Oral Care Implement

Abstract

An oral care implement which incorporates a head detachably coupled to a handle. The head has a neck portion and a head portion. The head portion has a laminate construction whereby a base structure is encapsulated by a sheet structure and a guard structure. A plurality of bristle tufts extend from a front surface of the sheet structure, the bristle tufts formed of a plurality of filament bristles. The base structure may be a material having a greater vibration transmissibility which is plastically deformable to form a desired head shape.

Description

BACKGROUND

Oral care, particularly care of an individual's teeth and gums, are of utmost importance to ensure overall health. However, typical oral care routines are time consuming. For instance, most dentists recommend brushing teeth for a minimum of two minutes. Those individuals who may have dexterity problems or may not wish to spend the required time brushing may suffer from poor oral health. Thus, a need exists for oral care implements which remedy the deficiencies in existing products.

BRIEF SUMMARY

The present invention is directed to an oral care implement having a handle and a head detachably coupled to the handle. The head has a neck portion and a head portion coupled to the neck portion. The head portion has a base structure, a sheet structure, and a guard structure. The sheet structure is in contact with the base structure and has a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure. The guard structure has a front surface and a rear surface. The front surface of the guard structure is joined to at least a portion of the rear surface of the sheet structure to encapsulate the base structure between the sheet structure and the guard structure.

In one aspect, the invention may be a head of an oral care implement having a neck portion and a head portion coupled to the neck portion. The head portion has a base structure, a sheet structure, and a guard structure. The sheet structure is in contact with the base structure and has a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure. The guard structure contacting a portion of the rear surface of the sheet structure and a rear surface of the base structure.

In another aspect, the invention may be a method of manufacturing an oral care implement. The method has a first step of providing a sheet structure, the sheet structure having a plurality of bristle tufts extending from a front surface of the sheet structure. The method has a second step of encapsulating a base structure between the sheet structure and a guard structure to form a head portion.

In a further aspect, the invention may be an oral care implement having a handle and a head detachably coupled to the handle. The head has a neck portion and a head portion coupled to the neck portion. The head portion has a sheet structure. The sheet structure has a first film layer, a second film layer, and a plurality of bristle tufts. The first film layer has a front surface and a rear surface, the front surface forming a front surface of the sheet structure. The second film layer has a front surface and a rear surface, the rear surface forming a rear surface of the sheet structure. The plurality of bristle tufts extend from the front surface of the first film layer.

In one aspect, the invention may be a head of an oral care implement having a neck portion and a head portion coupled to the neck portion. The head portion has a base structure and a sheet structure. The sheet structure has a first film layer, a second film layer, and a plurality of bristle tufts. A front surface of the first film layer forms a front surface of the sheet structure. A second film layer is joined to the first film layer, a rear surface of the second film layer forming a rear surface of the sheet structure. The plurality of bristle tufts extend from the front surface of the first film layer.

In another aspect, the invention may be a method of manufacturing a sheet structure of an oral care implement. The method has a first step of inserting a plurality of bristle filaments into a plurality of tuft holes of a tufting tool to form a plurality of bristle tufts. The method has a second step of fusing a first film layer to the base portions of the plurality of bristle tufts. Finally, the method has a third step of fusing a second film layer to the first film layer.

In a further aspect, the invention may be an oral care implement having a handle and a head detachably coupled to the handle, the handle having a vibration generation device. The head has a neck portion and a head portion coupled to the neck portion. The head portion has a base structure formed of a metallic material and a sheet structure in contact with the base structure. The sheet structure has a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure.

In one aspect, the invention may be a head of an oral care implement having a neck portion and a head portion coupled to the neck portion. The head portion has a base structure formed of a first material and a sheet structure in contact with the base structure. The sheet structure has a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure. The sheet structure is formed of a second material. The first material has a first vibration transmissibility that is greater than a second vibration transmissibility of the second material.

In another aspect, the invention may be a method of exciting bristle filaments. The method has a first step of providing an oral care implement, the oral care implement having a handle and a head, the head having a neck portion and a head portion, the head portion coupled to the neck portion and the neck portion coupled to the handle. The method has a second step of generating vibrations with a vibration generation device. In a third step, the method requires transmitting the vibrations from the handle to the bristle filaments via the neck portion, a metallic base structure of the head portion coupled to the neck portion, and a sheet structure of the head portion in contact with the base structure. The bristle filaments extend from the sheet structure.

In yet another aspect, the invention may be a method of forming a mouthpiece. The method has a first step of forming a flat laminate structure having a plurality of bristle tufts extending from a front surface of the flat laminate structure. The method has a second step of bending the flat laminate structure into a three-dimensional mouthpiece.

In one aspect, the invention may be a head of an oral care implement having a head portion, the head portion having a base structure formed of a first material and plurality of tuft blocks in contact with a front surface of the base structure. The plurality of tuft blocks each have a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface. The plurality of the tuft blocks is formed of a second material. The first material has a first vibration transmissibility that is greater than a second vibration transmissibility of the second material.

In another aspect, the invention may be an oral care implement having a handle and a head coupled to the handle. The head has a neck portion and a head portion coupled to the neck portion. The head portion has a base structure, a sheet structure, and a guard structure. The base structure extends from a proximal end to a distal end, the proximal end coupled to the neck portion. The sheet structure is in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure. The guard structure covers the base structure and is in contact with the sheet structure.

In yet another aspect, the invention may be a head of an oral care implement. The head may have a neck portion and a head portion coupled to the neck portion. The head portion has a base structure, a sheet structure, and a guard structure. The base structure has a front surface and an opposite rear surface. The base structure may be formed of a metallic material. The sheet structure is in contact with the base structure, the sheet structure having a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure. The guard structure covers the rear surface of the base structure.

In a further aspect, the invention may be a method of manufacturing a head of an oral care implement. First, a plurality of bristle filaments are joined to a flexible sheet to form a sheet structure having a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure. Second, the sheet structure is positioned in direct contact with a front surface of a base structure. Third, a rear surface of the base structure is covered with a guard structure. The guard structure is in direct contact with a perimeter of the sheet structure and covering a portion of the front surface of the base structure.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended 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 the accompanying drawings, wherein:

FIG. 1 is a perspective view of an oral care implement in accordance with an embodiment of the present invention;

FIG. 2 is a perspective view of a head of the oral care implement of FIG. 1;

FIG. 3 is an exploded perspective view of the head of FIG. 2;

FIG. 4 is a front view of the head of FIG. 2;

FIG. 5 is a cross-sectional view taken along line V-V of FIG. 2;

FIG. 6 is a cross-sectional view taken along line VI-VI of FIG. 4;

FIG. 7 is a rear view of the head of FIG. 2;

FIG. 8 is a left side view of the head of FIG. 2;

FIG. 9 is a right side view of the head of FIG. 2;

FIG. 10 is a top view of the head of FIG. 2;

FIG. 11 is a bottom view of the head of FIG. 2;

FIG. 12 is a perspective view of a sheet structure as may be used in the head of FIG. 2;

FIG. 13 is a top view of a tufting tool as may be used in the head of FIG. 2;

FIG. 13A is a detail view a plurality of tuft holes of the tool of FIG. 13;

FIG. 14A is a view of the tool of FIG. 13 shown in a first step of manufacturing the sheet structure;

FIG. 14B is a view of the tool in a second step of manufacturing the sheet structure;

FIG. 14C is a view of the tool in a third step of manufacturing the sheet structure;

FIG. 14D is a view of the tool in a fourth step of manufacturing the sheet structure;

FIG. 14E is a view of the tool in a fifth step of manufacturing the sheet structure;

FIG. 14F is a view of the tool in a fifth alternative step of manufacturing the sheet structure;

FIG. 14G is a view of the tool in a fifth second alternative step of manufacturing the sheet structure;

FIG. 14H is a view of the tool in a sixth step of manufacturing the sheet structure;

FIG. 14I is a view of the tool in a seventh step of manufacturing the sheet structure;

FIG. 14J is a view of the tool in a eighth step of manufacturing the sheet structure;

FIG. 15A is a view of the tool shown in the first step of manufacturing the sheet structure;

FIG. 15B is a view of the tool in the fifth step of manufacturing the sheet structure;

FIG. 15C is a view of the tool in the seventh step of manufacturing the sheet structure showing joining the bristles to a first film layer;

FIG. 15D is a view of the tool in an additional seventh step of manufacturing the sheet structure showing joining a second film layer to the first film layer;

FIG. 15E is a view of the tool prior to the eighth step of manufacturing the sheet structure showing a melt mat;

FIG. 16 is a perspective view of the sheet structure prior to trimming;

FIG. 17 is an exploded view of the sheet structure and the trimmed excess material subsequent to trimming;

FIG. 18 is a perspective view of a flat laminate structure used to form the head portion of FIG. 2;

FIG. 19 is an exploded view of a flat laminate structure of FIG. 18;

FIG. 20 is a perspective view of the base structure;

FIG. 21 is a top view of the base structure;

FIG. 22 is a perspective view of the flat laminate structure in an unbent state;

FIG. 23 is a perspective view of the flat laminate structure a first partially bent state;

FIG. 24 is a perspective view of the flat laminate structure a second partially bent state;

FIG. 25 is a perspective view of the flat laminate structure in a fully bent state;

FIG. 26 is a schematic view of a first alternate construction of the head portion with the bristles omitted;

FIG. 27 is a schematic view of a second alternate construction of the head portion with the bristles omitted;

FIG. 28 is a schematic view of a third alternate construction of the head portion with the bristles omitted;

FIG. 29 is a schematic view of a fourth alternate construction of the head portion with the bristles omitted;

FIG. 30 is a schematic view of a fifth alternate construction of the head portion with the bristles omitted;

FIG. 31 is a schematic view of a sixth alternate construction of the head portion with the bristles omitted;

FIG. 32 is a schematic view of a seventh alternate construction of the head portion with the bristles omitted;

FIG. 33 is a schematic view of an eighth alternate construction of the head portion with the bristles omitted;

FIG. 34 is a schematic view of a ninth alternate construction of the head portion;

FIG. 35 is a schematic view of a tenth alternate construction of the head portion;

FIG. 36 is a schematic view of an eleventh alternate construction of the head portion;

FIG. 37 is a schematic view of a twelfth alternate construction of the head portion;

FIG. 38 is a schematic view of a thirteenth alternate construction of the head portion;

FIG. 39 is a schematic view of a fourteenth alternate construction of the head portion;

FIG. 40 is a perspective view of an alternate embodiment of a head of the oral care implement of FIG. 1;

FIG. 41 is an exploded view of the head of FIG. 40;

FIG. 42 is a cross-section view of the head taken along line XLII-XLII of FIG. 40;

FIG. 43 is a perspective view of another alternate embodiment of a head of the oral care implement of FIG. 1;

FIG. 44 is an exploded view of the head of FIG. 43; and

FIG. 45 is a cross-section view of the head taken along line XLV-XLV of FIG. 43.

DETAILED DESCRIPTION

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

The description of illustrative embodiments of 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 derivatives 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 exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

Referring to FIG. 1, an oral care implement 1000 is illustrated in accordance with an embodiment of the present invention. The oral care implement 1000 is a powered device for cleaning a user's teeth and other oral tissues. The oral care implement 1000 has a head 100 and a handle 200, the head 100 having a neck portion 102 and a head portion 104. The handle 200 has a vibration generating device and a user interface 204 configured to control operation of the vibration generating device. The vibration generating device is preferably a motor, but may be any known type of vibration generating device suitable for transmitting vibrations from the handle 200 to the head 100 to excite cleaning elements on the head 100. Optionally, the head 100 may be detachably coupled to the handle 200 or it may be permanently attached.

