Oral care implement having a decorative member and a method of forming the same

An oral car implement (100) having a decorative member (150) recessed in a handle (120) of the oral care implement and having at least a portion thereof exposed via an aperture (140), and a method of forming the same. In one aspect, the invention can be an oral care implement (120) comprising: a handle having a longitudinal axis and a head (110) connected to the handle; the handle comprising a first transverse section (122) and a second transverse section (121), the first transverse section coupled to the second transverse section; a decorative member disposed between the first transverse section and the second transverse section; and an aperture extending through the first transverse section that exposes at least a portion of the decorative member.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present application is a U.S. national stage application under 35 U.S.C. §371 of PCT Application No. PCT/US2011/023368, filed Feb 1, 2011, the entirety of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to an oral care implement and method of manufacturing the same, and specifically to a handle of an oral care implement having a decorative member that is protected against wear and methods of manufacturing the same.

BACKGROUND OF THE INVENTION

Decorative members, such as logos, symbols, or other designs, are often applied to the handles of oral care implements. Such decorative members are used for a wide variety of reasons, including: to attract the attention of children; to identify the source and/or trade name of the oral care implement; to display a desired message and/or visual indicia; and/or to create a desired visual effect to the user. In some existing oral care implements, the decorative member is formed by providing a raised portion directly on the exterior surface of the toothbrush. However, this raised portion can be uncomfortable to a user, can be difficult to see, and/or can become easily worn during the natural use of the oral care implement.

It also known to embed a decorative member within the oral care implement so that it is viewable and protected against wear. In such known embodiment, the decorative member is embedded and completely encapsulated within the handle of the oral care implement. However, the decorative member is still viewable to the user by utilizing a transparent material to completely encapsulate the decorative member thereunder. While embedding and completely encapsulating the decorative member within the handle protects the decorative member against any damage due to wear, it also decreases and distorts the visibility of the decorative member. Such distortion is caused by: (1) the decorative member being viewed through the curved surfaces of the handle; and/or (2) the transparent material having a less than perfect transparency quality. Such distortion of the decorative member may make it difficult for a user to clearly view the decorative member. Furthermore, these oral care implements require additional materials in order to fully encapsulate the decorative member, which results in an added cost.

Thus, a need exists for an oral care implement having a decorative member wherein the decorative member is viewable without distortion, is protected against damage and wear and tear, and/or has a lower material cost.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to an oral care implement with a handle having a decorative member recessed therein and having at least a portion of the decorative member exposed via an aperture.

In one aspect, the invention can be an oral care implement comprising: a handle having a longitudinal axis and a head connected to the handle; the handle comprising a first transverse section and a second transverse section, the first transverse section coupled to the second transverse section; a decorative member disposed between the first transverse section and the second transverse section; and an aperture extending through the first transverse section that exposes at least a portion of the decorative member.

In another aspect, the invention can be a method of forming an oral care implement comprising: a) forming a first transverse section of a handle of the oral care implement, the first transverse section comprising an aperture extending therethrough; b) applying a decorative member to the first transverse section so that at least a portion of the decorative member covers the aperture; and c) forming a second transverse section of the handle on the first transverse section, the decorative member disposed between the first and second transverse sections.

In yet another aspect, the invention can be a method of forming an oral care implement comprising: a) forming a first transverse section of a handle of the oral care implement; b) applying a decorative member to the first transverse section; c) forming a second transverse section of the handle on the first transverse section, the decorative member disposed between the first and second transverse sections, and the second transverse section comprising an aperture through which at least a portion of the decorative member is exposed.

DETAILED DESCRIPTION OF THE INVENTION

Preferred embodiments of the present invention will now be described herein with respect to one possible embodiment of an oral care implement, namely a manual toothbrush. However, in other forms, the invention could be in the form of other oral care implements including a soft-tissue cleansing implement, a powered toothbrush, or other ansate implements designed for oral care.

