Source: https://patents.google.com/patent/US10405642B2/en
Timestamp: 2019-12-10 21:09:08
Document Index: 96237193

Matched Legal Cases: ['art 1', 'art 1', 'art 9', 'arts 2', 'art 1', 'art 9', 'art 1', 'art 1', 'art 1', 'art 1', 'arts 9', 'art 1', 'art 1', 'art 2', 'art 21', 'art 1', 'art 22', 'art 22', 'art 1', 'art 21', 'art 22', 'art 1', 'art 1', 'art.\n3', 'art.\n12', 'art.\n17', 'art.\n19', 'art;\n24', 'art.\n26', 'Application No. 13', 'Application No. 10']

US10405642B2 - Toothbrush and process for producing the same - Google Patents
US10405642B2
US10405642B2 US14/962,542 US201514962542A US10405642B2 US 10405642 B2 US10405642 B2 US 10405642B2 US 201514962542 A US201514962542 A US 201514962542A US 10405642 B2 US10405642 B2 US 10405642B2
US14/962,542
US20160088925A1 (en
2002-12-19 Priority to DE10259723.5 priority
2002-12-19 Priority to DE10259723 priority
2003-03-17 Priority to US10/388,744 priority patent/US6988777B2/en
2005-12-02 Priority to US11/291,911 priority patent/US7162767B2/en
2006-12-27 Priority to US11/645,664 priority patent/US7549187B2/en
2009-03-05 Priority to US12/379,992 priority patent/US7774891B2/en
2010-07-09 Priority to US12/805,064 priority patent/US7992247B2/en
2011-06-29 Priority to US13/067,844 priority patent/US8418306B2/en
2013-02-12 Priority to US13/765,151 priority patent/US8613123B2/en
2013-11-19 Priority to US14/083,896 priority patent/US9232852B2/en
2015-12-08 Priority to US14/962,542 priority patent/US10405642B2/en
2015-12-08 Application filed by Trisa Holding filed Critical Trisa Holding
2016-03-31 Publication of US20160088925A1 publication Critical patent/US20160088925A1/en
2019-09-10 Publication of US10405642B2 publication Critical patent/US10405642B2/en
239000004033 plastic Substances 0 claims 8
229920003023 plastics Polymers 0 claims 8
210000003128 Head Anatomy 0 description 56
238000003466 welding Methods 0 description 36
This is a Continuation of application Ser. No. 14/083,896 filed Nov. 19, 2013, which in turn is a Continuation of application Ser. No. 13/765,151 filed Feb. 12, 2013 which in turn is a Continuation of application Ser. No. 13/067,844 filed Jun. 29, 2011 which in turn is a Continuation of application Ser. No. 12/805,064 filed Jul. 9, 2010 which in turn is a Continuation of application Ser. No. 12/379,992 filed Mar. 5, 2009 which in turn is a Continuation of application Ser. No. 11/645,664 filed Dec. 27, 2006, which in turn is a Continuation of application Ser. No. 11/291,911 filed Dec. 2, 2005, which in turn is a Division of application Ser. No. 10/388,744 filed Mar. 17, 2003. The entire disclosures of the prior applications are hereby incorporated by reference herein in their entireties.
FIGS. 1A-1C show a toothbrush according to the invention with a rigid curved carrier element,
FIGS. 2A and 2B show a toothbrush with an elastic curved carrier element;
FIGS. 3A and 3B show toothbrushes with a carrier element with an undulating top surface;
FIGS. 4A and 4B show a toothbrush with a carrier element with a step;
FIGS. 5A and 5B show a toothbrush with two carrier elements and a shoulder located therebetween;
FIGS. 6A and 6B show a toothbrush with a carrier element comprising three segments;
FIGS. 7A and 7B show a toothbrush with a carrier element with a platform-like elevation;
FIGS. 8A and 8B show a toothbrush with a carrier element with an undulating top surface;
FIGS. 9A and 9B show a toothbrush with three carrier elements;
FIGS. 11A-11C show a head part for a toothbrush with three carrier elements;
FIGS. 12A and 12B show a toothbrush with a carrier element with a soft component and a hard component;
FIGS. 13A-13C, and FIG. 14 show toothbrushes with a curved carrier element and bristles which can be moved relative thereto;
FIGS. 15A-15D and FIGS. 16A-16C show toothbrushes with a carrier element with a hard component in the form of a lattice; and
FIGS. 17A-17C show a toothbrush with a carrier element which is only connected to it at certain points.