FIGS. 2-11 illustrate the head 100 in greater detail. As discussed above, the head 100 has a head portion 104 coupled to a neck portion 102. The neck portion 102 may engage a stem of the handle 200 or other engagement feature. The head portion 104 is coupled to the neck portion 102 and has a generally arcuate shape suitable for insertion into a user's oral cavity. The head portion 104 is configured to engage a plurality of the user's teeth simultaneously. The head 100 extends along a longitudinal axis A-A.

The head portion 104 extends along a path P-P. Optionally, the path P-P may be an arcuate path. The path P-P may be selected to correspond to a user's dental arch. Optionally, the path P-P may be a continuous arc or may be formed of a series of linear segments or arcs, or a combination of arcs and linear segments. Furthermore, the path P-P may be any shape forming a generally concave path and may incorporate any curved geometry. The path P-P extends parallel to a horizontal plane H-H, the horizontal plane H-H extending along a bottom surface 106 of the head portion 104.

The head portion 104 further has a wall 108, the wall 108 extending along the path P-P from a first distal end 110 to a second distal end 112. The wall 108 has a generally concave shape but need not take the form of a single arc of constant radius. The wall 108 may instead be a composite concave shape comprising a plurality of arcs and line segments, or other geometry that collectively forms a curved shape. A plurality of fingers 130 extend from the wall 108. Optionally, the head portion 104 may be symmetric about the connector 116 as illustrated, or the head portion 104 may be asymmetric about the connector 116. It is conceived that the head portion 104 may correspond to a user's full dental arch or only a portion of the user's dental arch.

In yet other implementations, the plurality of fingers 130 may not extend from a single wall 108. Instead, the fingers 130 may be arranged into a series of segments such that a plurality of distinct walls 108 are formed about the user's dental arch. When in a flat configuration, the head portion 104 may appear to have a zig-zag shape to form the desired shape for the head portion 104 when in the folded state.

In some implementations, the head portion 104 may be symmetrical and extend along a majority of the user's dental arch. In yet other implementations, the head portion 104 may be asymmetrical such that it extends along less than half of the user's dental arch. In other implementations, the head portion 104 may be configured to cover approximately one half of the user's dental arch. In these implementations, the head portion 104 may engage one side of the user's mouth at a time. The head portion 104 may be moved along the dental arch to brush all teeth of the dental arch. It is further contemplated that the head portion 104 may engage only a single jaw or may engage both upper and lower jaws simultaneously. Where the head portion 104 engages both upper and lower jaws, the fingers 130 may extend in opposite directions to engage different jaws or components of the head portion 104 may be duplicated to allow simultaneous brushing of both top and bottom jaws.

The plurality of fingers 130 each has a horizontal portion 132 extending from the wall 108 along the horizontal plane H-H. The plurality of fingers 130 also has a first bend 134, a tip portion 136, and a second bend 137. The tip portion 136 extends from the horizontal plane H-H at the first bend 134. The second bend 137 is located at the transition between the horizontal portion 132 and the wall 108. In the present embodiment there are five fingers 130, but in other embodiments there may be greater or fewer than five fingers 130. As can be seen, the fingers 130 are bent to form an L shape with respect to the horizontal plane H-H. The fingers 130 and the wall 108 generally form a U shape in cross-section. In other implementations, the tip portions 136 of the fingers 130 may extend from both sides of the horizontal plane H-H to enable simultaneous brushing of both top and bottom jaws. In yet other embodiments, the fingers 130 need not all have their horizontal portions 132 lying along the horizontal plane H-H. In these embodiments, the horizontal portions 132 may be angled with respect to one another, parallel but non-planar with respect to one another, or even have a radius of curvature which is greater than a radius of curvature of either of the first and second bends 134, 137.

Each of the fingers 130 is spaced and isolated from the other fingers 130, although in some embodiments the fingers 130 may be in surface contact. Preferably, the fingers 130 are not coupled to one another, but are exclusively coupled to the wall 108. An arcuate channel is formed between the fingers 130 and the wall 108. This arcuate channel effectively surrounds the user's teeth, ensuring brushing on three sides of each tooth simultaneously. Combined with movement along the user's dental arch, all surfaces of all teeth can be reached. The arcuate channel may have a U shape in cross-section but need not be symmetrical.

As can be seen, the head portion 104 has a plurality of bristle tufts 152, the plurality of bristle tufts 152 extending from the wall 108 and the plurality of fingers 130. The fingers 130 have bristle tufts 152 on both the horizontal portion 132 and the tip portion 136. The bristle tufts 152 are formed of filament bristles, and may be formed of any known bristle filament material. Such materials may include Polybutylene Terephthalate (“PBT”), nylon, polypropylene, or other natural or synthetic materials.

The head portion 104 is coupled to the neck portion 102 via a connector 114, the connector 114 being a part of the head portion 104 and engaging a socket 116 of the neck portion 102. Thus, the head portion 104 may be manufactured separately from the neck portion 102 and the head portion 104 may be assembled to the neck portion 102 by snapping the connector 114 of the head portion 104 into the socket 116 of the neck portion 102. In yet other optional configurations, the connector 114 and socket 116 may be omitted and the neck portion 102 may be directly attached to the head portion 104. The connector 114 and socket 116 may be a permanent connection or may be detachably coupled.

Turning to FIG. 12, a sheet structure 150 is illustrated, the sheet structure 150 comprising the plurality of bristle tufts 152 and forming a part of the head portion 104. The plurality of bristle tufts 152 are arranged in tuft blocks 153. The tuft blocks 153 are groupings of bristle tufts 152 which are spaced and isolated from other bristle tuft blocks 153. In some implementations, a single bristle tuft 152 may form a tuft block 153, while in other implementations all of the bristle tufts 152 may be arranged in a single tuft block 153. Each of the plurality of bristle tufts 152 is formed of bristle filaments. These filaments may be any conventional material used for forming bristle filaments, such as Polybutylene Terephthalate (“PBT”), nylon, polypropylene, or other natural or synthetic materials as discussed above. In the present implementation, the tuft blocks 153 have a step change in height from the surrounding portions of the sheet structure 150. This is optional and may be omitted, such that the tuft blocks 153 have the same height as the surrounding portions of the sheet structure 150.

The sheet structure 150 comprises a single tuft block 153 which extends along a length of the sheet structure 150 and a plurality of smaller tuft blocks 153 on fingers of the sheet structure 150. The sheet structure 150 may be formed of at least one sheet of flexible elastomeric material with the plurality of bristle tufts 152 attached, as will be discussed in greater detail below. In alternate configurations, the sheet structure 150 may exclusively be formed by a single tuft block 153. In yet other configurations, a plurality of individual tuft blocks 153 may be used without the sheet structure 150. This configuration will be discussed in greater detail below.

Turning to FIGS. 13 and 13A, a view of a tufting tool 300. The tufting tool 300 has a tuft plate 301 that receives filaments to form distinct tufts. The tuft plate 301 has a plurality of recesses 353, the recesses 353 each having a plurality of individual tuft holes 352 located therein. The recesses 353 may have only a single tuft hole 352 if desired. The tuft holes 352 may be circular as shown, square, rectangular, or any other desired shape. The tuft holes 352 may have different dimensions for different tuft holes 352, resulting in a plurality of diameters of tufts in the resulting device. In the present example, the diameter of the tuft holes is 1.5 mm, but it may be larger or smaller as desired. The tuft holes are spaced at a column pitch Pc and a row pitch PR. The column pitch PC and row pitch PR may vary or may be equal. In some implementations, the column pitch PC is 1.5 mm and the row pitch PR is 1.5 mm. Optionally, the spacing may vary between tuft holes 352 within a recess 353 or may vary between different recesses 353. Optionally, the tuft holes 352 may be spaced in irregular patterns, such as arcuate patterns, triangular patterns, or other arrangements. Thus, the tuft holes 352 do not necessarily need to be arranged in rows and columns.

FIGS. 14A-J illustrate a process for manufacturing the sheet structure 150 using the tufting tool 300 and various other equipment. In a first step, a plurality of bristle filaments 151 are loaded into a top section 302 of the tufting tool 300. Second, the plurality of bristle filaments 151 are agitated so that they fall into the tuft holes 352 in the tuft plate 301. The bristle filaments 151 fall until they engage a bottom plate 303, the bottom plate 303 optionally incorporating protuberances 304 or recesses. Thus, bristle tufts 152 are formed as a result of the bristle filaments 151 filling the tuft holes 352 in the tuft plate 301. The protuberances 304 or recesses allow the formation of tufts 152 having distal ends which are not all at the same height. Optionally, the height of the distal end of a single tuft 152 may vary or each tuft 152 may have a different height but all bristle filaments 151 within a particular tuft 152 may have substantially the same height. Optionally, the bristle filaments 151 may fill the tuft holes 352 by gravity alone.

Next, the bristle filaments 151 may be trimmed to a consistent length. The bristle filaments 151 may protrude beyond a top surface 305 of the tuft plate 301 or may be trimmed at the top surface 305 or below the top surface 305 as desired. As can be seen, the tuft plate 301 has a recess 353 in the top surface 305. The tuft plate 301 comprises the plurality of recesses 353 as mentioned above. The recesses 353 define the perimeter of the tuft blocks 153. In other implementations, the recesses 353 may be omitted, resulting in the tuft blocks 153 lacking a step or other sharp boundary from the rest of the sheet structure 150 as discussed above.

The trimmed bristle filaments 151 can then be prepared by applying heat from a heat source 306 to melt the base portions 154 of the plurality of bristle filaments 151 within each individual tuft 152 together. This results in tufts 152 where the base portions 154 of the bristle filaments 151 form a ball shape, joining each bristle filament 151 within each individual tuft 152 together. While some of the base portions 154 of one tuft 152 may bond to the base portions 154 of another tuft 152, this is not necessary or desired at this step. The heat source 306 applies heat without direct contact so that the base portions 154 melt without having the ball shape altered by direct contact with the heat source 306. The heat source 306 may be a radiant heat device, a convective heat device, or other heat source which is configured to heat a target object without direct contact with the target object. It is also conceived that the heat source 306 may be a heat stamp or other heating device which is kept spaced from the base portions 154 during this process step. In other words, the heat source 306 may be used for heating both with and without direct contact in different process steps.

In an alternate process step, instead of applying heat indirectly via the heat source 306, heat is applied via direct contact. For instance, the heat source 306 may be a hot stamping tool which is brought into contact with the top surface 305 of the tuft plate 301. The base portions 154 of the bristle filaments 151 are melted into a continuous sheet of material which connects all base portions 154 of all of the tufts 152 within a given bristle block 153. Thus, all tufts 152 are coupled together via the base portions 154 of the bristle filaments 151. In yet another alternate process step, no heat is applied to the base portions 154 of the tufts 152. The bristle filaments 151 remain independent of each other at this process step.

To summarize, three alternative process steps are possible subsequent to the step of trimming the bristle filaments 151. In a first alternative process step, the heat source 306 is used to indirectly heat the base portions 154 to form balls at a base end of the bristle tufts 152. In a second alternative process step, the heat source 306 is used to apply direct heat to the base portions 154 of the bristle filaments 151 of the tufts 152, causing the base portions 154 to melt into a continuous sheet joining all base portions 154 within a single bristle block 153. In a third alternative process step, no heat source is used and the trimmed bristle filaments 151 are simply left as trimmed for the next process step.

Turning to the next process step, a first film layer 155 is placed on the top surface 305 of the tuft plate 301. The first film layer 155 may have a thickness of 0.4 mm, or optionally may be thicker or thinner than 0.4 mm. For instance, the first film layer 155 may be 0.2 mm, 0.3 mm, 0.6 mm, 0.8 mm, or 1.0 mm as desired. The first film layer 155 is preferably a flexible sheet. The first film layer 155 is preferably an elastomeric material such as a thermoplastic elastomer. The first film layer 155 may be a different material from the material used to form the bristle filaments 151.