Referring now toFIG. 1, an oral care implement100is illustrated according to one embodiment of the present invention. The oral care implement100generally comprises a handle120and a head110. The handle120provides the user with a mechanism by which he/she can readily grip and manipulate the oral care implement100. The handle120includes ergonomic features which provide a high degree of control for the user while maintaining comfort. The head110is connected to the handle120by a neck115. The head110includes a set of teeth cleaning elements119which are generically illustrated.

Generally, the oral care implement100extends from a proximal end101(which is also the proximal end of the handle110) to a distal end102along a longitudinal axis A-A. Conceptually, the longitudinal axis A-A is a reference line that is generally coextensive with the three-dimensional center line of the handle120and the head110. Because the handle120is a non-linear structure (as can be seen inFIG. 2as viewed laterally) in the illustrated embodiment, the longitudinal axis A-A for the oral care implement100is also non-linear in the illustrated embodiment. However, the invention is not so limited, and in certain embodiments the oral care implement100may have a simple linear arrangement and thus a substantially linear longitudinal axis A-A.

As noted above, the head110is coupled to the handle120via the neck115. As discussed in greater detail below, the head120, the neck115, and an upper transverse section122of the handle120of the oral care implement100are formed as an integral structure using an injection molding process in the exemplified embodiment ofFIGS. 1-4. Furthermore, as discussed in greater detail below, in the exemplified embodiment ofFIG. 5, the head220, the neck215, and a lower transverse section221of the handle220of the oral care implement200are formed as an integral structure using an injection molding process. However, in other embodiments, the handle120and the head110may 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 welding, sonic welding, a tight-fit assembly, a coupling sleeve, adhesion or fasteners. Whether the head110and the handle120(or a transverse section thereof) are constructed as an integral piece or a multi-piece assembly (including connection techniques) is not limiting of the present invention in all embodiments. Furthermore, other manufacturing techniques may be used in place of and/or in addition to injection molding to create the handle110(of transverse sections thereof) and/or the head120(or components thereof), such as milling and/or machining

Referring now toFIGS. 1 and 2concurrently, the head110generally comprises a front surface111and a rear surface112. The front surface111and the rear surface112of the head110can take on a wide variety of shapes and contours, none of which are limiting of the present invention. For example, the front and rear surfaces111,112can be planar, contoured or combinations thereof. The front surface111and rear surface112are bound by a peripheral or lateral surface113.

A set of cleaning elements119, which are generically illustrated as a plurality of circular tufts of bristles, are provided on and extend outward from the front surface111of the head110for cleaning contact with an oral surface, preferably teeth. While the set of cleaning elements119is particularly suited for brushing teeth, the set of cleaning elements119can also be used to clean oral soft tissue, such as a tongue, gums, or cheeks instead of or in addition to teeth. As used herein, the term “cleaning element” is used in a generic sense to refer to any structure that can be used to clean or massage an oral surface through relative surface contact.

The set of cleaning elements119can be connected to the head110in any manner known in the art. For example, anchor free tufting (AFT) could be used to mount the cleaning elements. In AFT, a plate or membrane is secured to the brush head such as by ultrasonic welding. The bristles (or other elastomeric elements) extend through the plate or membrane. The free ends of the bristles on one side of the plate or membrane perform the cleaning function. The ends of the bristles on the other side of the plate or membrane are melted together by heat to be anchored in place. Any suitable form of cleaning elements may be used in the broad practice of this invention. Alternatively, the bristles could be mounted to tuft blocks or sections by extending through suitable openings in the tuft blocks so that the base of the bristles is mounted within or below the tuft block. Staple technology may also be used.

Furthermore, if desired, the rear surface112of the head110may also comprise additional structures for oral cleaning, such as a soft tissue cleanser. Such soft tissue cleansers are typically constructed of a thermoplastic elastomer (“TPE”) and include one or more projections, such as nubs and/or ridges, for engaging and massaging soft oral tissue, such as the tongue.