The carrier element 2, for the purpose of accommodating the clusters of bristles 3, has a plurality of cutouts 6 running between its top side 4 and its rear surface 8. By virtue of the alignment of these holes 6, it is possible to adjust the setting angle of the clusters of bristles 3. In terms of production, however, it is preferred for the holes 6 to run in the direction of the normal of the top surface 4. For fastening on the carrier element 2, the rear ends 3 a of the clusters of bristles 3 are melted by a heating die 12 (see FIG. 1C), with the result that a bristle coating 11 is produced. It is possible to provide further cleaning elements 19 which are made of flexible material (see FIGS. 5A and 5B) and have preferably been produced during the production of the carrier element 2 by two-component injection molding, before the bristle-covering operation. Even if the carrier element 2 itself consists of soft material and hard material, two-component injection molding is preferably used in order to produce it.
In the case of the toothbrush shown in FIGS. 1A and 1B, the carrier element 2 consists of a hard material, is largely rigid and is already arched concavely, both in the longitudinal direction and in the transverse direction, before it is installed in the head part 1. Its top side 4 and underside 8 run parallel to one another. The material thickness is preferably less than 5 mm, particularly preferably less than 3 mm. The bristles are all the same length, with the result that a bristle profile 14, 15 which follows the profile of the top surface 4 and of the front surface 5, and is concave in the longitudinal and transverse direction, is produced.
As is shown in FIG. 1C, the clusters of bristles 3 are first of all inserted into the cutouts 6 in the carrier element. A heating die 12, of which the top side 13 is adapted to the profile of the rear side 8 of the carrier element, is used to melt the bristle ends 3 a, with the result that the bristle coating 11 is formed. In the case of a contoured die, the bristle melt is advantageously of constant thickness throughout. Then, the carrier element 2 is connected to the head part by means of ultrasonic welding. For this purpose, the surface 2 a projects laterally, beyond the border part. The resulting shoulder 2 b comes into abutment against a shoulder 7 b of the cutout 7 during insertion into the head part 1, it being possible for the contact surface to serve as welding surface 10.
Furthermore, it is also possible for the bottom end 9 a of the border part 9, together with the base 7 a of the cutout 7, to serve as welding surface 10′. For this purpose, the parts 2 b and/or 9 a may have a tapered border 31 (see FIGS. 1C, 15A and 16A), these serving, during the welding operation, as an energy concentrator and a reservoir for material which is to be liquefied.
In the case of the example from FIGS. 2A and 2B, the carrier element 2, or the bristle-carrying surface 2 a thereof, consists largely of a thin hard material. It is flat when not covered with bristles and is thus easy to cover with bristles. During the bristle-covering operation, it is moved by the heating die into the arched shape illustrated and inserted into the cutout 7, with the result that it arches outward in the transverse direction and the clusters of bristles 3 are fanned out relative to one another. This produces a longitudinally flat and transversely convex bristle profile 14 and 15, respectively. Tests show that the bristle melt 11 adapts itself to the topography without fracturing. The carrier element 2 is then connected to the head part 1. In order to avoid material incompatibilities during ultrasonic welding, the border part 9 preferably consists of the hard component.
FIG. 3A shows a longitudinal section of a toothbrush with a rigid carrier element 2, of which the top surface 4 is of undulating form and the rear surface 8 is flat. The thickness of the bristle-carrying surface 2 a is preferably between not less than 3 mm and not more than 10 mm. Although all of the clusters of bristles 3 are in fact of the same basic length, their free lengths from the root 3 c on the top surface 4 as far as their front end 3 b differ on account of the height profile of the plate 2 a, with the result that different elastic properties of the bristles are realized. The angle of the cutouts 6, and thus the setting angle of the bristles, likewise varies. By means of such a carrier element, it is thus easy to produce bristle plates with different free bristle lengths and profile shapes, by use of a conventional flat AFT heating die.
