Oral care implement and method of assembling the same

An oral care implement that dispenses an oral care agent during use and a method of assembling such an oral care implement. The oral care implement may include a body having a head portion. The head portion may have a cavity with an open end. There may be at least one opening extending from the cavity to an outer surface of the head portion. A dissolvable element that includes an oral care agent may be positioned in the cavity. Furthermore, a supporting member may be positioned in the cavity. The supporting member may include a first coupling feature that couples the supporting member to the dissolvable element. Finally, an oral cleaning member may be coupled to the head portion to close the open end of the cavity.

BACKGROUND

The present invention relates to oral care implements, and particularly to an oral care implement that dispenses an oral care agent during use. The concept of an oral care implement or toothbrush that dispenses an agent is not new. Many such toothbrushes store a liquid product in the handle of the oral care implement so that a user can pump the liquid to the bristles either before or during use. Such pumps may include manual pumps or electric pumps. Another concept is one involving the passive dispensing of an oral care agent during use, such as by including a dissolvable tablet in the head that dissolves over time due to it being contacted by a user's saliva or toothpaste slurry. One issue with such oral care implements is that such dissolvable tablets are hard and may break apart before being entirely used up. When a dissolvable tablet of this type breaks apart, solid components of the tablet may pass through the openings that are designed for dispensing of the tablet in liquid form, which may cause discomfort or dissatisfaction to a person using the oral care implement for oral cavity cleaning. This may also cause the dissolvable table to deplete prematurely. Furthermore, in these types of devices it can be difficult for a user to determine when the agent has been depleted. Thus, a need exists for an oral care implement that overcomes these noted deficiencies.

BRIEF SUMMARY

The present invention is directed to an oral care implement that dispenses an oral care agent during use. In one aspect the invention may be an oral care implement comprising: a body comprising a head portion, the head portion comprising a cavity having an open end, at least one opening extending from the cavity to an outer surface of the head portion; a dissolvable element comprising an oral care agent positioned in the cavity; a supporting member positioned in the cavity, the supporting member comprising a first coupling feature that couples the supporting member to the dissolvable element; and an oral cleaning member coupled to the head portion and closing the open end of the cavity.

In another aspect, the invention may be an oral care implement comprising: a head portion comprising a cavity and an opening that extends from the cavity to an outer surface of the head; a supporting member located in the cavity, the supporting member comprising an adhesive surface; and a dissolvable element comprising an oral care agent located in the cavity, the dissolvable element coupled to the adhesive surface of the supporting member.

In yet another aspect, the invention may be an oral care implement comprising: a head portion comprising a cavity, at least one opening extending from the cavity to an outer surface of the head portion; a dissolvable element comprising an oral care agent located in the cavity adjacent to the opening, a portion of the dissolvable element that is visible through the opening comprising a first visual feature; a supporting member located in the cavity adjacent to the dissolvable element so that the dissolvable element is positioned between the supporting member and the opening, the supporting member comprising a second visual feature that is distinguishable from the first visual feature; and wherein upon at least partial depletion of the dissolvable element, the second visual feature of the supporting member becomes visible through the opening.

In a further aspect, the invention may be a method of assembling an oral care implement, the method comprising: contacting a second surface of a supporting member with a suction tool and generating a suction force to pick up the supporting member with the suction tool; contacting a first surface of the supporting member to a dissolvable element comprising an oral care agent while the supporting member is held by the suction tool, the first surface of the supporting member comprising a coupling feature that couples the dissolvable element to the supporting member; inserting a sub-assembly comprising the supporting member and the dissolvable element through an open end of a cavity of a head portion of an oral care implement while the sub-assembly is held by the suction tool; releasing the suction force of the suction tool to decouple the suction tool from the sub-assembly, thereby leaving the sub-assembly in the cavity of the head portion of the oral care implement; and coupling an oral cleaning member to the head portion of the oral care implement to close the open end of the cavity.

In another aspect, the invention may be a method of assembling an oral care implement, the method comprising: contacting a dissolvable element with a suction tool and generating a suction force to pick up the dissolvable element with the suction tool, the dissolvable element comprising a first visual feature; inserting the dissolvable element through an open end of a cavity of a head portion of an oral care implement and releasing the suction force, thereby placing the dissolvable element in the cavity; contacting a supporting member with the suction tool and generating a suction force to pick up the supporting member with the suction tool, the supporting member comprising a second visual feature that is distinguishable from the first visual feature; inserting the supporting member through the open end of the cavity of the head portion of the oral care implement and releasing the suction force, thereby placing the supporting member in the cavity adjacent to the dissolvable element; and attaching an oral cleaning member to the head portion of the oral care implement to close the open end of the cavity.

In still another aspect, the invention may be a method of assembling an oral care implement, the method comprising: contacting a second surface of a supporting member with a suction tool and generating a suction force to pick up the supporting member with the suction tool; contacting a first surface of the supporting member to a dissolvable element comprising an oral care agent while the supporting member is held by the suction tool, the suction force passing through the supporting member so that a sub-assembly including the support member and the dissolvable element are held by the suction tool via the suction force; inserting the sub-assembly through an open end of a cavity of a head portion of an oral care implement while the sub-assembly is held by the suction tool; releasing the suction force of the suction tool to decouple the suction tool from the sub-assembly, thereby leaving the sub-assembly in the cavity of the head portion of the oral care implement; and coupling an oral cleaning member to the head portion of the oral care implement to close the open end of the cavity.

In yet another aspect, the invention may be a method of assembling an oral care implement, the method comprising: placing a dissolvable element in a cavity of a head portion of an oral care implement through an open end of the cavity, the dissolvable element comprising a first visual feature; placing a supporting member in the cavity of the head portion of the oral care implement through the open top end of the cavity, the supporting member comprising a second visual feature that is distinguishable from the first visual feature; and attaching an oral cleaning member to the head portion of the oral care implement to close the open end of the cavity; wherein in a pre-use state, the first visual feature of the dissolvable element is visible through an opening in the head portion, and wherein upon at least partial depletion of the dissolvable element after one or more uses of the oral care implement for oral cavity cleaning, the second visual feature of the supporting member becomes visible through the opening in the head portion of the oral care implement.

DETAILED DESCRIPTION

Referring first toFIGS. 1-3 and 5Aconcurrently, an oral care implement100is illustrated in accordance with one embodiment of the present invention. In the exemplified embodiment, the oral care implement100is in the form of a manual toothbrush. However, in certain other embodiments the oral care implement100can take on other forms such as being a powered toothbrush, a tongue scraper, a gum and soft tissue cleanser, a water pick, an interdental device, a tooth polisher, a specially designed ansate implement having tooth engaging elements, or any other type of implement that is commonly used for oral care. Thus, it is to be understood that the inventive concepts discussed herein can be applied to any type of oral care implement unless a specific type of oral care implement is specified in the claims.

