Patent Description:
<CIT> refers to a first hard component for a toothbrush body. The toothbrush body is provided in its head part with bristles to form a complete toothbrush. The first hard component is produced from a hard plastic. In elevation, the first hard component has a vaguely S-shaped form and between an upper part and a lower part of the one-piece first hard component there extends a shoulder. The upper part has in the region of its later thumb rest a depression. A second hard component produced by means of a further hard plastic forms the carrying part of a neck part of the toothbrush body and the head part thereof.

<CIT> refers to a toothbrush which comprises a handle, a head and a neck arranged therebetween. A sectional surface extends from the free end of the handle to the free end of the head. Furthermore, the toothbrush comprises a further preferably softer plastic material which covers a part of the join along the periphery of the sectional surface. The softer plastic material at one or two points is adaptable for surrounding larger areas of the brush in order to form a grip portion.

<CIT> refers to an oral care implement comprising a base structure comprising a core component and a shell component surrounding the core component. The shell component comprises a substantially translucent first rigid material. The core component comprises a body formed of a second rigid material and a plurality of decorative elements.

The present invention is directed to an oral care implement defined in claim <NUM>.

An oral care implement comprises a body having a head portion, a gripping portion, and a neck portion located between the head and gripping portions; a plurality of tooth engaging elements extending from the head portion; the body comprising: a first component formed of a first hard plastic having a first ductility; and a second component formed of a second hard plastic having a second ductility that is greater than the first ductility.

The first component is formed of a polypropylene homopolymer; and the second component is formed of an impact-modified polypropylene.

The first component may be formed of a first material having a first hardness and a first ductility; and a second component may be formed of a second material having a second hardness and a second ductility; the ratio of the first hardness to the second hardness may be about <NUM>:<NUM> to about <NUM>:<NUM> and the ratio of the second ductility to the first ductility may range from about <NUM>:<NUM> to about <NUM>:<NUM>.

In an aspect useful to understand the present invention, a method of forming an oral care implement comprises: a) injection molding a first material into a first mold to form a first component, the first material comprises a first hard plastic having a first ductility; b) injection molding a second material onto the first component into a second mold, the second material forming a second component, the second material comprises a second hard plastic having a second ductility; whereby the combination of the first component and the second component form a body, and wherein the second ductility is greater than the first ductility.

According to the present application, the phrase "substantially free" means less than about <NUM> wt. According to the present application, the phrase "substantially equal" means ± <NUM>% of the referenced value.

Referring now to <FIG>, an oral care implement <NUM> comprising a body <NUM> that has an outer surface <NUM> (also referred to as an "exposed outer surface") is illustrated according to one embodiment of the present invention. The body <NUM> of the oral care implement <NUM> generally comprises a handle <NUM> (also referred to as a "handle portion" or "gripping portion"), a head <NUM> (also referred to as a "head portion"), and a neck <NUM> (also referred to as a "neck portion"). The handle <NUM> provides the user with a mechanism by which he/she can readily grip and manipulate the oral care implement <NUM>. The handle <NUM> is illustrated in the Figures according to one embodiment, but may also formed from other different shapes and sizes.

The body <NUM> extends from a proximal end <NUM> to a distal end <NUM>. The body <NUM> may extend along a longitudinal axis A-A from the distal end <NUM> to the proximal end <NUM>. The outer surface <NUM> of the body <NUM> may comprise a front surface <NUM> that is opposite a rear surface <NUM> and a first side surface <NUM> opposite a second side surface <NUM>. The first side surface <NUM> may extend from the front surface <NUM> to the rear surface <NUM> of the body <NUM>. The second side surface <NUM> may extend from the front surface <NUM> to the rear surface <NUM> of the body <NUM>.