After placement of the first film layer 155, the heat source 306 is applied to the first film layer 155 to bond the base portions 154 of the bristle filaments 151 to the first film layer 155. The base portions 154 are melted to the first film layer 155 and the recess 353 is at least partially filled with a mixture of material from the first film layer 155 and the base portions 154 of the bristle filaments 151. This mixture forms a melt mat 156, which is a layer of melted base portions 154 combined with material from the first film layer 155. The melt mat 156 may extend beyond the recess 353, depending on the amount of spread of the base portions 154 during this process step.

In an optional additional process step, a second film layer may be applied to the first film layer 155 and bonded using the heat source 306. This may further extend the melt mat 156 into the second film layer, ensuring improved retention of the tufts 152. If desired, more than two film layers may be used. Optionally, the first and second film layers may be formed of the same material, or in other implementations the first and second film layers may be formed of different materials. In a final process step, the sheet structure 150 is removed from the tufting tool 300. The tufts 152 are bonded to the first film layer 155, ensuring retention of the tufts 155. The sheet structure 150 is ready for additional processing steps as will discussed in greater detail below.

In certain embodiments, the sheet structure 150 may be formed, at least in part, of a biocompatible material, such as a food grade polymer. Suitable biocompatible materials include, without limitation, acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, polypropylene (PP), polyethylene naphthalate (PEN), polyethylene (PE), silicone, ethylene propylene diene monomer (EPDM), polycarbonate (PC), thermoplastic elastomers (TPE), and other plastics and elastomeric materials. Of course, the invention is not to be so limited in all embodiments and other materials are possible for construction of the sheet structure 150, and various components thereof. In certain embodiments, the sheet structure 150, or at least portions thereof, may be formed of an elastomeric material. A hybrid construction including components having different materials is contemplated.

Turning to FIGS. 15A-E, some additional detail is illustrated for the process of bonding the bristle filaments 151 to the film layers. In FIG. 15A, an example of loading bristle filaments 151 into the tuft holes 352 of the tuft plate 301 of the tufting tool 300. The tufting tool 300 is agitated up and down manually or via a mechanism such as a shaker table or vibration device to facilitate loading of the bristle filaments 151 into the tuft holes 352. FIG. 15B illustrates the filaments loaded into the tuft holes 352 of the tuft plate 301, with additional bristle filaments 151 that did not fit within the tuft holes 352. Heat is applied to the base portions 154 as discussed above to form the base portions 154 of the tufts 152 into a ball shape.

In FIG. 15C, the base portions 154 of the bristle filaments 151 are joined to the first film layer 155 using the heat source 306. A melt mat 156 is formed by material of the base portions 154 and the first film layer 155 when the heat source 306 is put in direct contact with the first film layer 155 and heat is applied to the base portions 154 and the first film layer 155. A front surface 159 of the first film layer 155 is in direct contact with the top surface 305 of the tuft plate 301 while an opposite rear surface 160 of the first film layer 155 is in direct contact with the heat source 306.

FIG. 15D illustrates a second film layer 157 applied to the first film layer 155 and bonded to the first film layer 155 via application of heat from the heat source 306. The heat source 306 is applied directly to the second film layer 157. A front surface 161 of the second film layer 157 is in direct contact with the rear surface 160 of the first film layer 155. A rear surface 162 of the second film layer 157 is opposite the front surface 161 of the second film layer 157. The rear surface 162 is in direct contract with the heat source 306. The melt mat 156 extends into the second film layer 157 when the first and second film layers 155, 157 are joined.

Thus, the sheet structure 150 is formed such that the recesses 353 are at least partially filled with material from the first film layer 155 and the plurality of bristle filaments 151, the material within the recesses 353 forming the tuft blocks 153. As can be seen in FIG. 15E, the melt mat 156 extends into the second film layer 157 but does not extend through an entirety of the thickness of the second film layer 157. The melt mat 156 may extend beyond the recesses 353 in the plane of the first and second film layers 155, 157, but only extends a portion of the thickness of the second film layer 157.

FIG. 16 illustrates the sheet structure 150 after joining the bristle filaments 151 of the plurality of bristle tufts 152 to the first and second film layers 155, 157. It should be noted that only one film layer or more than two film layers may be used to form the sheet structure 150. Furthermore, the tuft blocks 153 may not be clearly defined by the recesses 353 of the tufting tool 300 as illustrated, but instead may simply be defined by a perimeter of the respective groupings of bristle tufts 152. The recesses 353 may not be completely filled or even filled at all during the formation process. The plurality of bristle tufts 152 extend from a front surface 163 of the sheet structure 150. A rear surface 164 of the sheet structure 150 is opposite the front surface 163. FIG. 17 illustrates the sheet structure 150 after trimming the bristle film layer or layers. The sheet structure 150 is trimmed to remove excess material 158 not required for subsequent process steps.

In alternate configurations, the sheet structure 150 may be formed by molding instead of by laminating. The sheet structure 150 may be formed such that the bristle tufts 152 may be in-mold tufted. Thus, bristle tufts 152 may be installed in mold or other tool, then the layers may be bonded to the base portions 154 of the plurality of bristle filaments 151 via molding or the processes described previously. The bristle tufts 152 may be installed such that they are arranged in a two dimensional pattern as shown and described, or they may be installed in a three dimensional arrangement such that the resulting sheet structure 150 is non-planar. Thus, the sheet structure 150 formed via this in-mold tufting technique may be formed in the end-use shape.

Furthermore, protuberances or other structures may be formed on the sheet structure 150. It should be further noted that, regardless of manufacturing method, the bristle tufts 152 may be mounted to the sheet structure 150 individually, in blocks or groupings of tufts, or in a single group of tufts which is bonded to the rest of the sheet structure 150. The blocks or groupings of tufts 152 may have the base portions 154 of the bristle filaments 151 of all tufts 152 within the blocks joined together. Alternately, the base portions 154 of the bristle filaments 151 of each individual tuft 152 may remain separate, even when the tufts 152 are arranged in one or more blocks.

FIGS. 18-25 illustrate the head portion 104 during the formation process. FIGS. 18 and 19 illustrates a flat laminate structure 120 and an exploded view of the flat laminate structure 120 showing the sheet structure 150, two fasteners 165, a base structure 170, a guard structure 190, and a connector 114. FIGS. 20 and 21 illustrate the base structure 170. FIG. 22 illustrates the flat laminate structure 120 as assembled. FIGS. 23-25 illustrate different bending states which may be used to form the flat laminate structure 120 into the head portion 104.

The flat laminate structure 120 has a wall portion 122 and a plurality of finger portions 124 extending from the wall portion 122. As can be seen, the finger portions 124 need not extend perpendicular to the wall portion 122 and need not extend in a straight line. Instead, the finger portions 124 may have one or more angles along their length and may extend at an angle with respect to the wall portion 122. Each of the finger portions 124 is spaced and isolated from the other finger portions 124.

The plurality of bristle tufts 152 of the sheet structure 150 extend from a front surface 125 of the flat laminate structure 120. Thus, the plurality of bristle tufts 152 of the sheet structure 150 extend from the front surface 125 of the flat laminate structure 120. The front surface 125 of the flat laminate structure 120 is the same as the front surface 163 of the sheet structure 150. The flat laminate structure 120 also has a rear surface 126 opposite the front surface 125.

As shown in FIG. 19, the two fasteners 165 extend through apertures 171 in the base structure 170 to couple the connector 114 to the base structure 170. The base structure 170 is formed of a sheet of material such as sheet metal. The base structure 170 may be formed of iron, aluminum, copper, or any metallic element, metallic alloy, or metallic material thereof. For instance, the base structure 170 may be formed of a stainless steel, spring steel, or other alloy. In yet other implementations, the base structure 170 may be formed of polymer materials combined with a metal to form a composite structure. In other implementations, the base structure 170 may be formed of a polymer or other non-metallic material.

Preferably, the base structure 170 is formed of a material suitable to permit plastic deformation such as bending in subsequent assembly steps as will be discussed below. The material of the base structure 170 is selected to achieve the desired properties of the base structure 170. These properties may include vibration transmissibility, modulus of elasticity, acoustic impedance, mechanical impedance, or dynamic stiffness. It is desired that the base structure 170 be capable of transmitting vibrations efficiently while simultaneously being formable into the desired shape for brushing a user's teeth. The head portion 104 may take the form of a conventional toothbrush shape, a full or partial mouthpiece shape, or any other shape suitable for cleaning the user's oral cavity.

In one implementation, the base structure 170 is formed of a material having a higher vibration transmissibility than the material of the sheet structure 150 or the guard structure 190. In another implementation, the base structure 170 is formed of a material having a higher modulus of elasticity than the material of the sheet structure 150 or the guard structure 190. In another implementation, the base structure 170 is formed of a material having a higher acoustic impedance than the material of the sheet structure 150 or the guard structure 190. In yet another implementation, the base structure 170 is formed of a material having a higher mechanical impedance and dynamic stiffness than the material of the sheet structure 150 or the guard structure 190.

The base structure 170 is a substantially flat sheet of material having an embossed portion 172. The embossed portion 172 has the apertures 171 formed therein, allowing the heads of the fasteners 165 to remain below a front surface 173 of the base structure. The base structure 170 has a rear surface 174 which is opposite the front surface 173. The front and rear surfaces 173, 174 are substantially planar except for the embossed portion 172. The embossed portion 172 may be omitted if desired. The fasteners 165 need not be screws or bolts, but instead may be formed integrally with one of the other components of the flat laminate structure 120. For instance, the connector 114 may incorporate features which extend through the apertures 171 and are heat staked to the base structure 170. Alternately, the fasteners 165 may be separate components which are pressed, staked, ultrasonically welded, or otherwise joined to the connector 114. Any connection mechanism, including rivets, heat staking, press-fit, adhesive bonding, or any other known technique, may be used to join the connector 114 to the base structure. In yet other implementations, the base structure 170 may be integrally formed and monolithic with the connector 114.

Holes may be provided in the base structure 170 to enable superior engagement with the sheet structure 150 and the guard structure 190. Material from one of the sheet structure 150 and the guard structure 190 may flow through the holes in the base structure 170 to join the sheet structure 150 to the guard structure 190 by bonding the material from the sheet structure 150 to the material of the guard structure 190.

The base structure 170 further comprises a wall portion 175 and a plurality of finger potions 176. The wall portion 175 extends along a width of the base structure 170 and includes the embossed portion 172 and the apertures 171 in the embossed portion 172. The finger portions 176 extend approximately perpendicular to the wall portion 175, though they may be angled with respect to the wall portion 175 as desired. The finger portions 176 need not extend in a straight line and may have a bend or curve along their length.

The guard structure 190 may be constructed from sheet material or it may be a molded component which is either molded separately or over molded onto other components of the flat laminate structure 120. The guard structure 190 has a front surface 191 and an opposite rear surface 192. The front surface 191 may be generally planar but need not be exactly planar. As illustrated, the front surface 191 may have a recess to surround the base structure 170. A recess need not be formed in the front surface 191 of the guard structure, and this recess may optionally be formed into the rear surface 164 of the sheet structure 150 in an alternative configuration.