The oral care implement100comprises a body101that includes a head portion110and a handle portion120. The body101extends from a proximal end102to a distal end103along a longitudinal axis A-A. The handle portion120is an elongated structure that provides the mechanism by which the user can hold and manipulate the oral care implement100during use. In the exemplified embodiment, the handle portion120is generically depicted having various contours for user comfort. Of course, the invention is not to be limited by the specific shape illustrated for the handle portion120in all embodiments and in certain other embodiments the handle portion120can take on a wide variety of shapes, contours, and configurations, none of which are limiting of the present invention unless so specified in the claims. The handle portion120may include a neck portion121that extends to the head portion110.

In the exemplified embodiment, the handle portion120is formed of a hard or rigid plastic material, such as for example without limitation polymers and copolymers of ethylene, propylene, butadiene, vinyl compounds, and polyesters such as polyethylene terephthalate. The handle portion120may also include a grip that is formed of a resilient/elastomeric material. In such embodiments, the grip may be molded over a portion of the handle portion120that is typically gripped by a user's thumb and forefinger during use. Furthermore, it should be appreciated that additional regions of the handle portion120can be overmolded with the resilient/elastomeric material to enhance the gripability of the handle portion120during use. For example, portions of the handle portion120that are typically gripped by a user's palm during use may be overmolded with a thermoplastic elastomer or other resilient material to further increase comfort to a user. Furthermore, materials other than those noted above can be used to form the handle portion120, including metal, wood, or any other desired material that has sufficient structural rigidity to permit a user to grip the handle portion120and manipulate the oral care implement100during tooth brushing.

The head portion110of the oral care implement100is coupled to the handle portion120and comprises a front surface111and an opposing rear surface112. Furthermore, the head portion110comprises a peripheral surface113extending between the rear surface112and the front surface111. In the exemplified embodiment, the head portion110is formed integrally with the handle portion120as a single unitary structure using a molding, milling, machining, or other suitable process. However, in other embodiments the handle portion120and the head portion110may be formed as separate components which are operably connected at a later stage of the manufacturing process by any suitable technique known in the art, including without limitation thermal or ultrasonic welding, a tight-fit assembly, a coupling sleeve, threaded engagement, adhesion, or fasteners. Thus, the head portion110may, in certain embodiments, be formed of any of the rigid plastic materials described above as being used for forming the handle portion120, although the invention is not to be so limited in all embodiments and other materials that are commonly used during toothbrush head manufacture may also be used. In other embodiments, the head portion120may be formed as a part of a refill head that is intended to be repetitively coupled to and decoupled from the handle portion110for replacement of the head portion120without also requiring replacement of the handle portion110. This type of assembly is frequently used with powered toothbrushes because the expensive electronics are stored in the handle portion so it is undesirable to have to replace the handle portion when the bristles become worn. However, this type of assembly with a refill head can also be used with manual toothbrushes and the like.

The head portion110comprises a cavity114that is defined by a floor115and a sidewall116that extends from the floor115to an open end125of the cavity114. In the exemplified embodiment, the open end125of the cavity114is located in the front surface111of the head portion110. However, in other embodiments the open end125of the cavity114may be located in the rear surface112of the head portion110. The cavity114is an open space located within the head portion110that is surrounded by the sidewall116. The floor115of the cavity114is formed by the same portion of the head portion110that comprises the rear surface112of the head portion110, although the floor115and the rear surface112are opposite or opposing surfaces.

In the exemplified embodiment, the head portion110comprises an opening117that extends from the floor115of the cavity114to the rear surface112of the head portion110. Of course, the opening117can be positioned at other locations in other embodiments. In some embodiments, the opening117is positioned anywhere so long as the opening117extends from and forms a passageway between the cavity114and an outer surface of the head portion110. Thus, the opening117could extend from the cavity114to the front surface111of the head portion110or from the cavity114to a side surface of the head portion110, such as by being formed through the sidewall116of the cavity114and the peripheral surface113of the head portion110. In the exemplified embodiment, the opening117is circular-shaped, although the invention is not to be so limited and the opening117may take on any desired shape including oval, rectangular, square, triangular, or the like. The opening117can also be in the shape of an elongated slot extending across the head portion110in some embodiments. Furthermore, although there is only one of the openings117illustrated in the exemplified embodiment, there may be several openings in other embodiments, such as shown inFIGS. 5B and 6A-6C. In some embodiments, the opening117is needed to allow an oral care agent that is located in the cavity114to flow out of the cavity114and into a user's mouth during use of the oral care implement100, as described in more detail below.

To reiterate, in the exemplified embodiments, the openings117are illustrated as being formed in the rear surface of the head or head portion110. However, the invention is not to be so limited in all embodiments and the opening(s)117may be formed in a side surface of the head or in the front surface of the head in other embodiments. Thus, the openings117can be located anywhere along the head so long as they provide a passageway from the cavity to an outer surface of the head or to an exterior of the oral care implement100.

In the exemplified embodiment, the oral care implement100comprises an oral cleaning member190that closes the open end125of the head portion110. In the exemplified embodiment, the oral cleaning member comprises a head plate130that comprising a plate portion131and a plurality of tooth cleaning elements132that are intended for cleaning a user's teeth and other oral cavity surfaces. The head plate130is a separate and distinct component from the body101(and hence the head portion110) of the oral care implement100. The head plate130is coupled to the head portion110of the body101to form the head118of the oral care implement100. Specifically, the head plate130is coupled to the head portion110of the body101in such a manner so that the head plate130closes the open top end of the cavity114. The head plate130may be coupled to the head portion110using any desired technique, including thermal or ultrasonic welding, any fusion techniques such as thermal fusion, melting, a tight-fit assembly, a coupling sleeve, threaded engagement, adhesion, or fasteners. Thus, the head plate130and the head portion110are separately formed components that are secured together during manufacture of the oral care implement100to form the head118of the oral care implement100. The rear surface112of the head portion110of the body101forms the rear surface of the head118.

In oral care implements that couple the tooth cleaning elements132to the head portion110using anchor-free tufting (AFT), the oral cleaning member190will take the form of the head plate130. The plate portion131of the head plate130may be formed of the same material as the head portion110. For example, in some embodiments the plate portion131may be formed of a rigid plastic material such as polypropylene. In certain embodiments, the plate portion131of the head plate130may comprise an upper surface133and a lower surface134. When the head plate130is coupled to the head portion110of the body101, the head plate130and the head portion110collectively form the head118of the oral care implement100. The upper surface133of the plate portion131of the head plate130forms a portion of the front surface of the head and the front surface111of the head portion110forms the remainder of the front surface of the head118.

The head plate130comprises a plurality of holes135formed therethrough from the upper surface133to the lower surface134, and the tooth cleaning elements132may be mounted to the head plate130within the holes135. This is known as anchor-free tufting or AFT. In AFT, a plate or membrane (i.e., the head plate130) is created separately from the head portion110. The tooth cleaning elements132(such as bristles, elastomeric elements, and combinations thereof) are positioned into the head plate130so as to extend through the holes135of the head plate130. A first portion136of the tooth cleaning elements132extend from the upper surface133of the head plate130so that the first portions136of the tooth cleaning elements132can be used to perform the cleaning function. A second portion137of the tooth cleaning elements132extend from the lower surface134of the head plate130. A third portion138of the tooth cleaning elements132are located within the holes135in the head plate130.