FIG. 3B shows a cross section of modification of the example from FIG. 3A, in the case of which the profile of the underside 8 has been adapted to that of the top side 4. The advantages are material-related savings and shorter cycles during the production of the carrier elements 2 on account of quicker cooling. However, it is necessary to use a heating die which is adapted to the underside 8.
The toothbrush shown in FIGS. 4A and 4B has a carrier element 2 of which the bristle-carrying surface 2 a has a step 17 on the top side 4 and underside 8. The bristle profile 14 in the longitudinal direction follows the profile of the top surface 4 or front surface 5. Possible welding surfaces, once again, are the surface 10, already described in conjunction with FIG. 1, beneath the surface 2 a and the surface 10′ on the base of the cutout 7. The latter is preferred since, on account of the planar base 7 a, it is possible to form a continuous welding surface 10′. In the case of the welding surface 10, there is a non-welded location at the topography step 17. The profile of the bristle ends and the front surface 5 in the transverse direction is arched outward (FIG. 4B) and corresponds, in section, to FIG. 2B.
FIGS. 5A and 5B show a toothbrush with two carrier elements 2 which are arranged in two cutouts 7 to the sides of an elevated region 18 in the center of the head part 1. This produces a front surface 5 with two different levels. The carrier elements 2 are fastened, as has been described above, by ultrasonic welding along the welding surface 10 on the border of the carrier elements 2, said welding surface being located outside the bristle arrangement, as seen in plan view (FIG. 5B). It is also possible to weld just the surfaces on the periphery of the head part 1, while the surfaces 10″ adjacent to the elevated region 18 remain unwelded. A sufficient hold is achieved by welding at least 25% of the possible contact surfaces. The non-welded surfaces 10″ can provide the brush here with flexibility, in particular if the elevated region 18 consists of an elastic material, with the result that the brush head yields in a partially resilient manner during use.
Flexible cleaning elements 19 are arranged on the elevated region 18. Further in particular also flexible cleaning elements 20 are located outside the elevated region 18. The head part 1 has been produced with these elements, and the possibly provided elastic zone, by two-component injection molding. The elevated region 18 may also be realized by a further carrier plate which, as in the example of FIGS. 9A and 9B, is fitted precisely, with the two other carrier elements 2, into a common cutout 7.
FIGS. 6A and 6B show a similar toothbrush, although in this case the central elevated region 18 is realized by a single carrier element 2 with a stepped height profile. This is narrower in the central region 18, and the shape of the cutout 7 is adapted thereto. Welding takes place beneath the border 2 b of the carrier element 2 and in the border regions of the elevated region 18, with the result that the welding surface 10 runs on two levels. No welding takes place at the step locations 17. As an alternative, welding takes place on the base 7 a of the cutout 7, along the surface 10′.
FIGS. 7A and 7B show a further toothbrush with a centrally elevated region 18. The carrier element 2 has a central hole, with the result that it can be fitted over the elevated region 18. The carrier element 2 is welded to the head part 1 along the hole and on its outer border, as a result of which additional stiffening is achieved. Clusters of bristles 3 and flexible elements 20 are located on the carrier element 2.
The carrier element 2 of the toothbrush shown in FIGS. 8A and 8B is of undulating form in the longitudinal and transverse directions, this resulting in a correspondingly structured front surface 5. The bristle-carrying surface 2 a is also curved at the border, with the result that the contact and welding surface 10 is likewise curved. As an alternative, welding may take place in a single plane on the base 7 a (welding surface 10′).
FIGS. 9A and 9B show a toothbrush with two different levels, realized by three separate carrier elements 2 with border parts 9 of different lengths L, L′. These are inserted into three cutouts 7 separated by webs 30 or into a common cutout (not illustrated) and welded on the base 7 a thereof (welding surface 10′). As an alternative, welding may also take place on two levels on the surface 10, beneath the respective bristle-carrying surfaces 2 a. The central carrier element 2 comprises both conventional bristles and a flexible cleaning element 19.
FIGS. 11A-11C show a head part 1 for a toothbrush with three carrier elements 2. Three cutouts 7 are provided for accommodating the latter, transverse webs 30, in particular made of flexible material, being arranged between the individual cutouts. Welding takes place only on the periphery of the head part 1, along the line 10. The front surface may be designed, for example, as in FIG. 9.