In certain embodiments, the guard structure 190 may be formed, at least in part, of a biocompatible material, such as a food grade polymer. Suitable biocompatible materials include, without limitation, acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, polypropylene (PP), polyethylene naphthalate (PEN), polyethylene (PE), silicone, ethylene propylene diene monomer (EPDM), polycarbonate (PC), thermoplastic elastomers (TPE), and other plastics and elastomeric materials. Of course, the invention is not to be so limited in all embodiments and other materials are possible for construction of the guard structure 190, and various components thereof. In certain embodiments, the guard structure 190, or at least portions thereof, may be formed of an elastomeric material. A hybrid construction including components having different materials is contemplated.

The guard structure 190 has a perimeter portion 193 that extends beyond the base structure 170. Similarly, the sheet structure 150 has a perimeter portion 166 that extends beyond the base structure 170. In one possible assembly process for the flat laminate structure 120, the sheet structure 150, the base structure 170, and the guard structure 190 are layered and then the sheet structure 150 and the guard structure 190 are bonded or joined together to encapsulate the base structure 170. In another possible assembly process, the sheet structure 150 and the base structure 170 are layered and then the guard structure 190 is molded onto the sheet structure 150 and the base structure 170 to encapsulate the base structure 170. The guard structure 190 may be joined to the sheet structure 150 by thermal welding, ultrasonic welding, adhesive bonding, molding, or any other known process.

In yet other configurations, the guard structure 190 and the sheet structure 150 may be integrally formed and molded onto the base structure 170. Optionally, the material of the guard structure 190 and the sheet structure 150 may be the same or different, and one of the guard structure 190 or the sheet structure 150 may overlap the edges of the base structure 170 to protect the user from potentially sharp edges of the base structure 170.

Yet other processes are conceived which result in a flat laminate structure 120 as illustrated. The base structure 170 may simply be in direct contact with the sheet structure 150 and the guard structure 190 or the base structure 170 may be bonded or otherwise joined to the sheet structure 150 or the guard structure 190 at any point during the assembly process as desired. This may be done by melting one or more of the components or with adhesive or some other bonding technique. Optionally, the base structure 170 may be exposed through the guard structure 190 in some or more areas. In yet other embodiments, the guard structure 190 may be omitted if desired.

In each assembly process, it is conceived that the perimeter portion 193 of the guard structure 190 is joined to the perimeter portion 166 of the sheet structure 150. Thus, the sheet structure 150 and the guard structure 190 extend beyond a perimeter of the base structure 170. The rear surface 164 of the sheet structure 150 is in direct surface contact with the front surface 173 of the base structure 170 and is joined to the front surface 191 of the guard structure 190. The rear surface 174 of the base structure 170 is in direct surface contact with the front surface 191 of the guard structure 190. The connector 114 may be coupled to the base structure 170 during, prior to, or subsequent to encapsulation of the base structure 170. The connector 114 extends from the rear surface 174 of the base structure 170 and the rear surface 192 of the guard structure 190.

Optionally, the sheet structure 150 and the guard structure 190 may be formed, at least in part, of an elastomeric material. As discussed above, the first and second film layers 155, 157 may be formed of an elastomeric material. The guard structure 190 may be formed of the same elastomeric material as the first and second film layers 155, 157 of the sheet structure 150. Alternately, the material of the guard structure 190 and the first and second film layers 155, 157 of the sheet structure 150 need not be the same, and may be different. For instance, the first film layer 155, the second film layer 157, and the guard structure 190 may be elastomeric materials of different durometers, chemical compositions, or even may not be elastomeric material. Hard plastics such as ABS, Nylon, or other polymers may be used for some or all of the first film layer 155, the second film layer 157, and the guard structure 190 as noted above.

Preferably, an entirety of the front surface 173 of the base structure 170 is joined to the rear surface 164 of the sheet structure 150. An entirety of the rear surface 174 of the base structure 170 is joined to the front surface 191 of the guard structure 190. Thus, the base structure 170 is encapsulated by the guard structure 190 and the sheet structure 150. The perimeter portions 166, 193 of the sheet structure 150 and the guard structure 190 extend beyond the base structure 170. As noted previously, portions of the base structure 170 may be exposed through the guard structure 190. In particular, the guard structure 190 may have apertures which expose portions of the rear surface 174 of the base structure 170 if so desired.

Optionally, the guard structure 190 may be omitted and the sheet structure 150 may cover a perimeter of the base structure 170 or even wrap around the base structure 170 to cover a portion of the rear surface 174 of the base structure 170. In yet other configurations, the guard structure 190 may only cover a perimeter of the base structure 170. It is even conceived that the sheet structure 150 may cover both front and rear surfaces 173, 174 of the base structure 170 while the guard structure 190 may cover the perimeter of the base structure 170.

In yet other implementations, one or more tufts 152 or tuft blocks may be welded to the sheet structure 150. In this implementation, the sheet structure 150 may be molded and the tufts 152 may be subsequently welded or bonded to the sheet structure 150 instead of in-mold tufting as disclosed above. Optionally, the sheet structure 150 may be molded separately from the base structure 170 or the sheet structure 150 may be overmolded to the base structure 170. In another configuration, the bristle tufts 152 or bristle blocks may be put into a mold along with the base structure 170, and the sheet structure 150 may be overmolded onto both the bristle tufts 152 and the base structure 170 simultaneously. In yet another configuration, the base structure 170 may be coated. The coating may form both the sheet structure 150 and the guard structure 190. The bristle tufts 152 may be welded or bonded to the coating that forms the sheet structure 150.

In yet alternate configurations the tuft blocks 153 may be formed with the bristle tufts 152. The tuft blocks 153 may be formed of a hard plastic material such as ABS, Nylon, or other non-elastomeric plastics. The tuft blocks 153 may then have the bristle tufts 152 attached thereto to form a completed tuft block 153. The tuft blocks 153 may then be bonded, welded, or otherwise joined to the base structure 170. Thus, the sheet structure 150 may be omitted. Optionally, the guard structure 190 may be formed around the tuft blocks 153 to encapsulate the base structure 170, or the guard structure 190 may have portions of the front surface 191 left exposed.

As best illustrated in FIG. 22, the flat laminate structure 120 is shown in an unbent state, whereby the flat laminate structure 120 generally extends along a plane. As can be seen, the plurality of bristles 152 are arranged in the plurality of bristle blocks 153 which extend from the front surface 125 of the flat laminate structure 120. FIG. 23 illustrates the flat laminate structure 120 in a first partially bent state where the flat laminate structure 120 no longer extends along a plane. Instead, the flat laminate structure 120 has been bent to begin forming the flat laminate structure 120 into a head portion 104. FIG. 24 illustrates the flat laminate structure 120 in a second partially bent state where the finger portions 124 of the flat laminate structure 120 are partially bent. FIG. 24 illustrates the flat laminate structure 120 in a fully bent state. After transitioning from the unbent state to the fully bent state, the flat laminate structure 120 is converted into a head portion 104 which is ready for assembly with the neck portion 102.

In the first partially bent state shown in FIG. 23, the wall portion 122 of the flat laminate structure 120 has been bent about a path P-P. The path P-P may be an arc, a series of arcs, a combination of arcs and lines, or any other shape as desired. The path P-P may be designed to conform to a user's dental arch or an approximation thereof. The wall portion 122 of the flat laminate structure 120 may be bent all at once, or may be bent by making a series of smaller bends. In either case, the wall portion 122 is plastically deformed to achieve the desired shape. As can be seen, the finger portions 124 extend perpendicular to the path P-P and remain un-bent in the first partially bent state.

In the second partially bent shape shown in FIG. 24, the finger portions 124 of the flat laminate structure 120 are bent at a first bend 127 proximate a distal end 128 of the finger portions 124. Thus, the finger portions 176 of the base structure 170 extend to the distal end 128 of the finger portions 124 of the flat laminate structure. The finger portions 124 of the flat laminate structure 120 need not be bent at the same angle, and the bend angles may differ for each of the finger portions 124.

FIG. 25 illustrates the flat laminate structure 120 in a fully bent state. Thus, the flat laminate structure 120 has now been formed into the head portion 104. The finger portions 124 of the flat laminate structure 120 are bent at a second bend 129 proximate the wall portion 122. As discussed above, the finger portions 124 form an L shape, with horizontal portions 132 of the fingers 130 extending from the wall 108 along the horizontal plane H-H. An arcuate channel is formed by the wall 108 and the fingers 130 which receives teeth of a user's dental arch. By forming the flat laminate structure 120 in a series of states from the unbent state to a first partially bent state to a second partially bent state and then on to a fully bent state, the flat laminate structure 120 is converted into a head portion 104 which takes the form of a three-dimensional mouthpiece. The mouthpiece is configured to engage a dental arch of a user. More specifically, the mouthpiece is capable of brushing facial, labial, and biting surfaces of the user's teeth.

In some implementations, the finger portions 124 may be bent prior to bending of the wall portion 122. In other implementations, the finger portions 124 may be bent subsequent to the bending of the wall portion 122. In yet other implementations, the finger portions 124 may be bent simultaneously with the wall portion 122. In some implementations, the connector 114 may be coupled to the base structure 170 prior to bending of the finger portions 124 and the wall portion 122.

Turning to FIGS. 26-33, a series of alternate constructions for the head portion 104 are illustrated. Thus, each of these arrangements are examples of how the head portion 104 may be formed in addition to the examples described previously. Each of these embodiments are shown with the bristles omitted. In the embodiment of FIG. 26, the base structure 170 is encapsulated by the guard structure 190 only at a perimeter 177 of the base structure 170. A plurality of holes 171 may be formed in the base structure 170 to permit material of the guard structure 190 to pass therethrough and improve the attachment of the guard structure 190 to the base structure 170. Optionally, the bristles may be bonded directly to the base structure 170 or the sheet structure 150 may be bonded to some or all of the exposed base structure 170 on one or both sides of the base structure 170.

FIG. 27 illustrates another implementation where the sheet structure 150 is deformed around the base structure 170 and the guard structure 190 remains substantially planar prior to bending. Thus, the sheet structure 150 has a raised portion where it encapsulates the base structure 170. The perimeter portions 166, 193 of the sheet structure 150 and the guard structure 190 have a combined thickness which is less than a thickness of the sheet structure 150, guard structure 190, and base structure 170. In alternative configurations, the sheet structure 150 and the guard structure may be reversed such that the sheet structure 150 is planar and the guard structure 190 has a raised portion. Optionally, the sheet structure 150 and the guard structure 190 may be formed of the same material or different materials.

FIG. 28 illustrates an implementation where the sheet structure 150 has a recess 169 which receives the base structure 170. The guard structure 190 may be planar and bond to the sheet structure 150. The recess 169 may be formed in the sheet structure 150 prior to encapsulation of the base structure 170 or the recess 169 may be formed as a result of overmolding or another process. Optionally, the recess 169 may be formed in the guard structure 190 instead of the sheet structure 150. In this configuration, the sheet structure 150 may be substantially planar.

FIG. 29 illustrates a base structure 170 which is completely encapsulated. Thus, the sheet structure 150 and the guard structure 190 are integrally formed as a single monolithic component. This may be done by overmolding the base structure 170. Similarly, FIG. 30 illustrates a base structure 170 with a plurality of holes 171 formed therein to improve retention of the sheet structure 150 and the guard structure 190.

FIG. 31 illustrates an embodiment where only one side of the base structure 170 is exposed. Optionally the bristles may be attached to the base structure 170 directly or the guard structure 190 may be integrally formed with the sheet structure 150 and the guard structure 190 may only cover the perimeter 177 of the base structure 170.

FIG. 32 illustrates a guard structure 190 which surrounds the base structure 170. The sheet structure 150 may be formed of a different material and only be formed on one surface of the base structure 170. FIG. 33 illustrates a configuration where the sheet structure 150 extends through holes 171 in the base structure 170 and covers both sides of the base structure 170. The guard portion 190 surrounds the perimeter 177 of the base structure 170. The sheet structure 150 may also be formed of a different material from the guard portion 190.