The second portions137of the tooth cleaning elements132are melted together by heat to be anchored in place. As the tooth cleaning elements132are melted together, a melt matte106is formed. The melt matte106is a thin layer of plastic that is formed by melting the second portions137of the tooth cleaning elements132so that the second portions137of the tooth cleaning elements132transition into a liquid, at which point the liquid of the second portions127of the tooth cleaning elements132combine together into a single layer of liquid plastic that at least partially covers the lower surface134of the head plate130. After the heat is no longer applied, the melted second portions137of the tooth cleaning elements132cool and solidify/harden to form the melt matte106or thin layer of plastic. The melt matte106comprises a lower surface107.

After the tooth cleaning elements132are secured to the head plate130, the head plate130is secured to the head portion110such as by ultrasonic welding or mechanical techniques (i.e., snap-fit, interference fit, slot-and-tab, or the like) so that the upper surface133of the head plate130forms at least a portion of the front surface of the head118. When the head plate130is coupled to the head portion110, the melt matte106is located between the lower surface134of the head plate130and the floor115of the cavity114(or any other components located within the cavity114, as described below). The melt matte106, which is coupled directly to and in fact forms a part of the tooth cleaning elements132, prevents the tooth cleaning elements132from being pulled through the holes135in the head plate130to ensure that the tooth cleaning elements132remain attached to the head plate130during use of the oral care implement100.

As mentioned above, this technique for coupling the head plate130to the head portion110of the body101is known as anchor-free tufting (AFT). However, it should be appreciated that the invention is not intended to be limited to AFT in all embodiments. In other embodiments, the tooth cleaning elements132may be coupled to the head portion110using other known techniques, including in-mold tufting (IMT), anchor-free tufting (AFT), a modified AFT known as AMR, a newer technique known as PTt, or staples.

For example, in AMR, the handle is formed integrally with the head portion as a one-piece structure. After the handle and the head portion are formed, the bristles are inserted into holes in the head portion so that the free/cleaning ends of the bristles extend from the front surface of the head plate and the bottom ends of the bristles are adjacent to the rear surface of the head plate (similar to how the bristles are coupled to the head plate130in AFT as discussed above). After the bristles are inserted into the holes in the head portion, the bottom ends of the bristles are melted together by applying heat thereto, thereby forming a melt matte at the rear surface of the head portion. The melt matte is a thin layer of plastic that is formed by melting the bottom ends of the bristles so that the bottom ends of the bristles transition into a liquid, at which point the liquid of the bottom ends of the bristles combine together into a single layer of liquid plastic that at least partially covers the rear surface of the head portion. After the heat is no longer applied, the melted bottom ends of the bristles solidify/harden to form the melt matte/thin layer of plastic.

In some embodiments, after formation of the melt matte, a tissue cleanser is injection molded onto the rear surface of the head portion, thereby trapping the melt matte between the tissue cleanser and the rear surface of the head portion. In other embodiments, other structures may be coupled to the rear surface of the head portion to trap the melt matte between the rear surface of the head portion and such structure without the structure necessarily being a tissue cleanser (the structure can just be a plastic material that is used to form a smooth rear surface of the head, or the like). Thus, in AMR the oral cleaning member190is the tissue cleanser or other structure that is coupled to the rear surface of the head portion.

Of course, techniques other than AFT and AMR can be used for mounting the tooth cleaning elements132to the head portion110. For example, in a further modified version of the AFT and AMR processes discussed above, the head plate130may be formed by positioning the tooth cleaning elements132within a mold, and then molding the head plate130around the tooth cleaning elements132via an injection molding process. Another well known technique for coupling tooth cleaning elements to a toothbrush head involves the use of staples to staple U-shaped bristle tufts into the head. Such stapling techniques may only be used in accordance with the claimed invention if it can be done in a way that still allows for the cavity114to exist as described herein. Another variation is called PTt which includes arranging the bristles in tufts, melting bottom ends of each tuft to form a mushroom-shaped end, inserting the tufts in pre-cored holes in a toothbrush, and then applying pressure and heat for a predetermined period of time so that the surface of the brush head shapes itself to enclose the mushroom-shaped ends of the tufts to hold them firmly. Again, PTt may only be used if it can be done in a way that preserves or maintains the cavity in the head. In some embodiments, the invention may comprise an oral care implement comprising a head having a cavity regardless of whether the head includes a head portion and a head plate coupled there to or whether the head is an integral structure.

In the exemplified embodiment, the plurality of tooth cleaning elements132are depicted generically as comprising a plurality of tufts of bristles, each tuft of bristles comprising a plurality of bristles. Of course, the invention is not limited to including only bristles as the tooth cleaning elements132. Thus, it should be appreciated that the term “tooth cleaning elements” may be used in a generic sense to refer to any structure that can be used to clean, polish, or wipe the teeth and/or soft oral tissue (e.g. tongue, cheek, gums, etc.) through relative surface contact. Common examples of “tooth cleaning elements” include, without limitation, bristle tufts, filament bristles, fiber bristles, nylon bristles, polybutylene terephthalate (PBT) bristles, spiral bristles, rubber bristles, elastomeric protrusions, flexible polymer protrusions, combinations thereof, and/or structures containing such materials or combinations. Thus, any combination of these tooth cleaning elements may be used within the tooth cleaning elements132in some embodiments. Furthermore, where bristles are used for one or more of the tooth cleaning elements132, such bristles can be tapered, end-rounded, spiral, or the like.

In embodiments that use elastomeric materials to form one or more of the tooth cleaning elements132, suitable elastomeric materials may include any biocompatible resilient material suitable for uses in an oral hygiene apparatus. To provide optimum comfort as well as cleaning benefits, the elastomeric material of any such tooth cleaning element may have a hardness property in the range of A10 to A70 Shore hardness in one embodiment, or A8 to A25 Shore hardness in another embodiment. One suitable elastomeric material is styrene-ethylene/butylene-styrene block copolymer (SEBS) manufactured by GLS Corporation. Nevertheless, SEBS material from other manufacturers or other materials within and outside the noted hardness range could be used.

Although illustrated herein as having a specific arrangement and shape, the arrangement of the tooth cleaning elements132as well as the shapes thereof can be modified from that which is depicted in the figures. Thus, the collective tooth cleaning elements132can be any pattern or arrangement and each one of the tooth cleaning elements132can have any desired shape. Thus, the invention is not to be limited by the structure, pattern, orientation, and material of the tooth cleaning elements132in all embodiments.