The front surface <NUM> of the body <NUM> may extend from the distal end <NUM> to the proximal end <NUM> of the body <NUM>. The rear surface <NUM> of the body <NUM> may extend from the distal end <NUM> to the proximal end <NUM> of the body <NUM>. The first side surface <NUM> of the body <NUM> may extend from the distal end <NUM> to the proximal end <NUM> of the body <NUM>. The second side surface <NUM> of the body <NUM> may extend from the distal end <NUM> to the proximal end <NUM> of the body <NUM>.

It should be noted at this time that relative terms such as distal, middle, proximal, upper, lower, top, bottom, left, right etc. are merely used to delineate relative positions of the components of the body <NUM> with respect to one another and are not intended to be in any further way limiting of the present invention.

The body <NUM> may further comprise one or more surface features <NUM>, such as, but not limited to, one or more front face grooves <NUM>, rear face grooves <NUM>, front face finger depression <NUM>, and/or a rear face finger depression <NUM>. The front face grooves <NUM> may be present on the front surface <NUM> of the body <NUM>. The front face finger depression <NUM> may be present on the front surface <NUM> of the body <NUM>. The rear face grooves <NUM> may be present on the rear surface <NUM> of the body <NUM>. The rear face finger depression <NUM> may be present on the rear surface <NUM> of the body <NUM>.

The front face surface grooves <NUM> may be oriented substantially parallel to each other and extend at least partially between the distal <NUM> and proximal ends <NUM> of the body <NUM> in a direction that is substantially parallel to the longitudinal axis A-A. The front face finger depression <NUM> may be ovular in shape and have a first depression floor that extends to a first depth into the body <NUM>. The rear face surface grooves <NUM> may extend at least partially between the distal <NUM> and proximal ends <NUM> of the body <NUM> in a direction that is substantially parallel to the longitudinal axis A-A. The rear face finger depression <NUM> may be ovular in shape and have a second depression floor that extends to a second depth into the body <NUM>.

The head <NUM> may extend along the longitudinal axis A-A from a distal end <NUM> of the head <NUM> to a proximal end <NUM> of the head <NUM>. The head <NUM> generally comprises an outer surface <NUM> (also referred to as an "exposed outer surface") which comprises a front surface <NUM>, a rear surface <NUM> that is opposite the front surface <NUM> and a peripheral surface <NUM>. The peripheral surface <NUM> extends between the front surface <NUM> and the rear surface <NUM>, connecting the front and rear surfaces <NUM>, <NUM> and defining a perimeter edge of the front surface <NUM>.

The front surface <NUM>, the rear surface <NUM>, and the peripheral surface <NUM> of the head <NUM> can take on a wide variety of shapes and contours, none of which are limiting of the present invention. For example, the surfaces can be planar, contoured or combinations thereof. Furthermore, while the head <NUM> is normally widened relative to the neck <NUM>, it could in some constructions simply be a continuous extension or narrowing of the handle <NUM>. The outer surface <NUM> of the body <NUM> may comprise the outer surface <NUM> of the head <NUM>.

The body <NUM> may further comprises a first transverse axis B-B that intersects the first side surface <NUM> and the second side surface <NUM> of the body <NUM>. The first transverse axis B-B extends in a direction substantially orthogonal to the longitudinal axis A-A. The body <NUM> may further comprises a second transverse axis C-C that intersects the front surface <NUM> and the rear surface <NUM> of the body <NUM>. The second transverse axis C-C extends in a direction substantially orthogonal to the longitudinal axis A-A. The first transverse axis B-B is substantially orthogonal to the second transverse axis C-C. The first transverse axis B-B may be orthogonal to the second transverse axis C-C.

The oral care implement <NUM> may comprise a plurality of cleaning elements <NUM> that extend from the front surface <NUM> of the head <NUM>. 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 phrase 'tooth engaging elements" may be used in place of the phrase "cleaning element. " Common examples of "cleaning elements" include, without limitation, filament bristles, fiber bristles, nylon bristles, spiral bristles, rubber bristles, elastomeric protrusions, flexible polymer protrusions, combinations thereof and/or structures containing such materials or combinations. Although not shown, the oral care implement <NUM> may comprise a soft tissue cleanser. The soft tissue cleanser may be present on the rear surface <NUM> of the head <NUM>.