Still referring toFIGS. 1 and 2, the handle120is formed of a lower transverse section121and an upper transverse section122, which are coupled together. The upper transverse section122, which comprises an outer surface123and a bottom surface126, is integrally formed with the neck115and the head110to form a unitary structure. The lower transverse section121, which comprises a top surface125and an outer surface124, is coupled to the upper transverse section122. More specifically, the top surface125of the lower transverse section121is coupled to the bottom surface126of the upper transverse section122. The coupling of the lower and upper transverse sections121,122can be achieved in any manner known in the art such as, for example, thermal welding, sonic welding, a tight-fit assembly, a coupling sleeve, adhesion, fasteners or other techniques. In one exemplary embodiment, the coupling of the upper and lower transverse sections121,122are coupled together via a bond that is formed between the materials of the upper and lower transverse sections121,122during an injection molding process.

It should be noted that while the exemplary embodiments of the handles120,220of the oral care implements100,200ofFIGS. 1-5include two transverse sections, in other embodiments of the invention, more than two transverse sections may used to create the handles120,220. Moreover, gripping overlays, such as TPE overlays, can be included on one or all of the transverse sections as desired. Furthermore, while the transverse sections of the handles are arranged in an upper-lower relative arrangement in the exemplary embodiments of the invention, the invention is not so limited and the transverse sections may be arranged in a side-by-side (i.e., left-right) or angled relative arrangement.

The outer surface124of the lower transverse section121and the outer surface123of the upper transverse section122collectively form the outer surface of the handle120that enables a user to manipulate the oral care implement100during use. As can be seen inFIG. 4, the outer surfaces124,123collectively form an elliptical transverse cross-sectional profile for the handle120.

In one embodiment, one of the lower and upper transverse sections121,122is formed of a rigid material while the other one of the lower and upper transverse sections121,122is formed of an elastomeric material. In one such embodiment, the lower transverse section121is formed of an elastomeric material while the upper transverse section122is formed of a rigid material. In another such embodiment, the lower transverse section121is formed of a rigid material while the upper transverse section122is formed of an elastomeric material. In another embodiment, both the lower and upper transverse sections121,122are formed of a rigid material.

Suitable rigid materials include hard plastics, such as, without limitation, polyethylene, polypropylene (PP), polyamide, polyester, cellulosics, SAN, acrylic, ABS or any other of the commonly known hard thermoplastics used in toothbrush manufacturing. One suitable elastomeric material is a thermoplastic elastomer (“TPE”). In certain embodiments, the TPE has a hardness in a range of 8 to 65 shore A. However, the exact hardness of the TPE used in any specific embodiment of the invention will be dictated by the percentage of the transverse cross-sectional area of the handle occupied by the transverse section formed of TPE.

For reasons that will become apparent from the discussion below, the material selected for the upper transverse section122is preferably a transparent material, irrespective of whether the upper transverse section122is a rigid material or an elastomeric material. It should be understood that as used herein, the term “transparent” includes both colored transparency and colorless transparency, and is intended to include any material through which an embedded feature is visible therethrough as described below.

Suitable transparent materials include, without limitation, clarified PP, SAN, copolyester, transparent TPE, PET, ABS, CAP, PU. While not preferred, in some embodiments, the upper transverse section122can be formed of an opaque or other non-transparent material, irrespective of whether the upper transverse section122is a rigid material or an elastomeric material. The lower transverse section121can be formed of a transparent material or an opaque material, irrespective of whether the lower transverse section121is a rigid material or an elastomeric material

In the embodiment ofFIGS. 1-4, the lower transverse section121is formed of a transparent elastomeric material and the upper transverse section122is formed of a transparent rigid material. However, in another embodiment, the lower transverse section121is formed of an elastomeric rigid material and the upper transverse section122is formed of a transparent elastomeric material. In still another embodiment, the lower transverse section121is formed of a transparent rigid material and the upper transverse section122is formed of a transparent rigid material. In a further embodiment, the lower transverse section121is formed of an opaque rigid material and the upper transverse section122is formed of a transparent elastomeric material. In an even further embodiment, the lower transverse section121is formed of an opaque rigid material and the upper transverse section122is formed of a transparent rigid material. In a yet further embodiment, the lower transverse section121is formed of an opaque elastomeric material and the upper transverse section122is formed of a transparent rigid material.