Referring toFIGS. 3 and 5A, the oral care implement100further comprises a dissolvable element140and a supporting member160, each of which is positioned within the cavity114of the head portion120of the body101. Specifically, in the exemplified embodiment the supporting member160and the dissolvable element140are located within the cavity114of the head portion120between the head plate130and the floor115of the cavity114. More specifically, the dissolvable element140is located between the floor115of the cavity114and the supporting member160and the supporting member160is located between the dissolvable element140and the head plate130. Thus, the dissolvable element140is located adjacent to the floor115of the cavity114and adjacent to the opening117in the floor115of the cavity114. In the exemplified embodiment, there are no intervening structures or components between the dissolvable element140and the floor115of the cavity114. This may be desirable in some embodiments to ensure that an oral care agent can leach out of the dissolvable element140and into a user's oral cavity through the opening117as described further below.

Of course, the invention is not limited to the arrangement of the dissolvable element140and the supporting member160as shown herein in all embodiments. In other embodiments, the dissolvable element140may be positioned adjacent to one or both of the lateral sides of the head portion110and the supporting member160may be located more centrally within the cavity114. In some embodiments, the dissolvable element140is initially positioned nearest to the wall of the cavity114in which the opening117is located (or at least nearer to the opening117than the supporting member160is to the opening117) so that the dissolvable element140is visible through the opening117. Upon the dissolvable element140dissolving, the supporting member160becomes visible through the opening117.

In the exemplified embodiment, the supporting member160and the dissolvable element140are rather thin to allow them to fit within the cavity114of the oral care implement100. For example, the dissolvable element140may have a thickness between 0.1 mm and 2 mm in some embodiments. Similarly, the supporting member160may have a thickness between 0.1 mm and 2 mm in some embodiments. In some embodiments, the dissolvable element140may have a greater thickness than the supporting member160. However, the thickness of the dissolvable element140may be dependent, at least in part, on its dissolution rate such that it is sufficiently thick to make sure that it lasts for enough uses to equal the life cycle of the oral care implement100(typically around 3 months).

In the exemplified embodiment, the supporting member160comprises a first surface161that faces the dissolvable element140and a second surface162opposite the first surface161. In the exemplified embodiment, the supporting member160has an oval shape. However, the invention is not to be so limited and the shape of the supporting member160may be modified so long as it is configured to be retained in the cavity114of the head portion1120as described herein.

In the exemplified embodiment, the first surface161of the supporting member160comprises a first coupling feature. In some embodiments, the second surface161of the supporting member160may comprise a second coupling feature, but may be free of a coupling feature in other embodiments. Of course, in other embodiments the first and/or second coupling features may be omitted. For example, when the supporting member160includes coupling features, the supporting member160is designed to be coupled to the dissolvable element140and possibly also to the oral cleaning member190. In embodiments that omit the coupling features, the supporting member160may serve as an indication feature to indicate when the dissolvable element140has been depleted without also being coupled to the oral cleaning member190or the dissolvable element140.

In the exemplified embodiment, the first coupling feature is a first adhesive and the second coupling feature (when it exists) is a second adhesive. Each of the first and/or second adhesives may be any one of glue, cement, mucilage, paste, pressure-sensitive adhesives, ultraviolet light curing adhesives, contact adhesives, drying and non-reactive adhesives, solvent-based adhesives, polymer dispersion adhesives, or the like. The first and/or second adhesives may alternately be double-sided tape. The specific type of material used as the first and/or second adhesives are not to be limiting of the present invention unless so claimed.

Of course, the first coupling feature (and the second coupling feature when it is present) is not limited to being an adhesive. Rather, the first coupling feature is merely a feature that is configured to couple the supporting member160to the dissolvable element140in a reasonably fixed manner. Thus, the first coupling feature may be a mechanical feature that engages a feature on the dissolvable element140to couple the supporting member160to the dissolvable element140. For example, the first coupling feature may be a protrusion that engages a recess in the dissolvable element140, or the first coupling feature may be biasing grip arms that engage opposing edges of the dissolvable element140to couple the supporting member160to the dissolvable element140, or the first coupling feature may be a barb that penetrates the dissolvable element140to couple the supporting member160to the dissolvable element140. In other embodiments, the first coupling feature may be suction cups that facilitate coupling the supporting member160to the dissolvable element140. The second coupling feature can be any of the features noted herein for the first coupling feature when the second coupling feature is present. Coupling the supporting member160to the dissolvable element140can be desirable because it will keep the dissolvable element140together in one-piece even if it breaks at any time after manufacture of the oral care implement and it can also assist in the assembly of the oral care implement100as described in detail below.

As mentioned above, in the exemplified embodiment the first coupling feature is a first adhesive. The first adhesive may cover the entirety of the first surface161of the supporting member160or only a portion thereof. The first adhesive may be arranged as dots, straight lines, wavy lines, sinusoidal lines, random blotches, or the like as may be desired. Alternatively, the first adhesive may cover a perimeter region of the first surface161but not a central region or the first adhesive may cover a central region of the first surface161but not a perimeter region. Basically, the first adhesive may be arranged in any desired manner along the first surface161so long that has an adhesive bond that is sufficient to maintain a coupling between the supporting member160and the dissolvable element140as described herein. The second adhesive may cover the entirety of the second surface162of the supporting member160or only a portion thereof. The second adhesive may also be arranged as dots, straight lines, wavy lines, sinusoidal lines, random blotches, or the like. Moreover, in some embodiments the second adhesive may be omitted.

Referring toFIGS. 3 and 4A, a first embodiment of the supporting member160will be described. The supporting member160may comprise a substrate layer163having a front surface164and a rear surface165, and a first adhesive layer166covering at least a portion of the rear surface165. The substrate layer163may be formed of any desired material, including plastics, wood, metal, paper, cardboard, cellulosics, or the like. In the exemplified embodiment, the first adhesive layer166covers an entirety of the rear surface165of the substrate layer163. However, the invention is not to be so limited in all embodiments and the first adhesive layer166may cover only part of the rear surface165of the substrate layer163as noted herein above. The first adhesive layer166may be arranged in dots, straight lines, wavy lines, sinusoidal lines, or any other desired pattern on the rear surface165of the substrate layer164. In this embodiment, the front surface164of the substrate layer163is free of an adhesive layer thereon such that the front surface164of the substrate layer163is exposed and non-sticky. In this embodiment, the front surface164of the substrate layer163forms the second surface162of the supporting member160and the outer surface of the first adhesive layer166forms the first surface161of the supporting member160.

Referring toFIGS. 3 and 4B, a second embodiment of the supporting member160awill be described. In this embodiment, the supporting member160acomprises a substrate layer163a(which may be formed from any of the materials noted above for the substrate layer163) having a front surface164aand a rear surface165a, a first adhesive layer166acovering at least a portion of the rear surface165a, and a second adhesive layer167acovering at least a portion of the front surface164a. As with the supporting member160, the first and second adhesive layers166a,167amay be arranged in any pattern (dots, lines, waves, etc.) or they may cover the entirety of the substrate layer163aas shown. The first adhesive layer166,166aand the second adhesive layer167amay be any type of adhesive described herein or otherwise known. In this embodiment, the outer surface of the first adhesive layer166aforms the front surface161of the supporting member160aand the outer surface of the second adhesive layer167aforms the second surface162of the supporting member160a.

