Abstract:
An apparatus is provided that includes a mold that includes a first cavity defining a toothbrush body, a first injection unit in fluid communication with the first cavity and a second cavity, and a second injection unit also in fluid communication with the first cavity. An apparatus is also provided that includes a mold that includes a first cavity defining a toothbrush body, a second cavity defining a toothbrush body, where the first cavity and the second cavity define substantially identical toothbrush bodies, a first injection unit in fluid communication with the first cavity and a second injection unit incapable of being in fluid communication with the second cavity.

Description:
This application is a continuation of Ser. No. 09/067,328, filed Apr. 28, 1998 now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates to forming articles, and in particular to forming toothbrush bodies. 
     Toothbrushes generally include a toothbrush body that includes a handle portion and a head portion, and tufts of bristles located at or near the head portion. 
     Toothbrush bodies are generally made by injection molding machines. These toothbrush bodies often consist of plastic and include multiple components. The different components may differ in nature, color, texture, density, and hardness. For example, toothbrush bodies may include a relatively hard plastic base component and a colored rubberized gripping component. 
     After the toothbrush bodies are manufactured they are automatically removed from the molding machine and deposited onto a cooling conveyor. The cooling conveyor transports the toothbrush bodies to a bin. The bodies are then manually transported to a bristle tufting machine where they receive tufts of bristles and are formed into toothbrushes. 
     The tufting operation generally involves manually grabbing handfuls of differently colored toothbrush bodies so as to provide a mixture of differently colored toothbrush bodies to a hopper. A conveyor removes the toothbrush bodies randomly from the hopper and orients the bodies so that the head portion of the body is available to receive the tufts of bristles from the bristle tufting machine. The bristle tufting machine automatically staples tufts of bristles into the head of each toothbrush body to form a toothbrush. The finished toothbrushes are automatically deposited into a tray which is manually transported to a packaging machine. 
     SUMMARY OF THE INVENTION 
     In one aspect, the invention features an apparatus that includes a mold that includes a first cavity defining a toothbrush body, a first injection unit in fluid communication with the first cavity, and a second injection unit also in fluid communication with the first cavity. 
     In one embodiment, the apparatus further Includes a second cavity defining a second toothbrush body. The second cavity is in fluid communication with the first injection unit. In another embodiment, the apparatus further includes a third cavity defining a third toothbrush body. The third cavity is in fluid communication with the second injection unit. Preferably the first and second injection units are in alternate fluid communication with the first cavity. 
     In other embodiments, the mold further includes a fourth cavity defining a fourth toothbrush body, and the apparatus further includes a third injection unit. The third injection unit is in fluid communication with the third cavity and the fourth cavity. Preferably the second and third injection units are in alternate fluid communication with the third cavity. 
     The injection units are capable of substantially simultaneously injecting a first molding compound having a first property into the second cavity, injecting a second molding compound having a second property into the third cavity, and injecting either the first or the second molding compound into the first cavity to form toothbrush bodies having different properties. 
     In another embodiment, the apparatus further includes a gating device in fluid communication with the first and second injection units. The gating device is capable of directing the flow of molding compound to the first cavity such that either the first injection unit is in fluid communication with the first cavity or the second injection unit is in fluid communication with the first cavity. 
     In another embodiment, the apparatus further includes a) a second mold that includes a cavity defining a toothbrush body, b) a third injection unit in fluid communication with the second mold cavity, and c) an automated mechanical transfer for transferring a toothbrush body from the cavity of the second mold to the cavity of the first mold. 
     In another aspect, the invention features an apparatus that includes a mold that includes a first cavity defining a toothbrush body, and a second cavity defining a toothbrush body. The first cavity and the second cavity define substantially identical toothbrush bodies. The apparatus also includes a first injection unit in fluid communication with the first cavity, and a second injection unit in fluid communication with the second cavity. In one embodiment, the injection units are capable of injecting a first molding compound having a first property into the first cavity to form a toothbrush body having a first property, and injecting a second molding compound having a second property into the second cavity to form a toothbrush body having a second property. Preferably the injection units are capable of substantially simultaneously injecting the molding compounds into the cavities. 