The neck <NUM> may extend along the longitudinal axis A-A from a distal end <NUM> of the neck <NUM> to a proximal end <NUM> of the neck <NUM>. The neck <NUM> comprises an outer surface <NUM> (also referred to as an "exposed outer surface") and can take on a wide variety of shapes and contours, none of which are limiting of the present invention. The outer surface <NUM> of the body <NUM> may comprise the outer surface <NUM> of the neck <NUM>. For example, the surfaces can be planar, contoured or combinations thereof. Furthermore, while the neck <NUM> is normally narrowed relative to the head <NUM> and handle <NUM>, it could in some constructions simply be a continuous extension or narrowing of the handle <NUM>.

The handle <NUM> may extend along the longitudinal axis A-A from a distal end <NUM> of the handle <NUM> to a proximal end <NUM> of the handle <NUM>. The handle <NUM> comprises an outer surface <NUM> (also referred to as an "exposed outer surface") and can take on a wide variety of shapes and contours, none of which are limiting of the present invention. For example, the surfaces can be planar, contoured or combinations thereof. Furthermore, while the handle <NUM> is normally wider relative to the neck <NUM> and head <NUM>, it could be relatively narrower than the head <NUM>. The outer surface <NUM> of the body <NUM> may comprise the outer surface <NUM> of the handle <NUM>.

The head <NUM> may be operably connected to the handle <NUM> via the neck <NUM>. Specifically, the head <NUM> may extend along the longitudinal axis A-A from the distal end <NUM> to the head <NUM> to the proximal end <NUM> of the head <NUM> at which point the head <NUM> mates with the distal end <NUM> of the neck <NUM>. The neck <NUM> may extend along the longitudinal axis A-A from the distal end <NUM> to the neck <NUM> to the proximal end <NUM> of the neck <NUM> at which point the neck <NUM> mates with the distal end <NUM> of the handle <NUM>. The handle <NUM> may extend along the longitudinal axis A-A from the distal end <NUM> to the handle <NUM> to the proximal end <NUM> of the handle <NUM> at which point the handle <NUM> terminates. The distal end <NUM> of the head <NUM> may overlap with the distal end <NUM> of the body <NUM>. The proximal end <NUM> of the handle <NUM> may overlap with the proximal end <NUM> of the body <NUM>.

Referring now to <FIG>, the handle <NUM> may have a first length L<NUM> as measured from the distal end <NUM> to the proximal end <NUM> of the handle <NUM>. The head <NUM> may have a second length L<NUM> as measured from the distal end <NUM> to the proximal end <NUM> of the head <NUM>. The neck <NUM> may have a third length L<NUM> as measured from the distal end <NUM> to the proximal end <NUM> of the neck <NUM>. The body <NUM> may have an overall length L<NUM> as measured from the proximal end <NUM> to the distal end <NUM> of the body <NUM>. The sum of the first length L<NUM>, the second length L<NUM>, and the third length L<NUM> may equal the overall length L<NUM>.

Referring now to <FIG> and <FIG>, the body <NUM> comprises a first component <NUM> and a second component <NUM>. The first component <NUM> may extend along the longitudinal axis A-A from a proximal end <NUM> of the first component <NUM> to a distal end <NUM> of the first component <NUM>. The proximal end <NUM> of the first component <NUM> may overlap with the proximal end <NUM> of the body <NUM>. The distal end <NUM> of the first component <NUM> may overlap with the distal end <NUM> of the body <NUM>.