Referring back toFIGS. 3 and 5A, the supporting member160is illustrated as a flat, plate-like structure such that the first and second surfaces161,162are planar and flat. Of course, this is not required in all embodiments and the supporting member160may be modified in its structure while still enabling it to function in the manner described herein.

Still referring toFIGS. 3 and 5A, the dissolvable element140will be described. The dissolvable element140may be a food grade component that is solid in its initial, before-use state. The dissolvable element140may break or crumble if too much pressure is applied onto it. The dissolvable element140may be dissolvable during use such that when contacted by saliva or other liquids such as a toothpaste slurry, the dissolvable element140dissolves. Thus, the dissolvable element140is a solid body which at least partially, and preferably entirely, dissolves in water (i.e., saliva) during use of the oral care implement100. The dissolvable element140may be a solid component rather than being a liquid, although the dissolvable element140will turn into a liquid by dissolving when it gets wet. In some embodiments, the dissolvable element140may remain solid until it is completely dissolved or depleted. The dissolvable element140may be a dissolvable tablet. The dissolvable element140may release the oral care agent therefrom without dissolving completely.

The dissolvable element140comprises at least one oral care agent so that as the dissolvable element140dissolves, the oral care agent leaches or dissolves into the user's oral cavity to provide some type of benefit or desirable flavor. The dissolvable element140may comprise a water-dissolvable matrix comprising a polymer and the oral care agent. In some embodiments, the entirety of the dissolvable element140may dissolve during use such that the dissolvable element140reduces in size over continued use of the oral care implement100. In other embodiments, the dissolvable element140may dispense the oral care agent without completely dissolving.

The oral care agent used in the dissolvable element140may be any of a number of different oral care agents. For example, when the desired application site is a user's oral cavity, the oral care agent may be one that provides a benefit to a user's oral surfaces (i.e., a benefit agent) such as a sensorial or therapeutic benefit. For example without limitation, the oral care agent may be a mouthwash, a dentifrice, a tooth whitening agent such as peroxide containing tooth whitening compositions, or the like. Other contemplated oral care agents that may be used in the dissolvable element140include, for example without limitation, antibacterial agents; oxidative or whitening agents; enamel strengthening or repair agents; tooth erosion preventing agents; tooth sensitivity ingredients; gum health actives; nutritional ingredients; tartar control or anti-stain ingredients; enzymes; sensate ingredients; flavors or flavor ingredients; breath freshening ingredients; oral malodor reducing agents; anti-attachment agents or sealants; diagnostic solutions; occluding agents, dry mouth relief ingredients; catalysts to enhance the activity of any of these agents; colorants or aesthetic ingredients; and combinations thereof. In certain embodiments the oral care material is free of (i.e., is not) toothpaste. Instead, the oral care material in such embodiments is intended to provide benefits in addition to merely brushing one's teeth. In one embodiment, the oral care agent may be selected from the group consisting of a sensate, a flavorant, an amino acid, a monoglyceride, charcoal, an anti-bacterial or microbial agent, a whitening agent, an anti-plaque agent, and an anti-gingivitis agent. Furthermore, in still other embodiments the oral care agent can be a natural ingredient, such as for example without limitation, lotus seed; lotus flower, bamboo salt; jasmine; corn mint; camellia; aloe; gingko; tea tree oil; xylitol; sea salt; vitamin C; ginger; cactus; baking soda; pine tree salt; green tea; white pearl; black pearl; charcoal powder; nephrite or jade and Ag/Au+.

Flavor agents are agents that a user's taste buds can perceive to give taste sensation within the mouth. The sensation may be of any suitable taste, such as but not limited to fruit (e.g., berry, apple, watermelon, mixed fruit, etc.), mint flavors (e.g., mint, spearmint, peppermint, wintergreen, and one or more spices (e.g., cinnamon). A sensate provides a sensation within the user's oral cavity that is different from the flavor sensation as the sensation may not be dependent on the user's taste buds. Rather the sensation may be perceived throughout the user's entire oral cavity—for example on the cheeks or roof of the mouth. In a non-limiting embodiment, the sensation may comprise a cooling sensation. Other non-limiting examples of non-taste sensation may include a numbing effect, a heating effect, a tingling effect, and the like. Non-limiting examples of sensate include menthol, as well as menthol derivatives, such as cyclohexanecarboxamide, N-Ethyl-5-Methyl-2-(1-Methylethyl).

The oral care agent may comprise an anti-tartar agent, which may comprise at least one of a metal oxide, pyrophosphate, and potassium salt. Non-limiting examples of metal oxide include zinc oxide. Non-limiting examples of potassium salts include potassium nitrate, potassium citrate, potassium oxalate and mixtures thereof. In a preferred embodiment, the potassium salt may be potassium nitrate (KNO3). Non-limiting examples of polyphosphates in water soluble polyphosphates, including alkali metal pyrophosphates, such as tetrapotassium pyrophosphate, dipotassium pyrophosphate, tetrasodium pyrophosphate and disodium pyrophosphate. In a preferred embodiment, the polyphosphate is tetrapotassium pyrophosphate (“TKPP”).

The oral care agent may comprise an amino acid, which may be selected from one or more of L-arginine, lysine, citrullene, ornithine, creatine, histidine, diaminobutanoic acid, diaminoproprionic acid, salts thereof and/or combinations thereof. In a preferred embodiment, the amino acid is L-arginine.

The oral care agent may comprise charcoal, which may be activated charcoal. The term “activated charcoal” or “activated carbon” refers to charcoal that has been processed to have small, low-volume pores that increase the surface area. The release agent may further comprise one or more anti-bacterial agents or anti-microbial agents, whitening agents (e.g., hydrogen peroxide), and the like.

In other embodiments, the oral care implement may comprise an anti-bacterial or anti-microbial agent (or a whitening agent). In a non-limiting example, the oral care agent may be activated charcoal such as an anti-microbial agent. For an oral care implement having a predetermined lifespan based on regular usage and comprising the dissolvable element140, the oral care agent may be present in the dissolvable element140in a pre-selected concentration that allows for continual release of the oral care agent from the dissolvable element140over the entirety of that predetermined lifespan. Additionally, the concentration of the oral care agent may be pre-selected such that once the predetermined lifespan of the oral care implement is completed, the dissolvable element140may be substantially depleted.

In the exemplified embodiment, the dissolvable element140has an oval shape that matches the shape of the supporting member160. Furthermore, in the exemplified embodiment the dissolvable element140has the same size and dimensions as the supporting member160. Of course, the dissolvable element140may have different shapes and/or dimensions and sizes in other embodiments and the shape/size/dimensions of the dissolvable element140need not match the shape/size/dimensions of the supporting member160in all embodiments.