     In another aspect, the invention features an apparatus for substantially simultaneously molding a plurality of substantially similar toothbrush bodies such that at least one of the toothbrush bodies has a property that is different from another of the toothbrush bodies. 
     In other aspects, the invention features a process for substantially simultaneously forming toothbrush bodies having different properties in one mold. The process includes: a) selecting a first injection unit from a group of at least two injection units in fluid communication with a first mold cavity, b) injecting a first molding compound from the first injection unit into the first cavity to form a toothbrush body having a first property, and c) injecting a second molding compound, different from the first molding compound, into a second cavity of the mold to form a toothbrush body having a second property. In one embodiment, the step of injecting a first molding compound, and the step of injecting a second molding compound occur substantially simultaneously. Preferably the first toothbrush body includes a first color and the second toothbrush body includes a second color. The second color is different from the first color. 
     In another embodiment, the process for forming a toothbrush body includes a) injecting a first molding compound into a first mold cavity to form a first toothbrush body, b) transferring the first toothbrush body to a second mold cavity, the second mold cavity defining a second toothbrush body, c) selecting a first injection unit from a group of at least two injection units in fluid communication with the second mold cavity, and d) injecting a second molding compound from the first injection unit into the second mold cavity to form a second toothbrush body. 
     In one embodiment, the process for forming toothbrush bodies having different properties includes a) injecting a first molding compound into a plurality of first mold cavities to form a plurality of first toothbrush bodies, b) transferring the first toothbrush bodies to a plurality of second mold cavities, c) selecting a first injection unit from a group of at least two injection units in fluid communication with one of the second mold cavities, d) injecting a second molding compound from the first injection unit into the second mold cavity to form a second toothbrush body having a first property; and e) injecting a third molding compound into another of the second mold cavities to form a second toothbrush body having a second property. 
     In another aspect, the invention features a process for substantially simultaneously forming toothbrush bodies having different properties in one mold, where the mold includes a first cavity defining a toothbrush body and a second cavity defining a toothbrush body and the first cavity and the second cavity define substantially similar toothbrush bodies. The process includes (a) injecting a first molding compound into the first cavity of the mold to form a toothbrush body having a first property, and (b) injecting a second molding compound, different from the first molding compound, into the second cavity of the mold to form a toothbrush body having a second property. Preferably the first property is a first color and the second property is a second color. 
     In other aspects, the invention features an apparatus that includes a) a mold that includes a first cavity defining an article; b) a first injection unit in fluid communication with the first cavity; and c) a second injection unit also in fluid communication with the first cavity. In other embodiments, the apparatus includes (a) a mold that includes a first cavity defining an article, and a second cavity defining an article, the first cavity and the second cavity define substantially similar articles; (b) a first injection unit in fluid communication with the first cavity; and (c) a second injection unit in fluid communication with the second cavity. 
     In another aspect the invention features a process for substantially simultaneously forming articles having different properties in one mold. The process includes a) selecting a first injection unit from a group of at least two injection units in fluid communication with a first mold cavity; b) injecting a first molding compound from the first injection unit into the first cavity to form an article having a first property; and (c) injecting a second molding compound, different from the first molding compound, into a second cavity of the mold to form an article having a second property. 
     In another embodiment, the process for forming articles having different properties includes a) injecting a first molding compound into a plurality of first mold cavities to form a plurality of first articles; b) transferring said first articles to a plurality of second mold cavities; c) selecting a first injection unit from a group of at least two injection units in fluid communication with one of said second mold cavities; d) injecting a second molding compound from the first injection unit into one of said second mold cavities to form a second article having a second property; and e) injecting a third molding compound into another of said second mold cavities to form a second article having a third property. 
     As used herein, the term “toothbrush body” is intended to refer to any portion of the toothbrush body, e.g., the entire toothbrush body including the head portion and the handle portion; the head portion; the handle portion; portions of the head portion; and portions of the handle portion. 