Referring still toFIGS. 1 and 2concurrently, the handle120of the oral care implement100further comprises a decorative member150disposed between the lower transverse section121and the upper transverse section122. The decorative member150comprises a top surface153and a bottom surface154. The decorative member150can be any type of element that can be used to effectuate and/or include a visual indicia. For example, the decorative member150can be a layer of ink (or other colorant or pigment) printed directly onto one of the upper and/or lower transverse sections121,122. In other embodiments, the decorative member150may be a decal, which can be a single or multi-layer laminate, that is positioned between the lower and upper transverse sections121,122as illustrated. When the decorative member150is a decal, the visual indicia can be on one or both surfaces of the decal. Examples of visual indicia include, without limitation, logos, alphanumeric symbols, characters, animals, plants, patterns, symbols, combinations thereof, and/or other graphical elements.

In the illustrated embodiment, the bottom surface154of the decorative member150is in contact with the top surface125of the lower transverse section121while a portion of the top surface153of the decorative member150is in contact with the bottom surface126of the upper transverse section122. As a result, the decorative member150is “sandwiched” between the lower and upper transverse sections121,122. As can be seen, the entirety of the top surface153of the decorative member150is not in contact with the bottom surface126of the upper transverse section122. Therefore, the decorative member150can be conceptually divided into a covered portion152that is in contact with the bottom surface126of the upper transverse section122and an exposed portion151that is not in contact with the bottom surface126of the upper transverse section122. Thought of another way, the upper transverse section122overlies the covered portion152of the decorative member150while the exposed portion151is exposed via an aperture140, as will be discussed in more detail below.

As mentioned above, the upper transverse section122comprises an aperture140extending therethrough. The aperture140forms a transverse passageway through the upper transverse section122extending from outside of the oral care implement100to the exposed portion151of the decorative member150. In one embodiment, the aperture140occupies between 5% to 95% of the transverse cross-sectional area of the upper transverse section122(for at least one axial position). In a more specific embodiment, the aperture140occupies between 25% to 75% of the transverse cross-sectional area of the upper transverse section122(for at least one axial position). Of course, the invention is not to be limited by the size of the aperture140and may occupy more or less of the transverse cross-sectional area of the upper transverse section122as desired. Furthermore, in the exemplified embodiment, the aperture140is an oval that is elongated along the longitudinal axis A-A. Other shapes and sizes of the aperture140can be used to expose different sizes and shapes of the decorative member150or portions thereof as would be known to persons skilled in the art.

As noted above, in a preferred embodiment, the upper transverse section122is formed of a transparent material so that the covered portion152of the decorative member150, in addition to the exposed portion151, are visible to user. Specifically, the covered portion152of the decorative member150is visible through the transparent material of the upper transverse section122while the exposed portion is visible through the aperture140. While the visibility of the covered portion152of the decorative member150may be distorted or otherwise altered due to being viewed through the transparent material, the exposed portion151of the decorative member150will be clearly viewable without any distortion as it is viewed in an unimpeded manner via the aperture140.

The exposed portion151of the decorative member150is circumferentially surrounded by the covered portion152of the decorative member150. Thus, in the exemplified embodiment, the covered portion152of the decorative member150is a perimeter portion of the decorative member150. In other embodiment, the covered portion152of the decorative member150may only consist of a portion (or portions) of the perimeter of the decorative member150so that at least a part of the peripheral edge of the decorative member150is exposed through the aperture140. In other embodiments, the entirety of the decorative member150may be located within and exposed via the aperture140. In such an embodiment, the entirety of the decorative member150is the exposed portion151.

In certain embodiments, the visual indica are located, at least in part, on the exposed portion151of the decorative member150. Such positioning of the visual indicia enhances visibility of the visual indicia because it is not covered by the upper transverse section122. However, as will be described below, the exposed portion151of the decorative member150is still protected against wear and other contact damage because it is recessed with respect to the outer surface123of the handle120.