The first component <NUM> may comprise at least a portion of the head <NUM>, at least a portion of the neck <NUM>, and at least a portion of the handle <NUM> - as described further herein. The distal end <NUM> of the first component <NUM> may overlap with the distal end <NUM> of the head <NUM>. In some embodiments, the proximal end <NUM> of the first component <NUM> may overlap with the proximal end <NUM> of the handle <NUM>. The first component <NUM> may comprise the proximal end <NUM> of the head <NUM>. The first component <NUM> may comprise the distal end <NUM> of the handle <NUM>. The first component <NUM> may also comprise the distal end <NUM> of the neck <NUM>. The first component <NUM> may also comprise the proximal end <NUM> of the neck <NUM>.

The first component <NUM> may comprise an outer surface <NUM> (also referred to as an "exposed outer surface") and a core <NUM> that is surrounded by the outer surface <NUM>. The first component <NUM> may be a continuous unitary structure formed from a single shot of a first material in an injection molding process - whereby both the core <NUM> and the outer surface <NUM> are formed from the first material. In some embodiments, the first component <NUM> may comprise one or more apertures <NUM> that extend from the outer surface <NUM> through the core <NUM> forming an open passageway from opposite outer surfaces <NUM> on the first component <NUM> - as discussed further herein. The first component <NUM> may further comprise an anti-microbial agent (i.e., anti-fungal agent and/or anti-bacterial agent).

The first material may be a first polymeric material (also referred to as a "first plastic material"). The first plastic material is preferably a hard plastic. Therefore, the body <NUM> may be formed from a first hard plastic material. The phrase "hard plastic" refers to a material that is not elastomeric - e.g., "hard plastic" is not a thermoplastic elastomer ("TPE"). Rather, the phrase "hard plastic" refers to materials that exhibits a Shore D hardness value of at least <NUM>. According to the present invention, the first hard plastic material may have a Shore D hardness value ranging from about <NUM> to about <NUM> - including all hardness values and sub-ranges there-between. The first hard plastic material may have a Shore D hardness of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> - including ranges having minimum and maximum values of these integers. In a preferred embodiment, the first hard plastic material may have a Shore D hardness value ranging from about <NUM> to about <NUM> - including all hardness values and sub-ranges there-between.

The first hard plastic may include polyolefin homopolymer as well as polyolefin copolymers. Non-limiting examples of polyolefin include polyethylene, polypropylene, and mixtures thereof. In a preferred embodiment, the polyolefin of the present invention includes polypropylene.

The first hard plastic may have a first density ranging from about <NUM>/cm<NUM> to about <NUM>/cm<NUM> - including all densities and sub-ranges there-between. The first hard plastic may have a specific gravity ranging from about <NUM> to about <NUM> - including all densities and sub-ranges there-between. In a preferred embodiment, the first density may be about <NUM>/cm<NUM>. In a preferred embodiment, the first specific gravity may be about <NUM>.

The first hard plastic may have a first ductility as reflected by impact strength of the material. Impact strength is represented by the unit ft-lb/in and measured by performing an notched izod impact test using ASTM D256 methodology at room temperature (i.e., <NUM>). The izod impact test measures the amount of energy per unit distance before a material fractures. According to the present invention, the first hard plastic may have a first impact strength ranging from about <NUM> J/m (<NUM> ft-lb/in) to about <NUM> J/m (<NUM> ft-lb/in) - including all values and sub-ranges there-between. In some embodiments, the first hard plastic may have a first impact strength ranging from about <NUM> J/m (<NUM> ft-bl/in) to about <NUM> J/m (<NUM> ft-lb/in) - including all values and sub-ranges there-between. In some embodiments, the first hard plastic may have a first impact strength of about <NUM> J/m (<NUM> ft-lb/in).

The term "homopolymers" is an art accepted term that refers to a polymer being formed from a single type of mer unit - e.g., homopolymer of polypropylene only contains mer units of propylene. The term "copolymer" is an art accepted term that refers to a polymer being formed from a at least two different mer units. Copolymer include, but are not limited to, block copolymers, terpolymers, graft copolymers, alternating copolymers, periodic copolymers, and the like.