     The invention permits the manufacture of articles (e.g., toothbrush bodies) having a predetermined variety of properties (e.g., different colors) from a single mold in a single molding cycle. This in turn allows control over the subsequent manufacture and packaging of toothbrushes such that single packages of multiple toothbrushes can be manufactured where each package contains a predetermined multiple of toothbrushes having different properties (e.g., a predetermined number of red, yellow or blue handled toothbrushes in a single package). The invention also permits the selection of a predetermined variety of articles to achieve an array of articles having a variety of properties. The present invention thus avoids the need for manual intervention or assistance in the mixing of toothbrushes to achieve a desired mixture of toothbrushes having different properties in a single package. The apparatus also provides control over the color mixture in each package of toothbrushes shipped to a customer. 
     The arrangement of the injection units in the molding unit also advantageously permits variation in injection timing which allows molding compounds having differing cure rates to be injected into mold cavities at different times so that cure is completed substantially simultaneously for each molding compound. This allows a single mold cycle to accommodate a variety of molding compounds. 
     The apparatus of the present invention is also capable of producing an ordered array of toothbrush bodies and maintaining the relative order of the toothbrush bodies throughout the manufacturing process. Maintenance of the ordered array also simultaneously maintains the orientation of the toothbrush bodies, which facilitates tufting and packaging processes. 
     Other features and advantages of the invention will become apparent from the following description of the preferred embodiments thereof, and from the claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a toothbrush body. 
     FIG. 2 is a schematic view of one embodiment of the toothbrush manufacturing apparatus of the present invention. 
     FIG. 3 is a cross section view taken along line A-A′ of the injection molding unit of the apparatus FIG.  2 . 
     FIG. 4 is a top view of one embodiment of the conveyor of the apparatus of FIG.  2 . 
     FIG. 5 is a side view of the automated mechanical transfer and the conveyors of the apparatus of FIG.  2 . 
     FIG. 6 is a perspective view of one end of another embodiment of the conveyor of FIG.  2 . 
     FIG. 7 is a schematic view of another embodiment of the toothbrush manufacturing apparatus of the present invention. 
     FIG. 8 is a view taken in cross section along line B-B′ of the molding unit of FIG.  7 . 
     FIG. 9 is an enlarged top view of one part of the molding unit of FIG.  7 . 
     FIG. 10 is an enlarged, rotated top view of a portion of the mold of FIG.  7 . 
     FIG. 11 is a perspective view of one embodiment of the packaging unit of the apparatus of FIG.  7 . 
     FIG. 12 is a side view of one embodiment of the packaging unit of FIG.  11 . 
     FIG. 13 is a perspective view of another embodiment of the packaging unit of the apparatus of FIG.  7 . 
     FIG. 14 is a schematic view of another embodiment of the manufacturing apparatus of the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The invention features an apparatus and method for the automated manufacture of a plurality of articles. The apparatus is capable of permitting the selective manufacture of a plurality of articles having pre-selected properties in a single molding cycle. The invention also features an apparatus that is capable of simultaneous manufacture of a plurality of articles that differ from each other in at least one property (e.g., color, composition, texture, density, and hardness). The invention is particularly useful for toothbrush manufacturing and is described below with reference to toothbrushes, however, it is to be understood that the invention is applicable to any molded article. 
     Referring to FIG. 1, toothbrush body  12  includes handle portion  2  and head portion  4 . Toothbrush body  12  can further include a base member  6 , e.g., a portion made from a relatively harder, more rigid plastic such as polypropylene, and a gripping member  8 , e.g., a portion made from a relatively rubbery material such as, e.g., styrene-butadiene-styrene triblock copolymer (commercially available under the trade designation Kraton from Shell Chemical Co.). Multiple component toothbrush bodies are described, e.g., in U.S. Pat. No. 5,256,048 (Jacobs et al.). 
     The apparatus for manufacturing toothbrushes having toothbrush bodies of different properties will now be described using color as the property that differs. It is intended that the property that differs could be at least one of a variety of properties including, e.g., color, composition, texture, density, hardness, and various combinations thereof. 