The dissolvable element140comprises a first surface141and a second surface142opposite the first surface141. In the exemplified embodiment, when positioned in the cavity114of the head portion110, the first surface141of the dissolvable element140faces the floor115of the cavity114and the second surface142of the dissolvable element140faces the supporting member160. In the exemplified embodiment, both of the first and second surfaces141,142of the dissolvable element140are flat planar surfaces. However, this is not required in all embodiments. In fact, in some embodiments the first surface141of the dissolvable element140may include a protrusion or protruding portion that protrudes into the opening117when the dissolvable element140is properly positioned within the cavity114. In some embodiments the first surface161of the supporting member160and the second surface142of the dissolvable element140may be flat surfaces to ensure good conformal surface contact therebetween when the adhesive member10is coupled to the dissolvable element140.

Referring toFIG. 5A, in the exemplified embodiment the dissolvable element140is positioned in the cavity114with the first surface141facing the floor115and the second surface142facing the first surface161of the supporting member160. As noted above, the supporting member160comprises a first coupling feature, which may be a first adhesive located on the first surface161of the supporting member160in some embodiments. Thus, in the exemplified embodiment, the dissolvable element140adheres or otherwise sticks to the supporting member160due to the second surface142of the dissolvable element140being in contact with the first surface (or adhesive surface)161of the supporting member160. In other embodiments, the first coupling feature may take on other structural forms as described herein above, but in any case it will couple the dissolvable element140to the supporting member160. Thus, if the dissolvable element140were to become broken such as may occur during transit from the manufacturing facility to the retail store and/or to the consumer's home, the dissolvable element140will remain intact due to it being adhered to the supporting member160. This will prevent large pieces of the dissolvable element140from falling through the opening117. Rather, the dissolvable element140will remain together as a unit even if it becomes broken due to its adherence to the supporting member160.

As seen inFIG. 5A, the dissolvable element140overlies (or is aligned with) the opening117and the supporting member160overlies the dissolvable element140. Thus, the supporting member160also overlies (or is aligned with) the opening117although indirectly because the dissolvable element140is located between the opening117and the supporting member160. Stated another way, any plane that is transverse to the longitudinal axis A-A and perpendicular to the front and rear surfaces111,112of the head portion110that intersects the opening117(or any of the openings117when there are multiple) will also intersect the supporting member160(and the dissolvable element140before it starts to dissolve). Thus, during use of the oral care implement100, saliva and other fluids including toothpaste slurry can enter into the cavity114through the opening117and contact the dissolvable element140. Such contact between these fluids and the dissolvable element140will cause the dissolvable element140to dissolve and be released through the opening117and into the user's oral cavity. In this way, the user will benefit from or have a positive flavor experience from the oral care agent as it passes through the opening(s)117and into the user's oral cavity.

In some embodiments, the dissolvable element140may comprise a first visual feature and the supporting member160may comprise a second visual feature that is distinguishable from the first visual feature. In some embodiments the first visual feature may be a first color and the second visual feature may be a second color that is distinguishable from the first color. Different colors can be entirely different colors (i.e., red and blue) or different shades of the same color (e.g., royal blue and turquoise). Alternatively, instead of different colors the dissolvable element140and the supporting member160may have other differentiating visual features, such as indicia, words, patterns, or the like. In some embodiments, the dissolvable element140may not have any visual features, but the supporting member160may include a visual feature so that it is immediately apparent when a user is viewing the supporting member160through the openings117.

In some embodiments, the dissolvable element140and the supporting member160may merely be visually distinguishable from each other so that a user has a visual cue that the dissolvable element140is dissolving and/or has fully dissolved or depleted. Thus, as the dissolvable element140dissolves during use, the supporting member160may become exposed through the openings117because the supporting member160overlies/overlaps the openings117as noted above. In this way, the supporting member160may act as a visual indicator of the depletion of the dissolvable element140. Specifically, as the dissolvable element140dissolves and exposes the supporting member160, a user will know that the dissolvable element140is dissolving and will also know when the dissolvable element140has fully dissolved such that the oral care implement100needs to be replaced.

In some embodiments, the dissolvable element140may be designed to have a life cycle of three months such that after three months of normal twice-a-day toothbrushing the dissolvable element140has fully dissolved. As such, a user will know to replace the oral care implement100once the dissolvable element140is fully dissolved. Three months is a standard time period upon which it is generally desired for a toothbrush to be replaced and in this way the dissolvable element140and the supporting member160may act as a toothbrush replacement indicator. Of course, longer or shorter life spans for the dissolvable element140may also be applicable in other embodiments.

As noted above, in some embodiments the second surface162of the supporting member160may also comprise a coupling feature, which in some embodiments may be an adhesive. The purpose for this is to adhere or otherwise couple the supporting member160to the oral cleaning member190(e.g., the head plate130). Because the head plate130is coupled to the head portion110in a somewhat permanent manner that prevents movement of the head plate130(such as ultrasonic welding), this ensures that the supporting member160also remains in the static position within the cavity114. Specifically, portions of the second surface162of the supporting member160may be covered with an adhesive to adhere the supporting member160to the head plate130(or other oral cleaning member190) within the cavity114. One reason that this may be desirable is to prevent the supporting member160from moving excessively within the cavity114as the dissolvable element140dissolves. Specifically, without adhering the supporting member160to the head plate130, the supporting member160may tend to move downwardly towards the floor115of the cavity114as the dissolvable element140dissolves. Adhering the supporting member160to the head plate130by an adhesive will prevent this. As shown inFIG. 5A, the melt matte106and/or portions of the lower surface134of the plate portion131of the head plate130are in surface contact with the second surface162of the supporting member160. If the second surface162of the supporting member160comprises an adhesive, the plate portion131and/or the melt matte106will adhere to the supporting member160to hold everything in place within the cavity114.

FIG. 5Billustrates an alternative embodiment that includes an alternative technique for ensuring that the supporting member160does not move within the cavity114even as the dissolvable element140dissolves. Specifically, in this embodiment the sidewall116of the head portion110comprises a ledge119and the supporting member160rests atop of the ledge119. In this particular embodiment, the dissolvable element140hangs from the supporting member160and is elevated above the floor115of the cavity114. In other embodiments, the dissolvable element140could extend all the way to the floor115of the cavity114. At any rate, in this embodiment, even as the dissolvable element140dissolves, the supporting member160will remain in a fixed position due to it being supported by the ledge119.

In this embodiment, the first surface161of the supporting member160comprises a perimeter region168that is not covered by or coupled to the dissolvable element140. Thus, in this embodiment the supporting member160has a larger size in at least one dimension as compared to the dissolvable element140such that when the dissolvable element140is coupled or adhered to the supporting member160, an outer portion (the perimeter region168) of the first surface161of the supporting member160remains exposed and not covered by the dissolvable element140. As a result, the perimeter region168of the supporting member160can rest atop of the ledge119and the dissolvable element140can extend downwardly from the supporting member160towards the floor115of the cavity114. In this embodiment, the perimeter region168of the first surface161of the supporting member160rests directly atop of the ledge119and the supporting member160is sandwiched between the ledge119and the head plate130.