FIGS. 34-39 illustrate a variety of embodiments showing variations on the attachment of the bristle tufts 152. FIG. 34 illustrates that the bristle tufts 152 may be individually joined to the rest of the sheet structure 150. Thus, base portions 154 of the bristle filaments 151 are joined exclusively to base portions 154 of bristle filaments 151 within the same bristle tuft 152. In contrast, FIG. 35 illustrates that the base portions 154 of the bristle filaments 151 are joined across a plurality of bristle tufts 152 that form a single tuft block. FIG. 36 illustrates an implementation where the base portions 154 of the bristle filaments 151 are joined together such that all of the base portions 154 of the bristle filaments 151 of all of the bristle tufts 152 form a single tuft block. Optionally, in each embodiment, the bristle tufts 152 may be bonded as described above or they may be bonded using an adhesive or other method.

FIG. 37 illustrates an implementation where the base portions 154 of the bristle filaments 151 may be formed using an anchor free tufting or other technique to form a bristle block where the base portions 154 form a unitary structure. This structure is then bonded, welded, or otherwise joined to the remainder of the sheet structure 150. The sheet structure 150 may have pockets or recesses which receive the bristle blocks. Alternately, as shown in FIG. 38, the structure may sit on top of the layer or layers of the sheet structure 150. In yet other configurations as shown in FIG. 39, the bristle blocks may be embedded within the sheet structure 150 such that the material of the sheet structure 150 covers the base portions 154 and extends between adjacent bristle tufts 152. Optionally, the sheet structure 150 may have a non-planar surface. This may be as a result of the encapsulation of the base portions 154 or may be done to form additional cleaning structures such as protuberances from the material used to form the layer(s) of the sheet structure 150.

Turning to FIGS. 40-43, an alternate embodiment of a head 400 of the oral care implement 1000 is illustrated. The head 400 may be substituted for any of the head configurations discussed above. The head 400 is configured to operate with the handle 200 discussed above. The head 400 has a head portion 404 coupled to a neck portion 402. The neck portion 402 may engage a stem of the handle 200 or other engagement feature. The head portion 404 is coupled to the neck portion 402 and has a generally arcuate shape suitable for insertion into a user's oral cavity. The head portion 404 is configured to engage a plurality of the user's teeth simultaneously. The head 400 extends along a longitudinal axis A-A.

The head portion 404 has a front surface 406 and an opposite rear surface 408. A plurality of bristle tufts 452 extend from the front surface 406 of the head portion 404. The bristle tufts 452 are formed of filament bristles and may be formed of any known bristle filament material. Such materials may include Polybutylene Terephthalate (“PBT”), nylon, polypropylene, or other natural or synthetic materials.

The head portion 404 has a multi-component construction, with a sheet structure 450, a base structure 470, and a guard structure 490. The sheet structure 450 is formed of a flexible sheet 456 and the plurality of bristle tufts 452. The flexible sheet 456 may be an elastomeric material or may be a polymeric material. Preferably, the flexible sheet 456 has a thickness of less than 2.6 mm but may be thinner or thicker as desired. In other implementations, the flexible sheet 456 may be formed of a hard plastic material such as ABS, Nylon, Polytetrafluoroethylene (“PTFE”), polyethylene terephthalate (“PET”), or another similar polymer that is non-elastomeric. In all implementations, the flexible sheet 456 is sufficiently thin to permit bending using finger pressure.

The sheet structure 450 has a front surface 458, a rear surface 460 opposite the front surface 458, and a perimeter 462 extending between the front surface 458 and the rear surface 460. The plurality of bristle tufts 452 extend from the front surface 458 while no bristle tufts 452 extend from the rear surface 460. Optionally, one or more tuft blocks may be formed of melted portions of the bristles of the bristle tufts 452 which have been mixed with material of the flexible sheet 456. The tuft blocks may be formed either on the front surface 458 or the rear surface 460, depending on the method used to join the bristles of the bristle tufts 452 to the flexible sheet 456.

The base structure 470 may be formed of metal or a metallic material, such as steel, iron, aluminum, or another metallic material. Preferably, the base structure 470 is formed of a sheet metal material. The base structure 470 has a front surface 472 and a rear surface 474 opposite the front surface 472. The base structure 470 also extends from a proximal end 474 to a distal end 476. The base structure 470 is preferably embedded within the guard structure 490, except for a portion of the front surface 472 where the sheet structure 450 is coupled to the front surface 472 of the base structure 470. At least the proximal end 476 of the base structure 470 is coupled to the guard structure 490, allowing transfer of vibration from the handle 200 through the base structure 470 to the bristle tufts 452. As illustrated, both the proximal end 476 and the distal end 478 are coupled to the guard structure 490, but in other implementations the distal end 478 may be left exposed or may be covered by another component.

The guard structure 490 incorporates a cavity 492, the cavity 492 receiving the base structure 470 and the sheet structure 450. The guard structure 490 is preferably formed of a hard plastic material such as ABS, polystyrene, Nylon, or another non-elastomeric polymer. However, in other implementations, the guard structure 490 may be an elastomeric material. The guard structure 490 is preferably molded onto the base structure 470 and the sheet structure 450 but may also be molded or otherwise formed and the base structure 470 and sheet structure 450 may be assembled to the guard structure 490 subsequent to forming of the guard structure 490.

The sheet structure 450 is preferably thermally welded, heat welded, or adhesively bonded to the front surface 472 of the base structure 470 but may be attached in any known means. The sheet structure 450 and base structure 470 are then joined to the guard structure 490, the cavity 492 corresponding to the shape of the sheet structure 450 and the base structure 470. As noted above, this may be done by insert molding or the cavity 492 may be formed and the sheet structure 450 and base structure 470 subsequently installed. Preferably the base structure 470 extends into the neck portion 402 proximate a stem cavity 410 to better transmit vibrations from a vibration generating device in the handle 200 to the bristle tufts 452. In some implementations, the vibration generating device may be in direct physical contact with the base structure 470 when the head 400 is coupled to the handle 200 to further improve vibration transmission.

The guard structure 490 covers the base structure 470 and is in direct contact with the sheet structure 450. The guard structure 490 covers an entirety of the rear surface 474 of the base structure 470 and a portion of the front surface 472 of the base structure 470. The guard structure 490 extends up to the perimeter 460 of the sheet structure 450, encapsulating the base structure 470. This beneficially prevents contact between oral tissues of a user and the base structure 470, but in other embodiments, some portions of the base structure 470 may be exposed. For instance, portions of the rear surface 474 may be exposed through the guard structure 490 in certain implementations. An entirety of the rear surface 460 of the sheet structure 450 is in direct contact with the front surface 472 of the base structure 470. Preferably, the guard structure 490 is integrally formed with the neck portion 402, forming a monolithic, integrally formed component including both the guard structure 490 and the neck portion 402.

In a preferred method of manufacturing of the head 400, a plurality of bristle filaments are joined to a flexible sheet 456 to form a sheet structure 450. The sheet structure 450 has a front surface 458, a rear surface 460, and a perimeter 462. The plurality of bristle filaments form a plurality of bristle tufts 452 when they are joined to the flexible sheet 456. The plurality of bristle tufts 452 extend from the front surface 458 of the sheet structure 450. Subsequently, the sheet structure 450 is positioned in direct contact with a front surface 472 of a base structure 470 such that the rear surface 460 of the sheet structure is in direct contact with the front surface 472 of the base structure 470. Subsequently, a rear surface 474 of the base structure 470 is covered with a guard structure 490, the guard structure in direct contact with the perimeter 462 of the sheet structure 450 and covering a portion of the front surface 472 of the base structure 470.

Turning to FIGS. 43-45, another embodiment of the head 400 is illustrated. The head 400 illustrated in FIGS. 43-45 is identical to the head 400 illustrated in FIGS. 40-42 except as noted. The head 400 has a sheet structure 450, a base structure 470, and a guard structure 490. The sheet structure 450 has a plurality of bristle tufts 452 extending from a front surface 458. A rear surface 460 is opposite the front surface 458 and a perimeter 462 extends from the front surface 458 to the rear surface 460 of the sheet structure 450.

The base structure 470 has a front surface 472, a rear surface 474 opposite the front surface 472, a proximal end 476, and a distal end 478. The rear surface 460 of the sheet structure 450 is in direct surface contact with the front surface 472 of the base structure 470. The base structure 470 is preferably formed of a sheet metal material such as steel, or another material as discussed above. The base structure 470 is located within a cavity 492 of a guard structure 490, the guard structure 490 covering an entirety of the rear surface 474 of the base structure 470. The proximal end 476 of the base structure 470 extends into the neck portion 402.

The guard structure 490 also extends into contact with the front surface 472 of the base structure 470, the perimeter 462 of the sheet structure 450, and overlaps a portion of the front surface 458 of the sheet structure 450. The guard structure 490 beneficially overlaps the portion of the front surface 458 of the sheet structure 450 to enable improved retention of the sheet structure 450 and better seal the cavity 492 from moisture ingress. In some implementations, the sheet structure 450 may extend beyond the distal end 478 of the base structure 470, or the sheet structure 450 may terminate at the distal end 478 or the distal end 478 may extend beyond the sheet structure 450.

Exemplary Claim Set

Exemplary Claim 1: An oral care implement comprising: a handle; and a head detachably coupled to the handle, the head comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure; a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure; and a guard structure, the guard structure comprising a front surface and a rear surface, the front surface of the guard structure joined to at least a portion of the rear surface of the sheet structure to encapsulate the base structure between the sheet structure and the guard structure.

Exemplary Claim 2: The oral care implement of exemplary claim 1 wherein the sheet structure comprises an elastomeric material.

Exemplary Claim 3: The oral care implement of exemplary claim 1 or exemplary claim 2 wherein the guard structure comprises an elastomeric material.

Exemplary Claim 4: The oral care implement of any one of exemplary claims 1 to 3 wherein the sheet structure and the guard structure each comprise a perimeter portion, the sheet structure and the guard structure joined along their respective perimeter portions.

Exemplary Claim 5: The oral care implement of any one of exemplary claims 1 to 4 wherein the sheet structure is thermally welded to the guard structure.

Exemplary Claim 6: The oral care implement of any one of exemplary claims 1 to 4 wherein the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 7: The oral care implement of any one of exemplary claims 1 to 4 wherein the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 8: The oral care implement of any one of exemplary claims 1 to 4 wherein the guard structure is molded onto both the sheet structure and the guard structure.

Exemplary Claim 9: The oral care implement of any one of exemplary claims 1 to 8 wherein the base structure comprises a front surface and a rear surface, an entirety of the front surface of the base structure joined to the rear surface of the sheet structure and an entirety of the rear surface of the base structure joined to the front surface of the guard structure.

Exemplary Claim 10: The oral care implement of any one of exemplary claims 1 to 9 wherein the plurality of bristle tufts of the sheet structure are formed of a plurality of filament bristles.

Exemplary Claim 11: The oral care implement of any one of exemplary claims 1 to 10 wherein the base structure is metallic.

Exemplary Claim 12: The oral care implement of any one of exemplary claims 1 to 11 wherein the base structure is formed of sheet metal.

Exemplary Claim 13: The oral care implement of any one of exemplary claims 1 to 12 wherein the head portion extends along an arcuate path.

Exemplary Claim 14: The oral care implement of any one of exemplary claims 1 to 13 wherein the head portion comprises a concave wall and a plurality of fingers extending from the wall.

Exemplary Claim 15: The oral care implement of exemplary claim 14 wherein the plurality of fingers each comprise a horizontal portion extending from the wall along a horizontal plane.