     Referring to FIG. 2, toothbrush manufacturing apparatus  10  includes a horizontally mounted injection molding unit  100  that forms toothbrush bodies  12 , e.g., the relatively more rubbery gripping portion of a multi-component toothbrush handle. An automated mechanical transfer  300  removes the molded bodies  12  from molding unit  100  and loads them onto conveyor  400 , which transports the molded bodies to tufter  200 . Tufter  200  secures tufts of bristles to toothbrush body  12  to form the finished toothbrush. A second automated mechanical transfer  310  automatically picks the finished toothbrush and places it on conveyor  480  which moves the toothbrush to packaging unit  500 . Packaging unit  500  encases the finished toothbrush in a packaging material, e.g., a blister pack, or a box and cellophane, to form a packaged toothbrush. The packaged toothbrush can then be transported (e.g., by automated transport or conveyor) to a second packaging machine (not shown) where a number individually packaged toothbrushes are packaged together to form a second package. 
     Referring to FIGS. 2 and 3, horizontally mounted injection molding unit  100  includes a stationary mold part  14  and a mobile mold part  16 . Mobile mold part  16  travels along a horizontal path between a closed position in which mold parts  16 ,  14  are in sealing contact with each other, and an open position, in which mobile mold part  16  and stationary mold part  14  are separated by a distance to allow automated mechanical transfer  300  access to the formed bodies  12 . 
     In the closed position, mold parts  14  and  16  define a first set  14   a  of mold cavities A, B, C, D, E, F, G and H, each of which defines a portion  11   a  of a toothbrush body  12 , e.g., the rubberized gripper portion of the toothbrush body. The portion of each mold cavity A-H located on mold part  14  is shown in FIG.  3 . The mold cavities can define the entire toothbrush body, i.e., the handle portion and the head portion, or a portion of the toothbrush body. 
     Molding unit  100  also includes injection units  18   a - 18   d , which are in fluid communication with mold cavities A-H. Injection units  18   a - 18   d  are capable of injecting liquid molding compound into mold cavities A-H. 
     Each injection unit includes a reservoir  20   a - 20   d  for holding a molding compound, and conduits  22   a - 22   h  through which a molding compound can pass from a reservoir to a mold cavity. Preferably each reservoir contains a molding compound having a different color such that each mold cycle produces toothbrush bodies of different colors; preferably each mold cycle produces at least four differently colored toothbrush bodies, e.g., two blue, two red, two green, and two yellow toothbrush bodies. 
     Referring to FIG.  3 ,.reservoir  20   a  of injection unit  18   a  is connected to cavities A and B via conduits  22   a  and  22   b  respectively. Similarly, reservoir  20   b  is connected to cavities B, C, D and E via conduits  22   b - 22   e  respectively. Reservoir  20   c  is connected to cavities E-G via conduits  22   e  and  22   g , and reservoir  20   d  is connected to cavities G and H via conduits  22   g  and  22   h  respectively. Injection unit  18   b  shares conduit  22   b  with injection unit  18   a  and conduit  22   c  with injection unit  18   c . Injection units  18   c  and  18   d  share conduit  22   f.    
     Fluid communication between the injection units and the mold cavities can be controlled by gating manifolds  24   a - 24   f  which open and close the fluid communication between reservoirs  20   a - 20   b , and cavities B, E and G. Gating manifolds  24   a  and  24   b , for example, can be placed in an open position or a closed position to regulate the fluid communication between f reservoirs  20   a  and  20   b  and cavity B. When gating manifold  24   a  is in an open position, reservoir  20   a  is in fluid communication with cavity B such that a molding compound in reservoir  20   a  can travel through conduit  22   b  to cavity B. When gating manifold  24   a  is in the open position, manifold  24   b  can be in the open or closed position to maintain or close communication between reservoir  20   b  and cavity B. When manifold  24   b  is in the closed position, molding compound is prevented from flowing from reservoir  20   b  to cavity B. 
     In an alternate embodiment, a single manifold can be used to open communication between an injection unit and a cavity and simultaneously close communication between another injection unit and the same cavity and vice versa. Referring to cavity B, for example, a single manifold can open communication between injection unit  18   a  and cavity B and simultaneously close communication between injection unit  18 b and cavity B. 