Referring now toFIGS. 2 and 3concurrently, the details of the aperture140(and its forming structure) will be described in more detail. When the handle120of the oral care implement100is assembled (as illustrated inFIGS. 2 and 3), the aperture140forms a basin145in the outer surface123of the upper transverse section122. The floor of the basin145is formed by a top surface153of the decorative member150and, more specifically, the top surface153of the exposed portion151of the decorative member150. An upstanding wall141extends upward from the top surface153of the exposed portion151of the decorative member150and terminates at the outer surface123of the upper transverse section122. In the illustrated embodiment, the upstanding wall141extends from the top surface153of the decorative member150in an inclined manner relative thereto. In one embodiment, the upstanding wall141is inclined at an angle Θ relative to the top surface153, wherein the angle Θ is in a range between 93° to 135°. However, the invention is not so limited and, in other embodiments, the upstanding wall141may extend from the top surface153of the decorative member150in a substantially normal manner.

As mentioned above, the exposed portion151of the decorative member150is recessed relative to the outer surface123of the upper transverse section122. Thus, a user can grip the handle120without coming into contact with the decorative member150. This structure protects the decorative member150against wear and other contact-induced damage. Moreover, even if the oral care implement100is placed against a flat surface, such as a countertop, the decorative member150will not contact the flat surface because it is recessed relative to the outer gripping surface of the handle120.

Referring now toFIG. 4, a transverse cross-section of a portion of the oral care implement100that does not include the aperture140is illustrated. While the cross-sectional view ofFIG. 4is taken at a location near the proximal end101of the handle120, the description below is also applicable to the other portions of the handle120that do not include the aperture140but include the decorative member150. In these sections of the handle120, the covered portions152of the decorative member150are “sandwiched” between the lower and upper transverse sections121,122. In embodiments where the upper transverse section122is transparent, the decorative member150is visible through the upper transverse section122.

On the portions of the handle120that do not include the aperture140and do not include the decorative member150, the first transverse section121is coupled directly to the upper transverse section122through direct contact and coupling between the top surface125of the first transverse section121to the bottom surface126of the upper transverse section122in the manner discussed above. Of course, an intervening layer and/or material may be used in certain embodiments. Moreover, while the top and bottom surfaces125,126of the upper and lower transverse sections122,121are substantially planar in the exemplified embodiment, the invention is not so limited. In other embodiments, one or both of the top and bottom surfaces125,126of the upper and lower transverse sections122,121can be contoured and/or can include mating topography in the form of protrusions and depressions if desired.

Referring toFIG. 5, a second embodiment of an oral care implement200in accordance with the present invention is illustrated. The oral care implement200will be described using a similar numbering scheme as used for the oral care implement100discussed above, with the exception that the “200” series of numbers will be used. The oral care implement200is substantially similar to the oral care implement100except for differences discussed below. In order to avoid redundancy, only those aspects of the oral care implement200that differ from the oral care implement100will be described below with the understanding that the discussion above with respect to the oral care implement100is applicable in all other regards.

The oral care implement200comprises a handle220and a head210, the head210is connected to the handle220by a neck215. The handle220comprises a lower transverse section221and an upper transverse section222. In this embodiment, the lower transverse section221is integral with the neck215and the head210to form a unitary structure. The upper transverse section222is a separate component from the lower transverse section221, the neck215and the head210. The upper transverse section222is coupled to the lower transverse section221in the manner described above with reference toFIGS. 1 and 2. In both the embodiment ofFIG. 2and the embodiment ofFIG. 5, when the selected transverse section is integral with the neck and head, it is preferred that the selected transverse section be constructed of a suitable rigid material so that the head and neck have sufficient structural integrity.

A first method of forming the oral care implement100according to one embodiment of the present invention will now be described. While the method will be described below with respect to one particular embodiment of the oral care implement100regarding particular materials of construction of the transverse sections121,122and the decorative label150, it is to be understood that any of the material permutations described above can be utilized in the manufacturing process through suitable substitution.