Block copolymers refer to polymers having two different homopolymers subunits linked together by covalent bonds. Block copolymers having two or three distinct blocks are referred to as diblock copolymers and triblock copolymers, respectively. Terpolymers refer to copolymers formed from three distinct monomers - which results in a copolymer having three distinct mer units within the polymer backbone. Alternating copolymers refer to polymers have alternating repeating units formed from different mer units. Graft polymers refer to a polymer backbone formed from a first polymer and pendant polymer chains covalently bonded to and extending from the first polymer, whereby the pendant polymer chains may be formed from a second polymer.

The copolymers of the present invention include at least one block or repeating mer unit derived from an oleic source. Stated otherwise, the copolymers of the present invention are at least partially derived from an olein mer unit - whether as a block copolymer, terpolymer, alternative copolymer, etc. In a preferred embodiment, the copolymers of the present invention are at least partially derived from a propylene mer unit - e.g. copolymers of polypropylene.

The first component <NUM> may be formed from the first hard plastic material that is a homopolymer of polyolefin. Thus, the core <NUM> and the outer surface <NUM> of the first component <NUM> may comprise polyolefin homopolymer. In a preferred embodiment, the first component <NUM> may be formed from a first hard plastic material that is a homopolymer of polypropylene. Thus, the core <NUM> and the outer surface <NUM> of the first component <NUM> may comprise polypropylene homopolymers.

The first component <NUM> may extend along the longitudinal axis A-A a distance equal to a sum of the first length L<NUM>, the second length L<NUM>, and the third length L<NUM>. The first component <NUM> may extend along the longitudinal axis A-A a distance that is substantially equal to the overall length L<NUM> of the body <NUM>.

The first component <NUM> may comprise a front surface <NUM> that is opposite a rear surface <NUM> and a side surface <NUM> that extends between the front surface <NUM> and the rear surface <NUM>. The first transverse axis B-B may intersect the side surfaces <NUM> of the first component <NUM>. The second transverse axis C-C may intersect the front surface <NUM> and the rear surface <NUM> of the first component <NUM>.

Referring now to <FIG>, the first component <NUM> may comprise a support layer <NUM> having one or more apertures <NUM> (also referred to as one or more "through-holes") that extend through core <NUM> to form an open passageway through from opposite outer surfaces <NUM> of the first component <NUM>. The support layer <NUM> may comprise a first major surface <NUM> opposite a second major surface <NUM>. Specifically, an aperture <NUM> (or a plurality of apertures <NUM>) may extend from the front surface <NUM> of the first component <NUM>, through the core <NUM>, and to the rear surface <NUM> of the first component <NUM> in a direction that is substantially parallel to the second transverse axis C-C - thereby creating an open passageway that extends from the front surface <NUM> to the rear surface <NUM> of the first component <NUM>. The aperture <NUM> may also extend from the first major surface <NUM> to the second major surface <NUM> of the support layer <NUM> in a direction that is substantially parallel to the second transverse axis C-C - thereby creating an open passageway that extends from the first major surface <NUM> to the second major surface <NUM> of the support layer <NUM>. The apertures <NUM> may be defined by aperture walls <NUM> that form a closed perimeter defining the open passageway extending between the front and rear surfaces <NUM>, <NUM> of the first component <NUM>. The apertures <NUM> may be defined by aperture walls <NUM> that form a closed perimeter defining the open passageway extending between the first and second major surfaces <NUM>, <NUM> of the support layer <NUM>. The apertures <NUM> may occupy a first volume.

Although not pictured, in other embodiments, an aperture (or a plurality of apertures) may extend between the side surfaces <NUM> of the first component <NUM> in a direction that is substantially parallel to the first transverse axis B-B - thereby creating an open passageway that extends from opposite side surfaces <NUM> of the first component <NUM>. In such embodiments, the apertures may be defined by aperture walls that form a closed perimeter defining the open passageway extending between opposite side surfaces <NUM> of the first component <NUM>.