     Gating manifolds  24   a - 24   f  allow a number of toothbrush bodies having a variety of different colors to be manufactured simultaneously. By opening and closing the various manifolds, the number and variety of toothbrush bodies can be altered. In addition, by including injection units having more than one common conduit leading to more than one common cavity, the degrees of freedom, in terms of available color variety, are increased. For example, referring to FIG. 3, the molding compound in reservoir  20   b  can be transferred to two, three or four cavities depending upon the configuration of gating manifolds  24   b  and  24   c . The molding compound in reservoir  20   c  can be transferred to one, two or three cavities and the molding compounds in reservoirs  20   a  and  20   d  can be transferred to one or two cavities. 
     Although the molding unit is described as having eight mold cavities and four injection units, it is contemplated that any number of molding cavities and injection units could be placed in fluid communication with each other in various permutations. In addition, gating devices can be positioned as desired to control the flow of molding compound to the cavities. 
     The injection molding unit can further include a second set  14   b  of mold cavities A′-H′, each of which defines a second portion  1   b  of toothbrush body  12 , e.g., the relatively hard, more rigid plastic (e.g., polypropylene) base portion of the toothbrush body. The second portion  1   b  of toothbrush body  12  defined by mold cavities A′-H′is different (e.g., in shape, dimension and combinations thereof) from that portion  1   a  of toothbrush body  12  defined by cavities A-H. Injection unit  26  is in fluid communication with mold cavities A′-H′and is capable of injecting molding compound into mold cavities A′-H′to form second portion  1   b  of toothbrush body  12 . Preferably portion  11   b  of toothbrush body  12  is formed first and then portion  11   b  is transferred (e.g., by automated mechanical transfer) to the first set  14   a  of mold cavities A-H (e.g., portion  11   b  of toothbrush body formed in cavity A′ is transferred to cavity A) where colored molding compound is injected into cavities A-H to form a dual component toothbrush body, and where processing continues as described above. 
     Referring to FIGS. 2 and 4, automated mechanical transfer  300  assists in removing toothbrush bodies  12  from the mold cavities (e.g., mold cavities A-H) and transferring toothbrush bodies  12  to conveyor  400 . Automated mechanical transfer  300  preferably removes each toothbrush body  12   a - 12   h  simultaneously from injection molding unit  100  and transfers the bodies to a first position  42  on conveyor  400 . More preferably, automated mechanical transfer  300  simultaneously picks the entire array  34  of toothbrush bodies  12   a - 12   h  and places the array  34  onto conveyor  400  in the same order in which the bodies were formed. Automated mechanical transfer  300  is also capable of orienting the individual toothbrush bodies  12 , or the entire array  34  of toothbrush bodies  12   a - 12   h , such that the head portions of the toothbrush bodies  12  are in proper orientation for transfer to subsequent operations (e.g., bristle tufting machine  200  or packaging). 
     Referring to FIGS. 4-6, conveyor  400  includes a first conveyor  410 , e.g., a nested cooling conveyor, for receiving and cooling toothbrush bodies  12 , and a second conveyor  420 , e.g., a walking beam conveyor, for sequentially feeding toothbrush bodies  12  to tufter  200 . First conveyor  410  moves toothbrush bodies  12  to second conveyor  420  while maintaining toothbrush bodies  12  in the order in which they were placed onto the conveyor by automated mechanical transfer  300 . Toothbrush bodies  12  are then transferred to the second conveyor  420  from first conveyor  410 . The transfer from first conveyor  410  to second conveyor  420  can occur in a number of ways including, e.g., first conveyor  410  feeding toothbrush bodies directly onto second conveyor  420  arranged perpendicularly to first conveyor  410 , as shown in FIG. 4; automated mechanical transfer  300  picking the toothbrush bodies, e.g., the array  34  of toothbrush bodies  12   a - 12   h , from first conveyor  410  and placing the toothbrush bodies onto second conveyor  420 , as shown in FIGS. 5 and 6; and combinations thereof. Automated mechanical transfer  300  is capable of orienting the toothbrush bodies throughout the manufacturing process. 
