of the unit bundles of bristles to the head insert and coupling the head insert having the unit bundle of bristles fused thereto to a head part of the toothbrush.
According to another aspect of the invention, a method of manufacturing a toothbrush is provided and includes inserting bristles into a setting hole of a toothbrush head insert such that lower parts of the bristles are disposed on a lower surface of the head insert, adhering the lower parts of the bristles to the lower surface of the head insert using a heating apparatus and coupling the head insert having the bristles fused thereto to a head part of the toothbrush, where the inserting comprises inserting the bristles into the setting hole through a jig having a guide hole corresponding to the setting hole.
According to another aspect of the invention, a method of manufacturing a toothbrush is provided and includes inserting bristles into a setting hole of a toothbrush head insert such that lower parts of the bristles are disposed on a lower surface of the head insert, fastening the bristles to the head insert by application of adhesive to a lower surface of the head insert and a hardening of the adhesive and coupling the head insert having the bristles fastened thereto to a head part of the toothbrush.
According to yet another aspect of the invention, a toothbrush is provided and includes bristles, which are cut and thereby fused to each other at similar respective ends thereof, and which are arranged in a bundle having a predefined cross-sectional area, a head insert formed to define an inserting hole having a lower surface recessed from an upper surface thereof in which the bristles are set with the respective ends of the bristles adhered to the inserting hole lower surface and a head part to which the head insert is coupled.
According to yet another aspect of the invention, a toothbrush manufacturing method is provided and includes collecting bristles in a bundle thereof, each bristle having a first end to clean a user tooth and a second end opposite the first end, cutting the bundle proximate to the second ends using a heated cutter to thereby fuse the bristles, forming the bundle into a unit having a predefined cross-sectional shape, guiding the unit with the first ends leading the second ends into and through a setting hole formed in a head insert and having a shape corresponding to the unit cross-sectional shape such that the second ends align with a head insert recessed surface, adhering the second ends to the recessed surface and inserting the head insert into a toothbrush head.
The above and/or other aspects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which various embodiments are shown. This invention may, however, be embodied in many different forms, and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughout.
It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.
Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another elements as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower,” can therefore, encompasses both an orientation of “lower” and “upper,” depending on the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Exemplary embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.
The head insert 20 has a recess 22 in a lower surface thereof. The recess 22 has an area other than the perimeter of the lower surface of the head insert 20. A plurality of setting holes 24 is formed in the recess 22. The unit bundles of bristles 10 are respectively set in the setting holes 24. In an exemplary embodiment, the setting holes 24 are substantially circular and have a same size, although additional exemplary embodiments are not limited thereto, and it is understood that the setting holes 24 may have other shapes and be variably sized. In an exemplary embodiment, the setting holes 24 may be formed spaced apart from each other at substantially regular intervals in the overall area of the recess 22, although additional exemplary embodiments are not limited thereto, and it is understood that the spacing intervals may be regular or varied.
The head part 30 has a receiving depression 32 into which the head insert 20 is fitted such that the lower surface of the head insert 20 is disposed opposite to, e.g., faces, a bottom of the receiving depression 32.
Bristle Bundle Producing Operation
As shown in
With reference to
With reference to
In place of the paper band 50, a tying frame having a hole or depression may be used to tie up the processed bristles 1. When the tying frame is used, the bristles 1 are densely inserted into the hole or depression of the tying frame, which may allow the shape in which the bristles 1 are collected to be relatively easily set due to the fact that the shape is determined depending on the shape of the hole or the depression of the tying frame. As an example, if the hole or depression of the tying frame is circular, the collected bristles are also circular.
The bristle collecting operation S12 may include a bristle arranging operation in which the collected bristles 1 are arranged such that the ends thereof form a predetermined shape. For example, the bristle arranging operation may be implemented in such a way that the lower parts of the collected bristles 1 are placed on a bristle arrangement plate, the upper surface of which has a predefined uneven shape, and the bristles 1 are pressed onto the bristle arrangement plate. The ends of the collected bristles 1 then become arranged in a similar shape as that of the upper surface of the bristle arrangement plate.
As shown in
The process of adhering the lower parts of the bristles 1 includes cutting the lower parts of the bristles 1 using a cutter 60 which is heated to a predetermined temperature (for example, using a cutter having a heating wire therein). When the collected bristles 1 are cut, the paper band 50 which maintains the collected state of the bristles 1, is also cut along with the bristles 1. The lower parts of the collected bristles 1 are melted by heat of the cutter 60 when they are cut and, subsequently, the lower parts of the collected bristles 1 are adhered together by hardening of the lower parts which have been melted.