The first component <NUM> may further comprise a first recess cavity <NUM> (also referred to as a "first depression") that extends from the outer surface <NUM> of the first component <NUM> in a direction toward the rear surface <NUM> of the first component <NUM> and terminating at a first cavity floor <NUM> (also referred to as a "first depression floor"). The first recess cavity <NUM> may be defined by the first cavity floor and at least one first cavity wall <NUM> (also referred to as a "first depression wall"). The cavity wall <NUM> may intersect the first cavity floor <NUM>. The cavity wall <NUM> may intersect the outer surface <NUM> of the first component <NUM>. The first cavity floor <NUM> may be located between the outer surface <NUM> and the apertures <NUM> of the first component <NUM> in a direction along the second transverse axis C-C. The first cavity floor <NUM> may be smooth. In other embodiments, the first cavity floor <NUM> may be textured. The first recess cavity <NUM> may occupies a second volume. The second volume being the void extending from the outer surface <NUM> to the first cavity floor <NUM> and circumscribed by the cavity wall <NUM>. The first cavity floor <NUM> may form the first major surface <NUM> of the support layer <NUM>. Stated otherwise, the first major surface <NUM> of the support layer <NUM> may comprise the first cavity floor <NUM> of the first recess cavity <NUM>.

The first recess cavity <NUM> may have a substantially uniform depth as measured by the distance between the outer surface <NUM> of the first component <NUM> to the first cavity floor <NUM> when moving along a direction that is substantially parallel to the longitudinal axis A-A. The first recess cavity <NUM> may have a substantially uniform depth as measured by the distance between the outer surface <NUM> of the first component <NUM> to the first cavity floor <NUM> when moving along a direct that is substantially parallel to the first transverse axis B-B.

In other embodiments, the first recess cavity <NUM> may have a non-uniform depth as measured by the distance between the outer surface <NUM> of the first component <NUM> to the first cavity floor <NUM> when moving along a direction that is substantially parallel to the longitudinal axis A-A. In such embodiments, the depth of the first recess cavity <NUM> may increase while moving along the longitudinal axis A-A in a direction extending from the distal end <NUM> of the first component <NUM> to the proximal end <NUM> of the first component <NUM>. Alternatively, the depth of the first recess cavity <NUM> may decrease while moving along the longitudinal axis A-A in a direction from the distal end <NUM> of the first component <NUM> to the proximal end <NUM> of the first component <NUM>.

In some embodiments, the depth of the first recess cavity <NUM> may have a first depth as measured at the adjacent-most location of the proximal end <NUM> of the fir component <NUM>, a second depth as measured at the adjacent-most location of the distal end <NUM> of the first component <NUM>, and a third depth located between the first and second depths along the longitudinal axis A-A. In such embodiments, the third depth may be greater than the first and/or second depth. In other embodiments, the third depth may be less than the first and/or second depth.

In other embodiments, the first recess cavity <NUM> may have a non-uniform depth as measured by the distance between the outer surface <NUM> of the body <NUM> to the cavity floor <NUM> and moving along a direction that is substantially parallel to the first transverse axis B-B. In such embodiments, the depth of the first recess cavity <NUM> may increase while moving along the first transverse axis B-B in a direction extending between opposite side surfaces <NUM> of the first component <NUM>. Alternatively, the depth of the first recess cavity <NUM> may decrease while moving along the first transverse axis B-B in a direction extending between opposite side surfaces <NUM> of the first component <NUM>.

In some embodiments, the depth of the first recess cavity <NUM> may have a first depth as measured at the adjacent-most location to side surface <NUM> of the first component <NUM>, a second depth as measured at the adjacent-most location of an opposite side surface <NUM>, and a third depth located between the first and second depths along the longitudinal axis. In such embodiments, the third depth may be greater than the first and/or second depth. In other embodiments, the third depth may be less than the first and/or second depth.