     Tufter  200 , includes a plurality of tuft insertion devices capable of inserting a plurality of tufts of bristles into the head portion of the toothbrush body. Tufter  200  receives an oriented toothbrush body  12 , and inserts a plurality of tufts of bristles into the head portion  4  of the toothbrush body  12  to form a finished toothbrush  30 . Tufter  200  can also trim the bristles and end rounding the bristle filaments of head portion  4 . 
     Referring to FIG. 2, second automated mechanical transfer  310  automatically picks toothbrushes  30  from tufter  200  and places them on third conveyor  480  where they move to packaging machine  500 . Preferably second automated mechanical transfer  310  maintains the orientation and order of the toothbrushes such that control over the color variety is maintained. As a result, the color mixture set at the molding operation can be maintained throughout the toothbrush manufacturing process up to and including the step of packaging the toothbrushes. Packaging machine  500  packages each individual toothbrush into a package (e.g., a blister pack), and can also be configured to package a plurality of toothbrushes into a single package or a plurality of the individually packaged toothbrushes into a second package. 
     Apparatus  10  can also include a variety of additional processing units including, e.g., a second packaging machine for packaging the individually packaged toothbrushes into a second package such that the second package includes a variety of differently colored individually packaged toothbrushes. 
     A second apparatus  90  for manufacturing toothbrushes having different colored bodies, is shown in FIGS. 7-12. Features that are in common with apparatus  10  shown in FIGS. 2-6 are designated with the same reference numerals. Referring to FIGS. 7 and 8, apparatus  90  includes vertically mounted injection molding unit  600 , which forms toothbrush bodies, and automated mechanical transfer  300 , which removes the molded bodies from molding unit  600  and transfers them to a cooling station  700 . Automated mechanical transfer  300  then selects toothbrush bodies  12  from cooling station  700  so as to create an array of differently colored toothbrush bodies, e.g., an array of five toothbrush bodies that includes blue, green, red, purple, and yellow toothbrush bodies. The automated mechanical transfer can be programmed to select any number of toothbrush bodies in a variety of color combinations. Automated mechanical transfer  300  then places the selected array onto conveyor  710 , which feeds individual toothbrush bodies  12  to tufter  200 . After tufter  200  secures tufts of bristles to the toothbrush body to form finished toothbrush  30 , a second automated mechanical transfer  310  picks finished toothbrush  30  and places it on second conveyor  712 . Second conveyor  712  moves toothbrush  30  to packaging machine  800  where the toothbrush is packaged. Optionally, third automated mechanical transfer  320  selectively provides toothbrushes  30  to packaging machine  800 . 
     Vertically mounted injection molding unit  600  includes a stationary mold part  614  and a mobile mold part  616 , as shown in FIGS. 8-10. Mold parts  614 ,  616  are arranged such that mobile mold part  616  travels along a vertical path between an open position, (as shown in FIG. 8) in which the mold parts  614 ,  616  are separated by a distance to allow automated mechanical transfer  300  access to the formed bodies  12 , and a closed position in which mold parts  614 ,  616  are in sealing contact with each other. Referring to FIG. 10, mold part  614  includes a portion of a first set  614   a  of mold cavities A-T, each of which defines a portion  11   a  of a toothbrush body. Each of five injection units  618   a-e  is in fluid communication with four of the twenty cavities  2 A- 2 T, such that each injection unit  618   a-e  is capable of injecting a molding compound into four of the twenty cavities. 
     Referring to FIG. 10, injection unit  618   a  is in fluid communication with mold cavities  2 A- 2 D; injection unit  618   b  is in fluid communication with mold cavities  2 I- 2 L; injection unit  618   c  is in fluid communication with mold cavities  2 Q- 2 T; injection unit  618   d  is in fluid communication with mold cavities  2 M- 2 P; and injection unit  618   e  is in fluid communication with mold cavities  2 E- 2 H. 
     Preferably each injection unit injects a different molding compound into its corresponding cavities such that the toothbrush bodies formed from each of the different molding compounds exhibit different properties, e.g., color. 