At an initial step, the upper transverse section122of the handle120is formed. The upper transverse section122includes the aperture140. In one embodiment, the upper transverse section122is formed via a molding process, such as injection molding. In one embodiment of the injection molding process, a first mold half and second mold half are positioned together that collectively form an internal space/volume that corresponds to the size and shape of the upper transverse section122. A transparent rigid plastic, in molten form, is injected into the space/volume formed by the first mold half and the second mold half to form the upper transverse section122.

The decorative member150is applied to the bottom surface126of the upper transverse section122to at least partially cover (i.e., overlie) the aperture140. In this embodiment, the decorative member is preferably a decal, or other type of label, as described above. In one embodiment, the decorative member140is applied to the bottom surface126of the upper transverse section122to cover the entirety of the aperture140. The decorative member150is applied to the upper transverse section122subsequent to its injection molding formation and after adequate cooling of the molten transparent rigid plastic in one embodiment. In another embodiment, the decorative member150is positioned within the space/volume formed by the first and second mold halves prior to the injection of the molten transparent rigid plastic. In such an embodiment, the application of the decorative member150to the upper transverse section122occurs concurrently with the formation of the upper transverse section122.

While an injection molding process is described above to form the upper transverse section122with the aperture therein140, it is possible to form the aperture140in the upper transverse section122at a subsequent processing step, such as by milling, machining or drilling the previously formed upper transverse section122. Moreover, it is possible to form the upper transverse section122using other manufacturing techniques, such as stamping, machining, milling, and/or combinations thereof. Finally, while not required in all embodiments of the inventive method, during the formation of the upper transverse section122, the neck115and the head120of the oral care implement100are also concurrently and integrally formed as a unitary structure with the upper transverse section122using one of the techniques disclosed above, and preferably injection molding.

Once the upper transverse section122is formed and the decorative member150is applied thereto as described above, the lower transverse section121of the handle120is formed and coupled to the upper transverse section122so that the decorative member150is disposed therebetween and at least a portion151of the decorative member150is exposed via the aperture140. In one embodiment, the lower transverse section121is formed via a molding process, such as injection molding. In one embodiment, the lower transverse section121injection molding process is accomplished by leaving the recently formed upper transverse section122(with the applied decorative member150) in the first mold half, removing the second mold half, and positioning a third mold half into contact with the first mold half. In this embodiment, the third mold half will have a cavity/space formed therein that corresponds in size and shape to the lower transverse section121and the third mold half will be aligned with the first mold half so that the cavity/space will be in properly aligned spatial communication with the recently formed upper transverse section122(with the applied decorative member150). Once properly aligned, a transparent TPE, in molten form, is injected into and fills the cavity/space of the third mold half, thereby contacting and covering the rear surface154of the decorative member150and the exposed portions of the bottom surface126of the upper transverse section122.

While an injection molding process is described above to form the lower transverse section121, it is possible to form the lower transverse section121using other manufacturing techniques, such as stamping, machining, milling, and/or combinations thereof. Furthermore, while the upper transverse section122(with the applied decorative member150) remains in-situ within the first mold half while the second and third mold halves are alternated in the above-desired injection molding process, in certain embodiments, the upper transverse section122(with the applied decorative member150) will be transferred out of the first mold half after adequate cooling and positioned in an appropriate space of two different mating mold halves.

Preferably, when an injection molding process is used, the transparent TPE of the lower transverse section121and the transparent rigid plastic of the upper transverse section122are selected so that a suitable chemical bond develops therebetween. Of course, materials can be selected that do not chemically bond. In such circumstances, the lower and upper transverse sections121,122will be designed so that a mechanical coupling will be effectuated between the lower and upper transverse sections121,122, with the decorative member150secured therebetween. Alternatively, an intermediate layer can be disposed between the lower and upper transverse sections121,122to effectuate a suitable chemical bond and/or mechanical fit.

A second method of forming the oral care implement200according to another embodiment of the present invention will now be described. While the method will be described below with respect to one particular embodiment of the oral care implement200regarding particular materials of construction of the transverse sections221,222and the decorative label250, it is to be understood that any of the material permutations described above can be utilized in the manufacturing process through suitable substitution.