Exemplary Claim 16: The oral care implement of exemplary claim 15 wherein each of the plurality of fingers comprise a bend and a tip portion, the tip portion of the fingers diverging from the horizontal plane at the bend.

Exemplary Claim 17: The oral care implement of exemplary claim 14 wherein the plurality of fingers and the wall form an arcuate channel.

Exemplary Claim 18: The oral care implement of any one of exemplary claims 14 to 17 wherein each finger of the plurality of fingers forms an L shape.

Exemplary Claim 19: The oral care implement of any one of exemplary claims 14 to 18 wherein the plurality of fingers are spaced and isolated from one another.

Exemplary Claim 20: The oral care implement of any one of exemplary claims 14 to 19 wherein a first finger of the plurality of fingers comprises first and second bristle tufts of the plurality of bristle tufts, the first bristle tuft located on a horizontal portion of the first finger, the second bristle tuft located on a tip portion of the first finger, the tip portion angled with respect to the horizontal portion.

Exemplary Claim 21: The oral care implement of any one of exemplary claims 14 to 20 wherein the base structure extends to a tip portion of each of the plurality of fingers.

Exemplary Claim 22: A head of an oral care implement comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure; a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure; and a guard structure, the guard structure contacting a portion of the rear surface of the sheet structure and a rear surface of the base structure.

Exemplary Claim 23: The head of exemplary claim 22 wherein the sheet structure comprises an elastomeric material.

Exemplary Claim 24: The head of exemplary claim 22 or exemplary claim 23 wherein the guard structure comprises an elastomeric material.

Exemplary Claim 25: The head of any one of exemplary claims 22 to 24 wherein the sheet structure and the guard structure each comprise a perimeter portion, the sheet structure and the guard structure joined along their respective perimeter portions.

Exemplary Claim 26: The head of any one of exemplary claims 22 to 25 wherein the sheet structure is thermally welded to the guard structure.

Exemplary Claim 27: The head of any one of exemplary claims 22 to 25 wherein the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 28: The head of any one of exemplary claims 22 to 25 wherein the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 29: The head of any one of exemplary claims 22 to 25 wherein the guard structure is molded onto both the sheet structure and the guard structure.

Exemplary Claim 30: The head of any one of exemplary claims 22 to 29 wherein the base structure comprises a front surface and a rear surface, an entirety of the front surface of the base structure in contact with a rear surface of the sheet structure and an entirety of the rear surface of the base structure in contact with a front surface of the guard structure.

Exemplary Claim 31: The head of any one of exemplary claims 22 to 30 wherein the plurality of bristle tufts of the sheet structure are formed of a plurality of filament bristles.

Exemplary Claim 32: The head of any one of exemplary claims 22 to 31 wherein the base structure is metallic.

Exemplary Claim 33: The head of any one of exemplary claims 22 to 32 wherein the base structure is formed of sheet metal.

Exemplary Claim 34: The head of any one of exemplary claims 22 to 33 wherein the head portion extends along an arcuate path.

Exemplary Claim 35: The head of any one of exemplary claims 22 to 34 wherein the head portion comprises a concave wall and a plurality of fingers extending from the wall.

Exemplary Claim 36: The head of exemplary claim 35 wherein the plurality of fingers each comprise a horizontal portion extending from the wall along a horizontal plane.

Exemplary Claim 37: The head of exemplary claim 36 wherein each of the plurality of fingers comprise a bend and a tip portion, the tip portion of the fingers diverging from the horizontal plane at the bend.

Exemplary Claim 38: The head of exemplary claim 35 wherein the plurality of fingers and the wall form an arcuate channel.

Exemplary Claim 39: The head of any one of exemplary claims 35 to 38 wherein each finger of the plurality of fingers forms an L shape.

Exemplary Claim 40: The head of any one of exemplary claims 35 to 39 wherein the plurality of fingers are spaced and isolated from one another.

Exemplary Claim 41: The head of any one of exemplary claims 35 to 40 wherein a first finger of the plurality of fingers comprises first and second bristle tufts of the plurality of bristle tufts, the first bristle tuft located on a horizontal portion of the first finger, the second bristle tuft located on a tip portion of the first finger, the tip portion angled with respect to the horizontal portion.

Exemplary Claim 42: The head of any one of exemplary claims 35 to 41 wherein the base structure extends to a tip portion of each of the plurality of fingers.

Exemplary Claim 43: A method of manufacturing an oral care implement comprising: a) providing a sheet structure, the sheet structure comprising a plurality of bristle tufts extending from a front surface of the sheet structure; and b) encapsulating a base structure between the sheet structure and a guard structure to form a head portion.

Exemplary Claim 44: The method of exemplary claim 43 wherein, in step b), a rear surface of the sheet structure is in contact with a front surface of the base structure.

Exemplary Claim 45: The method of exemplary claim 43 or exemplary claim 44 wherein, in step b), a front surface of the guard structure is in contact with a rear surface of the base structure and a rear surface of the sheet structure.

Exemplary Claim 46: The method of any one of exemplary claims 43 to 45 further comprising a step of bending, wherein a wall of the head portion is bent into a concave shape.

Exemplary Claim 47: The method of exemplary claim 46 wherein, in the step of bending, a plurality of fingers of the head portion are bent such that they extend away from an inner surface of the wall.

Exemplary Claim 48: The method of exemplary claim 47 wherein, in the step of bending, each finger of the plurality of fingers is bent such that each finger of the plurality of fingers has an L shape.

Exemplary Claim 49: The method of any one of exemplary claims 43 to 48 wherein, prior to step b), a step of assembling comprises securing a connector to the base structure.

Exemplary Claim 50: The method of exemplary claim 49 wherein, subsequent to step b), the connector is coupled to a neck portion of the oral care implement.

Exemplary Claim 51: An oral care implement comprising: a handle; and a head detachably coupled to the handle, the head comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising a sheet structure, the sheet structure comprising: a first film layer having a front surface and a rear surface, the front surface forming a front surface of the sheet structure; a second film layer having a front surface and a rear surface, the rear surface forming a rear surface of the sheet structure; and a plurality of bristle tufts extending from the front surface of the first film layer; wherein the first and second film layers are formed of the same material.

Exemplary Claim 52: The oral care implement of exemplary claim 51 wherein the sheet structure comprises an elastomeric material.

Exemplary Claim 53: The oral care implement of exemplary claim 51 or exemplary claim 52 wherein the plurality of bristle tufts are formed of a plurality of bristle filaments.

Exemplary Claim 54: The oral care implement of exemplary claim 53 wherein the plurality of bristle filaments each have a cleaning portion and a base portion, the base portion, a portion of the first film layer, and a portion of the second film layer forming a melt mat.

Exemplary Claim 55: The oral care implement of any one of exemplary claims 51 to 54 further comprising a guard structure, the sheet structure and the guard structure each comprising a perimeter portion, the sheet structure and the guard structure joined along their respective perimeter portions.

Exemplary Claim 56: The oral care implement of exemplary claim 55 wherein the sheet structure is thermally welded to the guard structure.

Exemplary Claim 57: The oral care implement of exemplary claim 55 wherein the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 58: The oral care implement of exemplary claim 55 wherein the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 59: The oral care implement of any one of exemplary claims 51 to 58 wherein the first film layer and the second film layer are formed of a first material and the plurality of bristle tufts are formed of filaments of a second material, the first material being different from the second material.

Exemplary Claim 60: The oral care implement of any one of exemplary claims 51 to 59 wherein the sheet structure comprises a melt mat formed of material from the first film layer, the second film layer, and the plurality of bristle tufts.

Exemplary Claim 61: The oral care implement of any one of exemplary claims 51 to 60 wherein the first film layer and the second film layer each have a thickness of 0.8 mm or less.

Exemplary Claim 62: The oral care implement of exemplary claim 61 wherein the first film layer and the second film layer each have a thickness of 0.4 mm or less.

Exemplary Claim 63: The oral care implement of any one of exemplary claims 51 to 62 wherein the sheet structure comprises a melt mat formed of material from the first film layer, the second film layer, and the plurality of bristle tufts.

Exemplary Claim 64: A head of an oral care implement comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure having a front surface; and a sheet structure coupled to the base structure, the sheet structure comprising: a first film layer, a front surface of the first film layer forming a front surface of the sheet structure; a second film layer joined to the first film layer, a rear surface of the second film layer forming a rear surface of the sheet structure; a plurality of bristle tufts extending from the front surface of the first film layer; wherein the first and second film layers are formed of an elastomeric material; and wherein the rear surface of the sheet structure is in contact with the front surface of the base structure.

Exemplary Claim 65: The head of exemplary claim 64 wherein the first and second film layers are formed of the same material.

Exemplary Claim 66: The head of exemplary claim 64 or exemplary claim 65 wherein the plurality of bristle tufts are formed of a plurality of bristle filaments.

Exemplary Claim 67: The head of exemplary claim 66 wherein the plurality of bristle filaments each have a cleaning portion and a base portion, the base portion, a portion of the first film layer, and a portion of the second film layer forming a melt mat.

Exemplary Claim 68: The head of any one of exemplary claims 64 to 67 further comprising a guard structure, the sheet structure and the guard structure each comprising a perimeter portion, the sheet structure and the guard structure joined along their respective perimeter portions.

Exemplary Claim 69: The head of exemplary claim 68 wherein the sheet structure is thermally welded to the guard structure.

Exemplary Claim 70: The head of exemplary claim 68 wherein the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 71: The head of exemplary claim 68 wherein the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 72: The head of any one of exemplary claims 64 to 71 wherein the first film layer and the second film layer are formed of a first material and the plurality of bristle tufts are formed of filaments of a second material, the first material being different from the second material.

Exemplary Claim 73: The head of any one of exemplary claims 64 to 72 wherein the sheet structure comprises a melt mat formed of material from the first film layer, the second film layer, and the plurality of bristle tufts.

Exemplary Claim 74: The head of any one of exemplary claims 64 to 73 wherein the first film layer and the second film layer each have a thickness of 0.8 mm or less.

Exemplary Claim 75: The head of exemplary claim 74 wherein the first film layer and the second film layer each have a thickness of 0.4 mm or less.

Exemplary Claim 76: The head of any one of exemplary claims 64 to 75 wherein the sheet structure comprises a melt mat formed of material from the first film layer, the second film layer, and the plurality of bristle tufts.

Exemplary Claim 77: A method of manufacturing a sheet structure of an oral care implement comprising: a) inserting a plurality of bristle filaments into a plurality of tuft holes of a tufting tool to form a plurality of bristle tufts; b) fusing a first film layer to the base portions of the plurality of bristle tufts; and c) fusing a second film layer to the first film layer.

Exemplary Claim 78: The method of exemplary claim 77 wherein, subsequent to step a) and prior to step b), a step of melting a base portion of each of the plurality of bristle filaments.

Exemplary Claim 79: The method of exemplary claim 78 wherein the step of melting comprises forming a mushroom on each of the plurality of bristle tuft picks.

Exemplary Claim 80: The method of any one of exemplary claims 77 to 79 wherein the plurality of bristle tufts extend from a front surface of the first film layer.

Exemplary Claim 81: The method of any one of exemplary claims 77 to 80 wherein the first film layer and the second film layer are formed of an elastomeric material.

Exemplary Claim 82: The method of any one of exemplary claims 77 to 81 wherein the first film layer and the second film layer are formed of the same material.

Exemplary Claim 83: The method of exemplary claim 82 wherein the plurality of bristle filaments are formed of a different material from the first and second film layers.

Exemplary Claim 84: The method of any one of exemplary claims 77 to 83 wherein the first film layer has a thickness of approximately 0.4 mm and the second film layer has a thickness of approximately 0.4 mm.