FIG. 5Cillustrates another alternative embodiment of the oral care implement100. This embodiment is identical toFIG. 5Ain every aspect except that the head portion110comprises a plurality of the openings117that extend from the floor115of the cavity114to the rear surface112of the head portion110(which is also the rear surface of the head118). Thus, this figure is merely intended to illustrate that the head portion110may comprise a single opening extending from the floor115of the cavity114to the rear surface112or a plurality of such openings. When a plurality of the openings117are used, they can be arranged in any pattern (one non-limiting example of which is shown inFIGS. 6A-6Cdescribed below). In some embodiments all of the openings117may have the same size and/or area and in other embodiments the openings117may have different sizes and/or areas.

Referring toFIGS. 6A-6C, a rear view of the head portion110of the oral care implement100is illustrated. In this embodiment, the head portion110comprises a plurality of the openings117as described above with reference toFIG. 5C. There are larger openings117and smaller openings117, and of course additional sized openings could also be included and the openings117could take on a different pattern or arrangement. The change fromFIGS. 6A-6Cillustrates what happens when the dissolvable element140dissolves over time. Specifically, inFIG. 6Aonly the dissolvable element140is visible through the openings117. As noted above, the dissolvable element140overlies all of the openings117so that the dissolvable element140is visible through each of the openings117.

FIG. 6Billustrates the oral care implement100after some uses thereof. Thus, in this embodiment the dissolvable element140has dissolved, although not completely, such that the dissolvable element140is visible through some of the openings117and the supporting member160is visible through others of the openings117. Thus, a user can tell by looking through the openings117that the dissolvable element140has dissolved somewhat from its initial structure and size. In some embodiments, this is made possible due to the second visual feature on the supporting member160becoming visible through the openings117.

FIG. 6Cillustrates the oral care implement100after the dissolvable element140has dissolved entirely. Thus, in this figure only the supporting member160is visible through the openings117. The dissolvable element140has dissolved completely so it is no longer visible through the openings117. At this point in time, a user will know that it is time to replace the oral care implement100(or add another dissolvable element140into the cavity114if such replacement of the dissolvable element140is possible). A user can easily determine whether he/she is viewing the dissolvable element140or the supporting member160because they comprise different colors or other visual features that are distinguishable from one another as discussed above.

In the embodiments described above, the dissolvable element140and the supporting member160are located in the cavity114of the head portion110of the oral care implement100. As mentioned above, in some embodiments the supporting member160may be an indicator member and in such embodiments the supporting member160may not have any adhesive or other coupling features thereon. Rather, in such embodiments the supporting member160comprises the second visual feature that is distinguishable from the first visual feature of the dissolvable element140, but it may not have any adhesive or other coupling feature for adhering the dissolvable element140thereto. In such embodiments, the supporting member160still serves the indication function in that as the dissolvable element140dissolves it exposes the second visual feature of the supporting member160to indicate to a user that the dissolvable element140is dissolving or has depleted. However, such an indicator member will not have any adhesive thereon and will not adhere to the dissolvable element140.

Furthermore, in some embodiments the supporting member160may be omitted entirely such that the dissolvable element140is the only component located in the cavity114. In such embodiments the melt matte106may function as the supporting member. Specifically, in such embodiments the melt matte106may comprise a visual feature (i.e., a color, indicia, protrusions, indents, or the like) that is distinguishable from a visual feature of the dissolvable element140. This means that a user can readily distinguish between whether he is viewing the oral care agent140or if he is viewing the support member160(or the melt matte106when the melt matte106operates as the support member) through the opening117based on the visual feature seen through the opening117. In some embodiments, the visual feature is a color as noted above. The color of the melt matte106may be dictated by the color of the tooth cleaning elements132, and thus in some embodiments the tooth cleaning elements132may have a different color than the dissolvable element140.

Two colors can be distinguishable even if they are different shades of the same color so long as they are sufficiently different that a user would be able to distinguish between them. Thus, for example, the colors turquoise blue and royal blue are both shades of blue, but they are readily distinguishable from one another. In some embodiments, the dissolvable element140may be transparent and the adhesive/indicator member160may be opaque and colored. In such embodiments, the adhesive/indicator member160may be visible through the dissolvable element140due to its transparency. However, a user will nonetheless be able to determine whether the dissolvable element140is present or not. In other embodiments, the dissolvable element140may be white and the adhesive/indicator member160may be a non-white color. The adhesive/indicator member160need not be a solid color in all embodiments and it could have a pattern of color, such as a pattern of colored dots or lines or the like. In some embodiments, the visual appearance of the support member160(or the melt matte106when it functions as the support member) should merely be distinguishable from the visual appearance of the dissolvable element140, whether this is achieved by having those components formed from different colors or with other different visually identifiable features.

FIGS. 7A-7Eillustrate a method of assembling the oral care implement100in accordance with one embodiment of the present invention. Specifically,FIGS. 7A-7Eillustrate the method by which the dissolvable element140and the supporting member160are placed within the cavity114of the head portion110and the method by which the head plate130is coupled to the head portion110of the body101to form the head118.

First, referring toFIG. 7A, the dissolvable element140and the supporting member160are laid out next to each other. The dissolvable element140is positioned with its first surface141facing the structure on which it is positioned (i.e., table, counter, etc.) and with its second surface142exposed. The supporting member160is positioned with its first surface161(its adhesive surface) facing the structure on which it is positioned (i.e., table, counter, etc.) and with its second surface162exposed.

A user then grasps a suction tool200, which will be used to pick up the dissolvable element140and the supporting member160to place those components into the cavity114of the head portion110. The suction tool200may be any type of tool that can create a suction force when forced against another component so that the component sticks to the suction tool200so that it can be picked up by the suction tool200. Such suction tools are also known in the art as vacuum pens, vacuum pick up pens, or the like. The suction tool200comprises a handle201and a head202. The handle201may be a simple structure or may include various contours for user comfort and the head202may comprise a rubber disk, a suction cup, or the like. The suction tool200may include an actuator that is pressed to generate suction and released to release the suction or pressed a first time to generate suction and pressed a second time to release the suction (for example, a pneumatic suction pen). The suction tool200may also be a simple device that includes a suction cup on its end that, when pressed against an object, causes the object to be stuck to the suction tool via a suction force (for example, a manual suction pen).

Referring toFIG. 7B, the next step in the assembly process is to press the head202of the suction tool200onto the second surface162of the supporting member160and to generate a suction force with the suction tool200so that the suction tool200can pick up the supporting member160. This can be done by the simple act of applying a force onto the supporting member160with the head202of the suction tool200or by pressing an actuator as noted above. InFIG. 7B, the supporting member160is held by the suction tool200and is no longer being supported by the horizontal surface on which it was originally positioned.