As such, at the bristle adhering operation S13, a bundle of bristles 5 which is integrated by fusing of the lower parts of the bristles 1 is produced. Of course, if the bristle arranging operation was conducted at the bristle collecting operation S12, a bundle of bristles 5, the ends of which are arranged in a special shape, is produced.
With reference to
The lower part of the bundle of bristles 5 is placed on the worktable 72 of the cutting tool 70 and pushed toward the cutters 74. Thereby, the adhered lower part of the bundle of bristles 5 is cut by the cutters 74, and the bundle of bristles 5 is thus divided into a plurality of bundles. Thereafter, the bundle of bristles 5 which has been divided into a plurality of bundles is rotated to about 90 degrees (°) and is cut once more in the same or a similar manner, thus forming several rectangular unit bundles of bristles 10. The intervals at which the cutters 74 are spaced apart from each other are set such that the unit bundles of bristles 10 which are formed at the above-mentioned bristle cutting operation have cross-sectional areas corresponding to the areas of the setting holes 24.
With reference to
With reference to
The ends (opposite to the adhered lower part) of the unit bundles of bristles 10 are inserted into the inlet ends of the guide holes 86 and the unit bundles of bristles 10 are respectively inserted through the guide holes 86 into the setting holes 24 corresponding to the guide holes 86. The adhered lower parts of the unit bundles of bristles 10 are then disposed in the recess 22 of the head insert 20. Here, because each guide hole 86 is configured such that the size of the inlet end thereof is enlarged, each unit bundle of bristles 10 can be relatively easily inserted into and through the corresponding guide hole 86. Furthermore, the unit bundles of bristles 10, which are inserted into the corresponding guide holes 86, can be relatively easily inserted into the corresponding setting holes 24 along the inner surfaces of the guide holes 86. Therefore, the work of inserting the unit bundles of bristles 10 into the setting holes 24 can be relatively rapidly and precisely conducted. Following the inserting of the unit bundles of bristles 10 into the setting holes 24, the jig 85 is removed from the head insert 20.
In the bristle fastening operation S32 (refer to
If a head insert 20 (refer to
The method of fastening the unit bundles of bristles 10 to the head insert 20 may also be implemented by inserting a heating apparatus, e.g., a heating plate, into the recess 22 of the head insert 20 and applying heat and pressure thereto such that the adhered lower parts of the unit bundles of bristles 10 are fused. In this case, when the fusing process is completed, the unit bundles of bristles 10 are fastened to the head insert 20.
With reference to
The receiving depression 32 of the head part 30 may have a predetermined size, e.g., a size appropriate to forcibly fit the head insert 20 thereinto. Furthermore, a coupling groove 34 may be formed in the receiving depression 32 of the head part 30 along the perimeter of the receiving depression 32 and a coupling protrusion 26 may be provided on the perimeter of the lower surface of the head insert 20. The coupling protrusion 26 of the head insert 20 is fitted into the coupling groove 34 of the head part 30. In an exemplary embodiment, the head insert 20 is forcibly fitted into the receiving depression 32 and, the coupling protrusion 26 is fitted into the coupling groove 34. Therefore, the contact area and the contact strength between the head insert 20 and the head part 30 can be increased and, as a result, the coupling force between the head insert 20 and the head part 30 can be enhanced.
In this toothbrush manufacturing method, because the bundles of bristles, each lower part of which has an integrated structure, are set in the head insert 20, the quality of the manufactured toothbrush can be substantially increased. In addition, the arrangement and shape of the bristles can be diversified. Particularly, at the bristle collecting operation S12, if bristles 1 having different properties, e.g., different thicknesses, colors, shapes, are collected, a toothbrush in which various kinds of bristles 1 are set in each setting hole 24 may be manufactured.
The present invention should not be construed as being limited to the exemplary embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concept of the present invention to those skilled in the art.
For instance, in the above description, although the bristle processing operation S11 of the bristle bundle producing operation S10 has been illustrated as being conducted before the bristle collecting operation S12 is conducted, the bristle processing operation S11 may be conducted after the bristle collecting operation S12. At an extreme, the bristle processing operation S11 may be conducted as the last operation of the toothbrush manufacturing method. Furthermore, the method of inserting bristles into the head insert using the jig at the bristle insert operation S31 of the bristle setting operation S30 and the method of fastening the bristles to the head insert by coating the head insert with the adhesive, e.g., thermoplastic resin, at the bristle fastening operation S32 may be used in a method in which bristles in the strand state are directly set in the head insert without producing a bundle form.
While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit or scope of the present invention as defined by the following claims.
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