     Injection molding unit  600  can further include a second set  614   b  of mold cavities  2 A′- 2 H′, each of which defines a second portion  11   b  of a toothbrush body  12 , as shown in FIG. 10. A sixth injection unit  619 , in fluid communication with cavities  2 A′- 2 T′, is capable of injecting molding compound into each mold cavity  2 A′- 2 T′. The molding compound injected by the sixth injection unit is preferably of a material that, upon molding, exhibits a property that is distinct from that of the portions of the toothbrush body formed in mold cavities  2 A- 2 T. Portions  11   b  of toothbrush bodies  12  formed in mold cavities  2 A′- 2 T′ are then transferred to first set  614   a  of mold cavities  2 A- 2 T where processing continues as described above. 
     Referring to FIGS. 11 and 12, one embodiment of the packaging operation is shown in which automated mechanical transfer  300  picks a blister pack  107  and places it in position  111   a  of turret  111  where it remains ready to receive finished toothbrush  30 . Automated mechanical transfer  300  then returns to tufter  200  and retrieves a finished toothbrush  30 . Automated mechanical transfer  300  then transfers finished toothbrush to blister pack  107  waiting at index position  111   a  on turret  111 , and places finished toothbrush  30  into blister pack  107 . Blister pack  107 , filled with finished toothbrush  30 , is then indexed to full position  111   b  during which time automated mechanical transfer  300  retrieves a cover  109 , e.g., a film or card. Automated mechanical transfer  300  then returns to the filled blister pack  107  at index position  111   b  and places cover  109  onto the filled blister pack  107 . Automatic mechanical transfer  300  then transfers the blister pack assembly, shown at index position  111   c , to sealing unit  900 , where the blister pack assembly is sealed to form a package around the toothbrush. Automated mechanical transfer  300  waits for the completion of the sealing operation and then transfers the sealed package to a transport mechanism where the sealed package can undergo further processing, e.g., additional packaging or storage. Automated mechanical transfer  300  then returns to the ready position where it waits to start the process again with a newly formed set of injection molded toothbrush bodies. The automated mechanical transfer and packaging apparatus of FIGS. 11 and 12 can also be incorporated into apparatus  10 . 
     Referring to FIG. 13, another embodiment of packaging operation is shown. Packaging unit  802  forms blister packs  127  at position  122   a  and rotates formed blister pack  127  to position  122   b . A second automated transfer  320  picks toothbrush  30  and places toothbrush  30  into blister pack  127 . Packaging unit  802  rotates the filled blister pack to position  122   c , applies a cover  129  to filled blister pack  127 , and seals the assembly to form a packaged toothbrush  131 . If necessary, packaging unit  802  separates e.g., by punching or cutting, blister pack  127  from other blister packs with which it may be associated. 
     Referring to FIG. 14, another automated process  128  of the invention is shown in which first automated mechanical transfer  114  removes molded articles  140  from injection molding unit  112 , and transports articles  140  to cooling conveyor  116  or cooling station  118 . Optionally, automated mechanical transfer  114  selects articles based upon a predetermined criteria (e.g., color) and provides the selected articles (e.g., five articles each having a different color) in the form of an array to packaging machine  130 , or to conveyor  116 , which moves articles  140  to packaging machine  130 , such that articles having predetermined properties can be packaged substantially simultaneously. A second automated mechanical transfer  142  can assist in transferring articles  140  from conveyor  116  to blister pack  136  at first position  138   b  on packaging machine  130 . A third automated mechanical transfer  144  then transfers packaged articles  142  to second conveyor  134  and/or second packaging machine  136  for additional packaging. 
     Other embodiments are within the claims. For example, the automated processes of the invention can include a hot tufting operation in which tufts of bristles are secured to the body of the toothbrush by hot welding the bristle material to the toothbrush body. Examples of hot tufting operations are disclosed in U.S. Pat. No. 5,143,424 (Boucherie). The bristles can also be secured to the toothbrush body during the molding operation as disclosed, e.g., in U.S. Pat. No. 5,458,400 (Meyer), U.S. Pat. No. 5,609,890 (Boucherie), and U.S. Pat. No. 5,474,366 (Strutt et al.). 
     In addition, the apparatus can include one or more automated mechanical transfers for moving the toothbrush bodies and toothbrushes throughout the various stages of the processes disclosed.