As mentioned above, in some embodiments the second surface162of the supporting member160may comprise an adhesive. In such embodiments, it is preferable that there be a region on the second surface162that is free of the adhesive. The reason for this is that if the entirety of the second surface162of the supporting member160is covered by an adhesive, the suction tool200would stick to the supporting member160and it would be difficult to release the supporting member160from the suction tool200without a user using his/her hands to do so. Thus, for example, in the exemplified embodiment a central region of the second surface162of the supporting member160where the suction tool200is shown attached to the supporting member160is free of an adhesive in the exemplified embodiment. The exact location of the part of the second surface162of the supporting member160that is free of adhesive is not limiting of the present invention in all embodiments, although it could be the entire second surface162or any portion thereof upon which the suction tool200is intended to be attached to the supporting member160during assembly of the oral care implement100as described herein.

Next, the supporting member160is moved towards and pressed downwardly upon the second surface142of the dissolvable element140. Because the suction tool200is suctioned to the second surface162of the supporting member160, when the supporting member160is pressed onto the dissolvable element140, it is the first surface161of the supporting member160that contacts the second surface142of the dissolvable element140. Furthermore, as noted previously, in some embodiments the first surface161of the supporting member160comprises a coupling feature, which may be an adhesive. Thus, as the first surface161of the supporting member160is pressed into contact with the second surface142of the dissolvable element140, the dissolvable element140becomes coupled to the supporting member160due to the engagement of the coupling feature of the supporting member160with the dissolvable element140. In the exemplified embodiment, the coupling feature is an adhesive and the dissolvable element140adheres or otherwise sticks to the supporting member160when the supporting member160is pressed into contact with the dissolvable element140.

As noted above, in other embodiments the supporting member160may not include any coupling feature, including adhesive or other features as noted herein, on its first surface161. Thus, in some such embodiments, the supporting member160may be a permeable layer such that the suction force generated by the suction tool200can pass through the supporting member160and onto the dissolvable element140so that the suction tool200can pick up both the supporting member160and the dissolvable element140simultaneously. In still other embodiments, the supporting member160may comprise openings so that the suction force generated by the suction tool200can pass through the openings in the supporting member160so that the suction force is applied to the dissolvable element140as the supporting member160carried by the suction tool200is placed into contact with the dissolvable element140. Thus, the suction force may be applied to both the supporting member160and the dissolvable element140simultaneously in some embodiments, and in other embodiments the suction force may be applied only to the supporting member160and the dissolvable element140is coupled to the supporting member160due to the first coupling feature (e.g., adhesive or the like) of the supporting member160.

At this point, referring toFIG. 7C, the suction tool200is holding both the supporting member160and the dissolvable element140as a sub-assembly150. The user can then insert the sub-assembly150through the open top end of the cavity114of the head portion110of the oral care implement100using the suction tool200. Specifically, the sub-assembly150remains held by the suction tool200due to the suction force applied by the suction tool200onto the supporting member160and dissolvable element140(or just onto the supporting member160with the dissolvable element140being adhered or otherwise coupled to the supporting member160). Once the user has placed the sub-assembly150into the cavity114, the user can release the suction force of the suction tool200(either by pressing an actuator a second time, releasing an actuator that was previously being held in an activated state, or using any other known technique), which results in the sub-assembly150being positioned within the cavity114, as shown inFIG. 7D.

In the exemplified embodiment, the dissolvable element140rests atop of the floor115of the cavity114and the supporting member160rests atop of the dissolvable element140. In other embodiments, there may be a ledge (such as the ledge119shown inFIG. 5B) and the supporting member160or the dissolvable element140may rest atop of the ledge119. In either case, the sub-assembly150should be placed within the cavity114with the dissolvable element140adjacent to and facing the floor115of the cavity114.

Next, the oral cleaning member190, which in this embodiment is the head plate130but in other embodiments could be a tissue cleaner, tongue cleaner, or other structure, is coupled to the head portion110to close the top end of the cavity114. In the exemplified embodiment, this is done using the suction tool200. Specifically, the suction tool200is used to pick up the head plate130in the same way that the suction tool200was used to pick up the supporting member160. Of course, the head plate130could be put into its proper placement manually or using robotic arms in an automated assembly process. The head plate130is then placed into/over the opening in the top end of the cavity114and is coupled to the head portion120using the techniques described above. Once the head plate130is coupled to the head portion110, the head118is fully assembled as shown inFIG. 7E. The head plate130covers and closes the open top end of the cavity114so that a user cannot see into the cavity114through the front of the head118. However, the user can still see into the cavity114through the opening(s)117in the rear surface of the head118as described herein above.

In other embodiments the support member160may not comprise any coupling features thereon and the support member160may also not be permeable or have openings for the suction to pass through. In such embodiments, the dissolvable element140will first be picked up (by a suction tool or otherwise) and inserted into the cavity114of the head portion110. Next, the supporting member160will be picked up (by a suction tool or otherwise) and inserted into the cavity114atop of the dissolvable element140. Finally, the oral cleaning member190(e.g., the head plate130) will be coupled to the head portion110to close the open top end of the cavity114thereby trapping the supporting member160and the dissolvable element140in the cavity114. Thus, when the support member160does not include a coupling feature for coupling it to the dissolvable element140and the suction of the suction tool200cannot pass through the support member160, the assembly of the oral care implement100may be achieved in a two-step process by placing each of the dissolvable element140and the supporting member160in the cavity114in separate steps.

As noted above, the dissolvable element140dissolves or otherwise becomes depleted over time. Thus, when the oral care implement100is first assembled and prior to a first use thereof (i.e., a pre-use state), the dissolvable element140is visible through any openings117in the head portion110. Then, after one or more uses of the oral care implement100to clean oral cavity surfaces, the dissolvable element140begins to dissolve or otherwise deplete. Specifically, in some embodiments the dissolvable element140may dissolve in the user's saliva or toothpaste slurry during use. As the dissolvable element140dissolves, the supporting member160becomes exposed or otherwise visible through the openings117. As the oral care implement100is used more and more, more of the dissolvable element140dissolves and more of the supporting member160becomes visible through the openings117until the dissolvable element140is completely depleted. Once the dissolvable element140is completely depleted, a user will know it is time to replace the oral care implement100. In some embodiments, the dissolvable element140is designed to deplete after three-months of use of the oral care implement100, which is the recommended period of time for replacement of an oral care implement.

As mentioned above, in some embodiments the oral care implement could be a powered toothbrush. In such an embodiment, the powered toothbrush would include a handle portion and a refill head that is attachable to the handle portion. In such an embodiment, the features described above, and particularly related to the dissolvable element140and the supporting member160, are located in and/or formed as a part of the refill head. Such a refill head including the inventive concepts noted herein could also be used and attachable to a handle for a manual toothbrush that has a removable/replaceable head.