FIGS. 12A and 12B show a toothbrush with a carrier element with a soft component and a hard component. The actual bristle-carrying part 2 a of the carrier element 2 is formed from a soft material 21, which is elastically deformable. The bristles are thus suspended and/or anchored in an elastic manner. The cushion-like part 21 yields under loading, which is particularly advantageous for the teeth. For easier connection to the head part 1, the carrier element 2 has a peripheral frame part 22 made of preferably the same hard material as the head part. The arching is produced during the production of the carrier element 2. The underside of the frame part 22 rests on corresponding shoulders 7 b in the recess 7 in the head part 1, the contact surface defining the welding surface 10. The cavity between the underside 8 of the carrier element 2 and the base 7 a of the cutout 7 allows, during use, a certain deflection of the elastic part 21, and in some circumstances even a reversal from the convex state to the concave state.
FIGS. 13A-13C and FIG. 14 show a carrier element and the head part of the toothbrush in the case of which the rear ends 3 a of the clusters of bristles 3, rather than being firmly fused to the bristle-carrying surface 2 a, can be displaced in the holes 6. This is achieved by suitable material selection, e.g., polypropylene for the carrier element and polyamide for the bristle filaments. Furthermore, rather than being melted to form a uniform bristle coating, the rear ends 3 a are melted, by a heating die 12 having protrusions 23, to form separate webs 24 made of bristle melt. For the resilient mounting of the clusters of bristles 3, an elastic membrane 25 is arranged in the head part. In the case of FIG. 13C, this membrane is arranged within a cutout 7 and is placed in position before the carrier element 2 is fitted. In the case of FIG. 14, it forms an outer surface of the head part. It is molded on during the production of the head part. The rear bristle ends 3 a, which are melted in a die-like manner, are forced upward by the membrane, with the result that the bristle-carrying surface 2 a arches to form a cushion.
FIGS. 15A-15D and FIGS. 16A-16C show toothbrushes with a two-component carrier element 2. The latter comprises a hard component in the form of a lattice, in this case formed from sleeves 26, with holes 6 for accommodating clusters of bristles, and webs 27 which connect said sleeves. Also provided is a frame part 22 which is made of the hard component and of which the edge 31, which in the application case is directed toward the base, is of tapered configuration and serves as welding surface 10. The region between the sleeves 26 is filled with an elastic soft material 28. In the example from FIG. 15, the material 28 is injected above and beneath the webs. This produces a flat elastic structure, i.e., a toothbrush with a flat front surface 5 which deforms during use. In the example from FIG. 16, the material 28 is only injected above the web. The shape of the top surface 4 is influenced by the shape of the injection mold. In the case of FIG. 16, this is selected so as to produce a cushion which yields during use. FIG. 15D shows the view of a head part 1 with the carrier element 2 inserted, the webs 27, which connect the sleeves 26 and are covered by soft material 28, only being depicted for explanatory purposes.
FIGS. 17A and 17B show the side view, in the longitudinal and transverse directions, of a further toothbrush, in the case of which the carrier plate 2 is only welded to the head part 1 in four subregions 10. This four-point suspension renders the carrier plate particularly compliant. For this purpose, the head part has lateral cutouts 30 through which a cavity 32 beneath the carrier plate is accessible. The carrier plate is spaced apart from the head part there to a considerable extent, i.e., by more than 0.5 mm. Deposits between the brush head and carrier plate may thus be washed out to good effect. The carrier plate consists predominantly of elastomeric material or of a thin layer, e.g., less than 1 mm, of a hard component and can be deflected in a flexible manner in relation to the welding surfaces 10. The carrier plate is preferably provided with a lateral border of 2 mm or more (not shown here) in order that the unsightly bristle melt is not visible to the user. All of the variants described above may also be realized as exchangeable heads, without the carrier element being permanently welded to the toothbrush handle. It is also possible for the flexible carrier plate to perform a sensor function, e.g., for monitoring the contact pressure.
a head part connected to the handle part, the head part having a front face and a rear face; and
at least one carrier element non-releasably connected to the head part, the at least one carrier element having a top surface, a rear surface and clusters of bristle filaments having a rear end melted to form a bristle melt, wherein:
the at least one carrier element contains an additive which is not used in the head part and the handle part;
the head part contains an elastic material integrally molded with the head part; and
the elastic material is at least partially arranged beneath the at least one carrier element.