The first component <NUM> may comprise a second recess cavity <NUM> (also referred to as a "second depression") present on the rear surface <NUM> of the first component <NUM>, whereby the second recess cavity <NUM> extends from the outer surface <NUM> to a second cavity floor <NUM> (also referred to as a "second depression floor"). The foregoing discussion with respect to the first recess cavity <NUM> also applies to the second recess cavity <NUM>. As discussed further herein, the apertures <NUM> may extend between the first cavity floor <NUM> and the second cavity floor <NUM>. The second recess cavity <NUM> may form a void that occupies a third volume.

The second and third volume may be equal. In other embodiments, the second and third volume may be different. The second volume may be greater than the third volume. The third volume may be greater than the second volume.

The maximum depth of the first recess cavity <NUM> may be equal to the maximum depth of the second recess cavity <NUM>. In other embodiments, the maximum depth of the first recess cavity <NUM> may be greater than the maximum depth of the second recess cavity <NUM>. In other embodiments, the maximum depth of the first recess cavity <NUM> may be less than the maximum depth of the second recess cavity <NUM>.

The apertures <NUM> may extend from the first cavity floor <NUM> of the first recess cavity <NUM> to the second cavity floor <NUM> of the second recess cavity <NUM>. Specifically, the aperture walls <NUM> may extend from the first cavity floor <NUM> of the first recess cavity <NUM> to the second cavity floor <NUM> of the second recess cavity <NUM>. The second cavity floor <NUM> may form the second major surface <NUM> of the support layer <NUM>. Stated otherwise, the second major surface <NUM> of the support layer <NUM> may comprise the second cavity floor <NUM> of the second recess cavity <NUM>.

The second component <NUM> may be over-molded onto the first component <NUM>. The second component <NUM> extends along the longitudinal axis A-A from a proximal end <NUM> of the second component <NUM> to a distal end <NUM> of the second component <NUM>. The second component <NUM> may comprise at least a portion of the handle <NUM>. The second component <NUM> may comprise at least a portion of the neck <NUM>. The second component <NUM> may comprise at least a portion of the head <NUM>. As discussed in greater detail herein, the second component <NUM> may comprise a first layer <NUM> and a second layer <NUM>. In some embodiments, the first component <NUM> may comprise a support layer <NUM> that is disposed between the first and second support layers <NUM>, <NUM> of the second component <NUM>.

The proximal end <NUM> of the second component <NUM> may overlap with the proximal end <NUM> of the body <NUM> (not pictured). In the exemplified embodiments, the proximal end <NUM> of the second component <NUM> may not overlap but be immediately adjacent to the proximal end <NUM> of the body10.

The second component <NUM> may extend a total distance (herein referred to as the over-mold distance) as measured from the proximal end <NUM> to the distal end <NUM> of the second component <NUM>. The over-mold distance may be greater than the first length L<NUM> of the handle <NUM>.

The second component <NUM> may extend continuously along the longitudinal axis A-A a distance equal to a sum of the total first length L<NUM> and at least a portion of the third length L<NUM>. The over-mold distance may be equal to the sum of the first length L<NUM> of the handle <NUM> and the third length L<NUM> of the neck <NUM>. The over-mold distance may be greater than the sum of the first length L<NUM> of the handle <NUM> and the third length L<NUM> of the neck <NUM>. The over-mold distance may be less than the overall length L<NUM> of the body <NUM>.

In some embodiments, the second component <NUM> may continuously extend across the distal end <NUM> of the handle and past the distal end <NUM> of the neck <NUM> towards the proximal end <NUM> of the neck <NUM>. In such embodiment, the proximal end <NUM> of the second component <NUM> may terminate at a location between the distal end <NUM> of the neck <NUM> and the proximal end <NUM> of the neck <NUM>.