At an initial step, the lower transverse section221of the handle220is formed. In one embodiment, the lower transverse section221is formed via a molding process, such as injection molding. In one embodiment of the injection molding process, a first mold half and second mold half are positioned together that collectively form an internal space/volume that corresponds to the size and shape of the lower transverse section221. A transparent rigid plastic, in molten form, is injected into the space/volume formed by the first mold half and the second mold half to form the lower transverse section221.

The decorative member250is applied to the top surface225of the lower transverse section222. The decorative member250in this embodiment can be a decal or a layer of ink printed on the top surface225. The decorative member250is applied to the lower transverse section221subsequent to its injection molding formation and after adequate cooling of the molten transparent rigid plastic in one embodiment. In another embodiment, the decorative member250is positioned within the space/volume formed by the first and second mold halves prior to the injection of the molten transparent rigid plastic. In such an embodiment, the application of the decorative member250to the lower transverse section221occurs concurrently with the formation of the lower transverse section221.

While an injection molding process is described above to form the lower transverse section221, it is possible to form the lower transverse section221using other manufacturing techniques, such as stamping, machining, milling, and/or combinations thereof. Finally, while not required in all embodiments of the inventive method, during the formation of the lower transverse section221, the neck215and the head220of the oral care implement200are also concurrently and integrally formed as a unitary structure with the lower transverse section222using one of the techniques disclosed above, and preferably injection molding.

Once the lower transverse section221is formed and the decorative member150is applied thereto as described above, the upper transverse section222of the handle220is formed and coupled to the lower transverse section221so that the decorative member250is disposed therebetween and at least a portion251of the decorative member250is exposed via an aperture240in the upper transverse section222. In one embodiment, the upper transverse section222is formed via a molding process, such as injection molding. In one embodiment, the upper transverse section222injection molding process is accomplished by leaving the recently formed lower transverse section221(with the applied decorative member150) in the first mold half, removing the second mold half, and positioning a third mold half into contact with the first mold half. In this embodiment, the third mold half will have a cavity/space formed therein that corresponds in size and shape to the upper transverse section222and the third mold half will be aligned with the first mold half so that the cavity/space will be in properly aligned spatial communication with the recently formed lower transverse section221(with the applied decorative member250). Once properly aligned, a transparent TPE, in molten form, is injected into and fills the cavity/space of the third mold half, thereby contacting and covering a portion252of the top surface253of the decorative member250and the exposed portions of the top surface225of the lower transverse section221. The third mold has a plug portion that corresponds in size and shape to the aperture240and contacts the upper surface253of the decorative member250. As a result, the aperture240is formed in alignment with a portion251of the decorative member250that will remain exposed via the resulting aperture240.

While an injection molding process is described above that forms the upper transverse section222, it is possible to form the upper transverse section222using other manufacturing techniques, such as stamping, machining, milling, and/or combinations thereof. Furthermore, while the lower transverse section221(with the applied decorative member150) remains in-situ within the first mold half while the second and third mold halves are alternated in the above-desired injection molding process, in certain embodiments, the lower transverse section221(with the applied decorative member250) will be transferred out of the first mold half after adequate cooling and positioned in an appropriate space of two different mating mold halves.

Preferably, when an injection molding process is utilized, the transparent TPE of the upper transverse section222and the transparent rigid plastic of the lower transverse section221are selected so that a suitable chemical bond develops therebetween. Of course, materials can be selected that do not chemically bond. In such circumstances, the lower and upper transverse sections221,222will be designed so that a mechanical coupling will be effectuated between the lower and upper transverse sections221,222, with the decorative member250secured therebetween. Alternatively, an intermediate layer can be disposed between the lower and upper transverse sections221,222to effectuate a suitable chemical bond and/or mechanical fit.

While a number of embodiments of the current invention have been described and illustrated in detail, various alternatives and modifications will become readily apparent to those skilled in the art without departing from the spirit and scope of the invention. As various changes could be made in the above methods, compositions and structures without departing from the scope of the invention, it is intended that all matter contained in this application, including all mechanisms and/or modes of interaction described above, shall be interpreted as illustrative only and not limiting in any way the scope of the appended claims.