Exemplary Claim 85: The method of any one of exemplary claims 77 to 84 wherein the first and second film layers are free of perforations.

Exemplary Claim 86: The method of any one of exemplary claims 77 to 85 wherein a melt mat is formed during the steps of fusing, the melt mat comprising base portions of the plurality of bristle filaments, a portion of the first film layer, and a portion of the second film layer.

Exemplary Claim 87: An oral care implement comprising: a handle comprising a vibration generation device; and a head detachably coupled to the handle, the head comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure formed of a metallic material; a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure.

Exemplary Claim 88: The oral care implement of exemplary claim 87 wherein the base structure extends from the neck portion to first and second distal ends of the head portion.

Exemplary Claim 89: The oral care implement of exemplary claim 87 or exemplary claim 88 wherein the head portion extends along an arcuate path.

Exemplary Claim 90: The oral care implement of any one of exemplary claims 87 to 89 wherein the head portion comprises a concave wall and a plurality of fingers extending from the concave wall.

Exemplary Claim 91: The oral care implement of exemplary claim 90 wherein each of the plurality of fingers comprises a horizontal portion extending from the concave wall along a horizontal plane.

Exemplary Claim 92: The oral care implement of exemplary claim 91 wherein each of the plurality of fingers comprise a bend and a tip portion, the tip portion of the fingers diverging from the horizontal plane at the bend.

Exemplary Claim 93: The oral care implement of exemplary claim 90 wherein the plurality of fingers and the concave wall form an arcuate channel.

Exemplary Claim 94: The oral care implement of any one of exemplary claims 90 to 93 wherein each finger of the plurality of fingers forms an L shape.

Exemplary Claim 95: The oral care implement of any one of exemplary claims 90 to 94 wherein the plurality of fingers are spaced and isolated from one another.

Exemplary Claim 96: The oral care implement of any one of exemplary claims 90 to 95 wherein a first finger of the plurality of fingers comprises first and second bristle tufts of the plurality of bristle tufts, the first bristle tuft located on a horizontal portion of the first finger, the second bristle tuft located on a tip portion of the first finger, the tip portion angled with respect to the horizontal portion.

Exemplary Claim 97: The oral care implement of any one of exemplary claims 90 to 96 wherein the base structure extends to a tip portion of each of the plurality of fingers.

Exemplary Claim 98: The oral care implement of any one of exemplary claims 87 to 97 wherein the sheet structure comprises an elastomeric material.

Exemplary Claim 99: The oral care implement of any one of exemplary claims 87 to 98 further comprising a guard structure, wherein the guard structure comprises an elastomeric material.

Exemplary Claim 100: The oral care implement of exemplary claim 99 wherein the sheet structure and the guard structure each comprise a perimeter portion, the sheet structure and the guard structure joined along their respective perimeter portions.

Exemplary Claim 101: The oral care implement of exemplary claim 99 wherein the sheet structure is thermally welded to the guard structure.

Exemplary Claim 102: The oral care implement of exemplary claim 99 wherein the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 103: The oral care implement of exemplary claim 99 wherein the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 104: The oral care implement of exemplary claim 99 wherein the guard structure is molded onto both the sheet structure and the guard structure.

Exemplary Claim 105: The oral care implement of any one of exemplary claims 87 to 104 wherein the base structure comprises a front surface and a rear surface, an entirety of the front surface of the base structure joined to the rear surface of the sheet structure.

Exemplary Claim 106: The oral care implement of any one of exemplary claims 87 to 105 wherein the plurality of bristle tufts of the sheet structure are formed of a plurality of filament bristles.

Exemplary Claim 107: A head of an oral care implement comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure formed of a first material; a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure, the sheet structure formed of a second material; wherein the first material has a first vibration transmissibility that is greater than a second vibration transmissibility of the second material.

Exemplary Claim 108: The head of exemplary claim 107 wherein the first material is a metallic material.

Exemplary Claim 109: The head of exemplary claim 107 or 108 wherein the base structure is formed of sheet metal.

Exemplary Claim 110: The head of any one of exemplary claims 107 to 109 wherein the sheet structure comprises an elastomeric material.

Exemplary Claim 111: The head of any one of exemplary claims 107 to 110 wherein the base structure extends from the neck portion to first and second distal ends of the head portion.

Exemplary Claim 112: The head of any one of exemplary claims 107 to 111 wherein the head portion extends along an arcuate path.

Exemplary Claim 113: The head of any one of exemplary claims 107 to 112 wherein the head portion comprises a concave wall and a plurality of fingers extending from the concave wall.

Exemplary Claim 114: The head of exemplary claim 113 wherein each of the plurality of fingers comprises a horizontal portion extending from the concave wall along a horizontal plane.

Exemplary Claim 115: The head of exemplary claim 114 wherein each of the plurality of fingers comprise a bend and a tip portion, the tip portion of the fingers diverging from the horizontal plane at the bend.

Exemplary Claim 116: The head of exemplary claim 113 wherein the plurality of fingers and the concave wall form an arcuate channel.

Exemplary Claim 117: The head of any one of exemplary claims 113 to 116 wherein each finger of the plurality of fingers forms an L shape.

Exemplary Claim 118: The head of any one of exemplary claims 113 to 117 wherein the plurality of fingers are spaced and isolated from one another.

Exemplary Claim 119: The head of any one of exemplary claims 113 to 118 wherein a first finger of the plurality of fingers comprises first and second bristle tufts of the plurality of bristle tufts, the first bristle tuft located on a horizontal portion of the first finger, the second bristle tuft located on a tip portion of the first finger, the tip portion angled with respect to the horizontal portion.

Exemplary Claim 120: The head of any one of exemplary claims 113 to 119 wherein the base structure extends to a tip portion of each of the plurality of fingers.

Exemplary Claim 121: The head of any one of exemplary claims 107 to 120 further comprising a guard structure, wherein the guard structure comprises an elastomeric material.

Exemplary Claim 122: The head of exemplary claim 121 wherein the sheet structure and the guard structure each comprise a perimeter portion, the sheet structure and the guard structure joined along their respective perimeter portions.

Exemplary Claim 123: The head of exemplary claim 121 wherein the sheet structure is thermally welded to the guard structure.

Exemplary Claim 124: The head of exemplary claim 121 wherein the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 125: The head of exemplary claim 121 wherein the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 126: The head of exemplary claim 121 wherein the guard structure is molded onto both the sheet structure and the guard structure.

Exemplary Claim 127: The head of any one of exemplary claims 107 to 126 wherein the base structure comprises a front surface and a rear surface, an entirety of the front surface of the base structure joined to the rear surface of the sheet structure.

Exemplary Claim 128: The head of any one of exemplary claims 107 to 127 wherein the plurality of bristle tufts of the sheet structure are formed of a plurality of filament bristles.

Exemplary Claim 129: A method of exciting bristle filaments comprising: a) providing an oral care implement, the oral care implement comprising a handle and a head, the head comprising a neck portion and a head portion, the head portion coupled to the neck portion and the neck portion coupled to the handle; b) generating vibrations with a vibration generation device; and c) transmitting the vibrations from the handle to the bristle filaments via the neck portion, a metallic base structure of the head portion coupled to the neck portion, and a sheet structure of the head portion in contact with the base structure; wherein the bristle filaments extend from the sheet structure.

Exemplary Claim 130: The method of exemplary claim 129 wherein the base structure is formed of a first material and the sheet structure comprises a second material, the first material having a first vibration transmissibility that is greater than a second vibration transmissibility of the second material.

Exemplary Claim 131: The method of exemplary claim 129 or 130 wherein the base structure is formed of a metallic material.

Exemplary Claim 132: The method of any one of exemplary claims 129 to 131 wherein the base structure extends from the neck portion to first and second distal ends of the head portion.

Exemplary Claim 133: The method of any one of exemplary claims 129 to 132 wherein the head portion extends along an arcuate path.

Exemplary Claim 134: The method of any one of exemplary claims 129 to 133 wherein the head portion comprises a concave wall and a plurality of fingers extending from the concave wall.

Exemplary Claim 135: The method of exemplary claim 134 wherein each of the plurality of fingers comprises a horizontal portion extending from the concave wall along a horizontal plane.

Exemplary Claim 136: The method of exemplary claim 135 wherein each of the plurality of fingers comprise a bend and a tip portion, the tip portion of the fingers diverging from the horizontal plane at the bend.

Exemplary Claim 137: The method of exemplary claim 134 wherein the plurality of fingers and the concave wall form an arcuate channel.

Exemplary Claim 138: The method of any one of exemplary claims 134 to 137 wherein each finger of the plurality of fingers forms an L shape.

Exemplary Claim 139: The method of any one of exemplary claims 134 to 138 wherein the plurality of fingers are spaced and isolated from one another.

Exemplary Claim 140: The method of any one of exemplary claims 134 to 139 wherein a first finger of the plurality of fingers comprises first and second bristle tufts of the plurality of bristle tufts, the first bristle tuft located on a horizontal portion of the first finger, the second bristle tuft located on a tip portion of the first finger, the tip portion angled with respect to the horizontal portion.

Exemplary Claim 141: The method of any one of exemplary claims 134 to 140 wherein the base structure extends to a tip portion of each of the plurality of fingers.

Exemplary Claim 142: The method of any one of exemplary claims 129 to 141 wherein the base structure comprises a front surface and a rear surface, an entirety of the front surface of the base structure joined to the rear surface of the sheet structure.

Exemplary Claim 143: A method of forming a mouthpiece comprising: a) forming a flat laminate structure having a plurality of bristle tufts extending from a front surface of the flat laminate structure; and b) bending the flat laminate structure into a three-dimensional mouthpiece.

Exemplary Claim 144: The method of exemplary claim 143 wherein the flat laminate structure comprises a sheet structure, a base structure, the sheet structure comprising the plurality of bristle tufts.

Exemplary Claim 145: The method of exemplary claim 144 wherein the flat laminate structure further comprises a guard structure, the sheet structure and the guard structure encapsulating the base structure.

Exemplary Claim 146: The method of any one of exemplary claims 143 to 145 wherein the flat laminate structure is plastically deformed during step b).

Exemplary Claim 147: The method of any one of exemplary claims 143 to 146 wherein step b) further comprises step b-1), step b-1) comprising bending a wall portion of the flat laminate structure into a concave shape.

Exemplary Claim 148: The method of any one of exemplary claims 143 to 147 wherein step b) further comprises step b-2), step b-2) comprising bending a plurality of finger portions of the flat laminate structure.

Exemplary Claim 149: The method of any one of exemplary claims 143 to 148 further comprising step c), step c) comprising coupling a connector to the flat laminate structure.

Exemplary Claim 150: The method of exemplary claim 149 wherein the connector is configured to engage a socket of a neck portion.

Exemplary Claim 151: The method of exemplary claim 149 or exemplary claim 150 wherein step c) is performed prior to step b).

Exemplary Claim 152: The method of any one of exemplary claims 143 to 151 wherein the flat laminate structure comprises a sheet structure and a base structure, the base structure being metallic.

Exemplary Claim 153: The method of exemplary claim 152 wherein the sheet structure comprises an elastomeric material and the plurality of bristle tufts.

Exemplary Claim 154: A head of an oral care implement comprising: a head portion comprising: a base structure formed of a first material; and a plurality of tuft blocks in contact with a front surface of the base structure, the plurality of tuft blocks each comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface, the plurality of tuft blocks formed of a second material; wherein the first material has a first vibration transmissibility that is greater than a second vibration transmissibility of the second material.

Exemplary Claim 155: The head of exemplary claim 154 wherein the first material is a metallic material.

