Method of forming a head plate and formation of oral care implement using the same

Patent metadata

Field	Value
Publication number	US-9398802-B2
Application number	US-201214385354-A
Country	US
Kind code	B2
Filing date	Mar 9, 2012
Priority date	Mar 9, 2012
Publication date	Jul 26, 2016
Grant date	Jul 26, 2016

Abstract

A method of forming a head plate for enhanced cleaning action during brushing. In one embodiment, the invention can be a method of forming a head plate comprising: a) forming a mounting plate comprising a first section and a second section, the first section separated from the second section by a gap, a groove formed into the second section that extends from the gap to a cleaning element location; b) positioning the mounting plate in a mold cavity; c) injecting a molten resilient material into the mold cavity so that the molten resilient material: ( 1 ) flows into the gap; ( 2 ) flows into the groove; and ( 3 ) flows into a cleaning element chamber; and d) solidifying the molten resilient material, the solidified resilient material in the gap coupling the first and second sections of the plate together, the solidified resilient material in the cleaning element chamber forming a first resilient tooth cleaning element.

First claim

What is claimed is:

1. A method of forming a head plate having one or more tooth cleaning elements, the method comprising:
a) forming a mounting plate, the mounting plate comprising a first section and a second section, the first section separated from the second section by a first gap, a first groove formed into a front surface of the second section that extends from the first gap to a cleaning element location of the second section;
b) positioning the mounting plate in a mold cavity so that a first cleaning element chamber of the mold cavity is aligned with the cleaning element location;
c) injecting a molten resilient material into the mold cavity so that the molten resilient material: (1) flows into the first gap; (2) flows into the first groove; and (3) flows into the first cleaning element chamber; and
d) cooling to solidify the molten resilient material, wherein the solidified resilient material in the first gap forms a first resilient hinge that couples the first and second sections of the mounting plate together while the solidified resilient material in the first cleaning element chamber forms a first resilient tooth cleaning element extending from the front surface of the second section of the mounting plate at the cleaning element location.

2. The method according to claim 1 wherein step a) further comprises forming the mounting plate so that the second section comprises a first through-hole at the cleaning element location, the first groove extending from the first gap to the first through-hole; wherein step c) further comprises injecting the molten resilient material into the mold cavity so that the molten resilient material also flows into the first through-hole; and wherein step d) further comprises the solidified resilient material in the first through-hole forming a base portion of the first resilient tooth cleaning element and the solidified resilient material in the cleaning element chamber forming a tooth cleaning portion of the first resilient tooth cleaning element.

3. The method according to claim 2 wherein a portion of the base portion of the first resilient tooth cleaning element is exposed via the rear surface of the second section.

4. The method according to claim 3 wherein the second section comprises one or more tuft through-holes, the method further comprising:
inserting a bristle tuft into each of the one or more tuft through-holes so that a rear portion of the bristle tuft protrudes beyond the rear surface of the second section and a tooth cleaning portion of the bristle tuft protrudes beyond the front surface of the second section; and
melting the rear portion of the bristle tuft to form a bristle melt, the bristle melt being larger than the tuft through-hole in which the bristle tuft is located, the bristle melt coupled to the exposed portion of the base portion of the first resilient tooth cleaning element to form a second matte adjacent the rear surface of the second section.

5. The method according to claim 1 wherein the base portion of the first resilient tooth cleaning element and the tooth cleaning portion of the first resilient tooth cleaning element are integrally formed.

6. The method according to claim 1 wherein step d) further comprises the solidified resilient material in the first groove forming a first strip extending between the first resilient hinge and the first resilient tooth cleaning element.

7. The method according to claim 1 wherein the mounting plate comprises a longitudinal axis, the first gap extending transversely across the entire width of the mounting plate, and the first groove extends longitudinally from the first gap to the cleaning element location, the cleaning element location located in a central region of the second section.

8. The method according to claim 1 wherein step a) further comprises forming the mounting plate to include a third section separated from the second section by a second gap, and a second groove formed into the front surface of the second section that extends from the cleaning element location to the second gap; and wherein step c) further comprises injecting the molten resilient material into the mold cavity so that the molten resilient material also flows into the second groove and into the second gap; and wherein step d) further comprises the solidified resilient material in the second gap forming a second resilient hinge that flexibly couples the second and third sections together.

9. The method according to claim 8 wherein step d) further comprises the solidified resilient material in the second groove forming a second strip extending between the second resilient hinge and the first resilient tooth cleaning element.

10. The method according to claim 9 wherein the first groove and the second groove extend along a longitudinal axis of the mounting plate from opposite sides of the cleaning element location.

11. The method according to claim 1 further comprising:
e) inserting one or more bristle tufts into one or more tuft through-holes formed in the second section of the mounting plate, a tooth cleaning portion of the one or more bristle tufts protruding from the front surface of the second section.

12. The method according to claim 1 wherein step a) further comprises forming the mounting plate so that a third groove is formed into a front surface of the first section, the third groove extending from the first gap, and wherein step c) further comprises injecting the molten resilient material into the mold cavity so that the molten resilient material also flows into the third groove.

13. The method according to claim 1 wherein step a) further comprises forming the mounting plate so that the second section comprises an island in the cleaning element location; wherein step b) comprises positioning the mounting plate in the mold cavity so that the first cleaning element chamber of the mold cavity and a second cleaning element chamber of the mold cavity are aligned with the cleaning element location and adjacent the island; wherein step c) further comprises injecting the molten resilient material into the mold cavity so that the molten resilient material also flows into the second cleaning element chamber, and wherein step d) further comprises the solidified resilient material in the second cleaning element chamber forming a second resilient tooth cleaning element extending from the second section of the mounting plate at the cleaning element location, the first and second resilient tooth cleaning elements located adjacent the island.

14. The method according to claim 13 wherein the first and second resilient tooth cleaning elements are located on opposite sides of the island.

15. The method according to claim 13 wherein step c) further comprises injecting the molten resilient material into the mold cavity so that the molten resilient material flows through the first groove into the first and second cleaning element chambers.

16. The method according to claim 1 wherein step a) further comprises forming the mounting plate so that the mounting plate comprises a first strut in the first gap, the first strut having a first end connected to the first section and a second end connected to the second section; and wherein step c) further comprises injecting the molten resilient material into the mold cavity so that the molten resilient material flows into the first gap to surround the first strut, and wherein the first strut and the solidified resilient material in the first gap collectively form the first resilient hinge.

17. The method according to claim 1 wherein step c) is performed in a si

Assignees

• Moskovich Robert
• Rooney Michael
• Colgate Palmolive Co

Inventors

• Moskovich Robert
• Rooney Michael

Classifications

• A46D3/005

  by moulding or casting a body around bristles or tufts of bristles · CPC title

• B29C45/14336

  Coating a portion of the article, e.g. the edge of the article (B29C45/14573 and B29C45/14598 take precedence) · CPC title

• A46D3/00

  Preparing, {i.e. Manufacturing} brush bodies · CPC title

• B29L2031/425

  Toothbrush · CPC title

• B29C45/0017

  moulding interconnected elements which are movable with respect to one another, e.g. chains or hinges · CPC title