2. The toothbrush according to claim 1, wherein
the at least one carrier element comprises a different color than the head part.
3. The toothbrush according to claim 1, wherein
the at least one carrier element comprises additives such as flavorings, temperature indicators or antibacterial substances.
4. The toothbrush according to claim 1, wherein
the bristle melt forms separate webs.
5. The toothbrush according to claim 1, wherein
the head part contains a plurality of cutouts running between the top surface and the rear surface of the at least one carrier element, and
the clusters of bristle filaments are guided through the cutouts.
6. The toothbrush according to claim 5, wherein
the cutouts are located at least partially in an elastic material of the at least one carrier element.
7. The toothbrush according to claim 5, wherein
the cutouts are located at least partially in a hard plastic material of the at least one carrier element.
8. The toothbrush according to claim 1, wherein
the at least one carrier element is a two-component carrier element.
9. The toothbrush according to claim 1, wherein
the bristle melt at least partially covers the rear surface of the at least one carrier element.
10. The toothbrush according to claim 1, wherein
the at least one carrier element is made of a hard plastic material.
11. The toothbrush according to claim 1, wherein
the at least one carrier element is made of a same hard plastic material as the head part.
12. The toothbrush according to claim 1, wherein
the at least one carrier element is made of a hard plastic material and a soft plastic material.
13. The toothbrush according to claim 12, wherein
the hard plastic material is at least one of PET, acrylonitrile-butadiene-styrene, styrene-acrylonitrile, and polypropylene; and
the soft plastic material is a thermoplastic elastomer.
14. The toothbrush according to claim 1, wherein
the at least one carrier element is connected to the head part only in sub-regions.
15. The toothbrush according to claim 1, wherein
in a contact region of the at least one carrier element and the head part, edges or grooves are formed.
16. The toothbrush according to claim 1, wherein
the at least one carrier element is at least partially spaced apart from the head part.
17. The toothbrush according to claim 1, wherein
the at least one carrier element includes non-bristle containing cleaning elements made of a soft material.
18. The toothbrush according to claim 1, wherein
the elastic material and the at least one carrier element contact one another in a front end region of the head part.
19. The toothbrush according to claim 1, wherein
in a central portion of the head part an elevated region is provided which includes multiple non-bristle containing flexible cleaning elements.
20. The toothbrush according to claim 1, wherein
the clusters of bristle filaments produce profiles which (i) differ in a longitudinal direction and a transverse direction in relation to the head part and (ii) have different levels of rigidity.
21. The toothbrush according to claim 1, wherein
the at least one carrier element consists of a soft-elastic material, and slightly protrudes from the head part in a vertical direction.
22. The toothbrush according to claim 1, wherein
the at least one carrier element comprises two portions which are separated from one another by a central portion of the head part carrying at least one of (i) the clusters of bristle filaments and (ii) flexible non-bristle containing cleaning elements.
the at least one carrier element comprises a different color than the head part;
24. The toothbrush according to claim 23, wherein
25. The toothbrush according to claim 23, wherein
the at least one carrier element contains an additive which is not used in the head part and the handle part.
26. The toothbrush according to claim 23, wherein
27. The toothbrush according to claim 23, wherein
28. The toothbrush according to claim 23, wherein
29. The toothbrush according to claim 23, wherein
in a central portion of the head part an elevated region is provided which includes multiple non-bristle-containing flexible cleaning elements.
30. The toothbrush according to claim 23, wherein
31. The toothbrush according to claim 23, wherein
a head part to the handle part, the head part having a front face and a rear face; and
at least one carrier element non-releasably connected to the head part, the at least one carrier element having a top surface, a rear surface and clusters of bristle filaments having a rear end melted to form a bristle melt, wherein
the at least one carrier element comprises two portions which are separated from one another by a central portion of the head part carrying the clusters of bristle filaments and/or flexible non-bristle containing cleaning elements.
33. The toothbrush according to claim 32, wherein
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