Exemplary Claim 156: The head of exemplary claim 154 or 155 wherein the base structure is formed of sheet metal.

Exemplary Claim 157: The head of any one of exemplary claims 154 to 156 wherein the plurality of tuft blocks comprises a non-elastomeric material.

Exemplary Claim 158: The head of any one of exemplary claims 154 to 157 wherein the base structure extends from a neck portion to first and second distal ends of the head portion.

Exemplary Claim 159: The head of any one of exemplary claims 154 to 158 wherein the head portion extends along an arcuate path.

Exemplary Claim 160: The head of any one of exemplary claims 154 to 159 wherein the head portion comprises a concave wall and a plurality of fingers extending from the concave wall.

Exemplary Claim 161: The head of exemplary claim 160 wherein each of the plurality of fingers comprises a horizontal portion extending from the concave wall along a horizontal plane.

Exemplary Claim 162: The head of exemplary claim 161 wherein each of the plurality of fingers comprise a bend and a tip portion, the tip portion of the fingers diverging from the horizontal plane at the bend.

Exemplary Claim 163: The head of exemplary claim 160 wherein the plurality of fingers and the concave wall form an arcuate channel.

Exemplary Claim 164: The head of any one of exemplary claims 160 to 163 wherein each finger of the plurality of fingers forms an L shape.

Exemplary Claim 165: The head of any one of exemplary claims 160 to 164 wherein the plurality of fingers are spaced and isolated from one another.

Exemplary Claim 166: The head of any one of exemplary claims 160 to 165 wherein a first finger of the plurality of fingers comprises first and second bristle tufts of the plurality of bristle tufts, the first bristle tuft located on a horizontal portion of the first finger, the second bristle tuft located on a tip portion of the first finger, the tip portion angled with respect to the horizontal portion.

Exemplary Claim 167: The head of any one of exemplary claims 160 to 166 wherein the base structure extends to a tip portion of each of the plurality of fingers.

Exemplary Claim 168: The head of any one of exemplary claims 154 to 167 further comprising a guard structure, wherein the guard structure comprises an elastomeric material.

Exemplary Claim 169: The head of exemplary claim 168 wherein the plurality of tuft blocks are thermally welded to the guard structure.

Exemplary Claim 170: The head of exemplary claim 168 wherein the plurality of tuft blocks are ultrasonically welded to the guard structure.

Exemplary Claim 171: The head of exemplary claim 168 wherein the plurality of tuft blocks are adhesively bonded to the guard structure.

Exemplary Claim 172: The head of exemplary claim 168 wherein the guard structure is molded onto both the plurality of tuft blocks and the guard structure.

Exemplary Claim 173: The head of any one of exemplary claims 154 to 172 wherein the plurality of bristle tufts of the plurality of tuft blocks are formed of a plurality of filament bristles.

Exemplary Claim 174: An oral care implement comprising: a handle; and a head coupled to the handle, the head comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure extending from a proximal end to a distal end, the proximal end coupled to the neck portion; a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure; and a guard structure, the guard structure covering the base structure and in contact with the sheet structure.

Exemplary Claim 175: The oral care implement of exemplary claim 174 wherein the sheet structure comprises an elastomeric material.

Exemplary Claim 176: The oral care implement of exemplary claim 174 or exemplary claim 175 wherein the guard structure comprises a hard plastic material.

Exemplary Claim 177: The oral care implement of any one of exemplary claims 174 to 176 wherein the sheet structure is thermally welded to the guard structure.

Exemplary Claim 178: The oral care implement of any one of exemplary claims 174 to 176 wherein the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 179: The oral care implement of any one of exemplary claims 174 to 176 wherein the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 180: The oral care implement of any one of exemplary claims 174 to 176 wherein the guard structure is molded onto both the sheet structure and the guard structure.

Exemplary Claim 181: The oral care implement of any one of exemplary claims 174 to 180 wherein the base structure comprises a front surface and a rear surface, an entirety of the rear surface of the sheet structure joined to the front surface of the base structure and an entirety of the rear surface of the base structure in contact with the guard structure.

Exemplary Claim 182: The oral care implement of any one of exemplary claims 174 to 181 wherein the plurality of bristle tufts of the sheet structure are formed of a plurality of filament bristles.

Exemplary Claim 183: The oral care implement of any one of exemplary claims 174 to 182 wherein the base structure is metallic.

Exemplary Claim 184: The oral care implement of any one of exemplary claims 174 to 183 wherein the base structure is formed of sheet metal.

Exemplary Claim 185: The oral care implement of any one of exemplary claims 174 to 184 wherein the base structure extends into a neck portion of the head.

Exemplary Claim 186: The oral care implement of any one of exemplary claims 174 to 185 wherein the sheet structure comprises a perimeter extending between the front surface and the rear surface, the perimeter in contact with the guard structure.

Exemplary Claim 187: The oral care implement of any one of exemplary claims 174 to 186 wherein the guard structure overlaps a portion of the front surface of the sheet structure.

Exemplary Claim 188: A head of an oral care implement comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure having a front surface and an opposite rear surface, the base structure formed of a metallic material; a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure; and a guard structure, the guard structure covering the rear surface of the base structure.

Exemplary Claim 189: The head of exemplary claim 188 wherein the sheet structure comprises an elastomeric material.

Exemplary Claim 190: The head of exemplary claim 188 or exemplary claim 189 wherein the guard structure comprises a hard plastic material.

Exemplary Claim 191: The head of any one of exemplary claims 188 to 190 wherein the sheet structure is thermally welded to the guard structure.

Exemplary Claim 192: The head of any one of exemplary claims 188 to 191 wherein the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 193: The head of any one of exemplary claims 188 to 191 wherein the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 194: The head of any one of exemplary claims 188 to 191 wherein the guard structure is molded onto both the sheet structure and the guard structure.

Exemplary Claim 195: The head of any one of exemplary claims 188 to 194 wherein an entirety of the rear surface of the sheet structure is joined to the front surface of the base structure and an entirety of the rear surface of the base structure is in contact with the guard structure.

Exemplary Claim 196: The oral care implement of any one of exemplary claims 188 to 195 wherein the plurality of bristle tufts of the sheet structure are formed of a plurality of filament bristles.

Exemplary Claim 197: The oral care implement of any one of exemplary claims 188 to 196 wherein the base structure is metallic.

Exemplary Claim 198: The oral care implement of any one of exemplary claims 188 to 197 wherein the base structure is formed of sheet metal.

Exemplary Claim 199: The oral care implement of any one of exemplary claims 188 to 198 wherein the base structure extends into a neck portion of the head.

Exemplary Claim 200: The oral care implement of any one of exemplary claims 188 to 199 wherein the sheet structure comprises a perimeter extending between the front surface and the rear surface, the perimeter in contact with the guard structure.

Exemplary Claim 201: The oral care implement of any one of exemplary claims 188 to 200 wherein the guard structure overlaps a portion of the front surface of the sheet structure.

Exemplary Claim 202: A method of manufacturing a head of an oral care implement comprising: a) joining a plurality of bristle filaments to a flexible sheet to form a sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure; b) positioning the sheet structure in direct contact with a front surface of a base structure; and c) covering a rear surface of the base structure with a guard structure, the guard structure in direct contact with a perimeter of the sheet structure and covering a portion of the front surface of the base structure.

Exemplary Claim 203: The method of exemplary claim 202 wherein, in step c), the guard structure covers a portion of the front surface of the sheet structure.

Exemplary Claim 204: The method of exemplary claim 202 or exemplary claim 203 wherein the sheet structure comprises an elastomeric material.

Exemplary Claim 205: The method of any one of exemplary claims 202 to 204 wherein the guard structure comprises a hard plastic material.

Exemplary Claim 206: The method of any one of exemplary claims 202 to 205 wherein the base structure comprises a metallic material.

Exemplary Claim 207: The method of any one of exemplary claims 202 to 206 wherein, in step b), the sheet structure is thermally welded to the guard structure.

Exemplary Claim 208: The method of any one of exemplary claims 202 to 206 wherein, in step b), the sheet structure is ultrasonically welded to the guard structure.

Exemplary Claim 209: The method of any one of exemplary claims 202 to 206 wherein, in step b), the sheet structure is adhesively bonded to the guard structure.

Exemplary Claim 210: The head of any one of exemplary claims 202 to 209 wherein, in step c), the guard structure is molded onto both the sheet structure and the guard structure.

As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by reference in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

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 spirit and scope of the invention should be construed broadly as set forth in the appended claims.

Claims

1. An oral care implement comprising: a handle; anda head detachably coupled to the handle, the head comprising:a neck portion; anda head portion coupled to the neck portion, the head portion comprising:a base structure;a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure; anda guard structure, the guard structure comprising a front surface and a rear surface, the front surface of the guard structure joined to at least a portion of the rear surface of the sheet structure to encapsulate the base structure between the sheet structure and the guard structure.

2. The oral care implement of claim 1 wherein the sheet structure comprises an elastomeric material.

3. The oral care implement of claim 1 wherein the guard structure comprises an elastomeric material.

4. The oral care implement of claim 1 wherein the sheet structure and the guard structure each comprise a perimeter portion, the sheet structure and the guard structure joined along their respective perimeter portions.

5.-8. (canceled)

9. The oral care implement of claim 1 wherein the base structure comprises a front surface and a rear surface, an entirety of the front surface of the base structure joined to the rear surface of the sheet structure and an entirety of the rear surface of the base structure joined to the front surface of the guard structure.

10. The oral care implement of claim 1 wherein the plurality of bristle tufts of the sheet structure are formed of a plurality of filament bristles.

11. The oral care implement of claim 1 wherein the base structure is metallic.

12. The oral care implement of claim 1 wherein the base structure is formed of sheet metal.

13. The oral care implement of claim 1 wherein the head portion extends along an arcuate path.

14. The oral care implement of claim 1 wherein the head portion comprises a concave wall and a plurality of fingers extending from the wall, wherein the plurality of fingers each comprise a horizontal portion extending from the wall along a horizontal plane, and wherein each of the plurality of fingers comprise a bend and a tip portion, the tip portion of the fingers diverging from the horizontal plane at the bend.

15.-20. (canceled)

21. The oral care implement of claim 14 wherein the base structure extends to a tip portion of each of the plurality of fingers.

22. A head of an oral care implement comprising: a neck portion; anda head portion coupled to the neck portion, the head portion comprising:a base structure;a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle tufts extending from the front surface of the sheet structure; anda guard structure, the guard structure contacting a portion of the rear surface of the sheet structure and a rear surface of the base structure.

23. The head of claim 22 wherein the sheet structure comprises an elastomeric material.

24. The head of claim 22 wherein the guard structure comprises an elastomeric material.

25.-29. (canceled)

30. The head of claim 22 wherein the base structure comprises a front surface and a rear surface, an entirety of the front surface of the base structure in contact with a rear surface of the sheet structure and an entirety of the rear surface of the base structure in contact with a front surface of the guard structure.

31. The head of claim 22 wherein the plurality of bristle tufts of the sheet structure are formed of a plurality of filament bristles.

32. (canceled)

33. The head of claim 22 wherein the base structure is formed of sheet metal.

34.-42. (canceled)

43. A method of manufacturing an oral care implement comprising: a) providing a sheet structure, the sheet structure comprising a plurality of bristle tufts extending from a front surface of the sheet structure; andb) encapsulating a base structure between the sheet structure and a guard structure to form a head portion.

44.-48. (canceled)

49. The method of claim 43 wherein, prior to step b), a step of assembling comprises securing a connector to the base structure.

50. The method of claim 49 wherein, subsequent to step b), the connector is coupled to a neck portion of the oral care implement.

51.-210. (canceled)