As described in greater detail herein, in other embodiments, the second component <NUM> may terminate before reaching the distal end <NUM> of the body <NUM> along the longitudinal axis A-A, such that the distal end <NUM> of the body <NUM> is formed by the distal end <NUM> of the first component <NUM>. In such embodiments, the second component <NUM> may extend an over-mold distance that covers only a portion of the second length L<NUM> of the head <NUM> - whereby the over-mold distance extends over at least a portion of the handle <NUM>, extends over at least a portion of the neck <NUM>, and at least a portion of the head <NUM> of the body <NUM> - as discussed further herein. In some embodiments, the first component <NUM> forms an exposed proximal end surface <NUM> of the body <NUM> that extends between the exposed first and second side surfaces <NUM>, <NUM> of the body <NUM>.

The second component <NUM> may comprise an outer surface <NUM> (also referred to as an "exposed outer surface") that is opposite an inner surface <NUM>, as well as core <NUM> that is formed there-between. The second component <NUM> may be a continuous unitary structure formed from a single shot of a second material that is over-molded onto the first component <NUM> in an injection molding process - whereby the outer surface <NUM>, inner surface <NUM>, and the core <NUM> are formed from the second material. The second component <NUM> may further comprise an anti-microbial agent (i.e., anti-fungal agent and/or anti-bacterial agent).

The second material may be a second polymeric material (also referred to as a "second plastic material"). The second plastic material is preferably a hard plastic. Therefore, the second component <NUM> may be formed from a second hard plastic material. According to the present invention, the second hard plastic material may have a Shore D hardness value ranging from about <NUM> to about <NUM> - including all hardness values and sub-ranges there-between. The hardness of the first plastic material and the second plastic material may be substantially equal. The second hard plastic material may have a Shore D hardness of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> - including ranges having minimum and maximum values of these integers.

Additionally, the second hard plastic material is more ductile than the first hard plastic material (also referred as the second hard plastic material as having a "greater ductility" than the first hard plastic material). The term "ductility" refers to a material's ability to deform without fracture.

The second hard plastic may include one of the aforementioned polyolefin homopolymer or copolymers. In a preferred embodiment, the second hard plastic material is a copolymer of polypropylene - whereby the copolymer includes first blocks and/or mer units of propylene (or polypropylene) and second blocks that are different from the first blocks, whereby the second blocks impart greater ductility to the second hard plastic material when compared to the first hard plastic material. In a preferred embodiment, the second hard plastic material is impact-modified polypropylene copolymer, whereby the second block is ethylene. The second block may be referenced to as a "co-mer'' - whereby the co-mer is present in an amount ranging from about <NUM> wt. % to about <NUM> wt. % based on the total weight of the copolymer - including all amounts and sub-ranges there-between. In a preferred embodiment, the co-mer may be present in an amount ranging from about <NUM> wt. % to about <NUM> wt. % based on the total weight of the copolymer - including all amounts and sub-ranges there-between.

The second hard plastic may have a second density of about <NUM>/cm<NUM> to about <NUM>/cm<NUM> - including all densities and sub-ranges there-between. The second hard plastic may have a first specific gravity ranging from about <NUM> to about <NUM> - including all densities and sub-ranges there-between. In a preferred embodiment, the first density may be about <NUM>/cm<NUM>. In a preferred embodiment, the first gravity may be about <NUM>. The first density may be substantially equal to the second density. The first specific gravity may be substantially equal to the second specific gravity.

The second hard plastic may have a second ductility as reflected by impact strength of the material. According to the present invention, the second hard plastic may have a second impact strength ranging from about <NUM> J/m (<NUM> ft-lb/in) to about <NUM> J/ m (<NUM> ft-1b/in) - including all values and sub-ranges there-between. In some embodiments, the second hard plastic may have a second impact strength ranging from about <NUM> J/m (<NUM> ft-lb/in) to about <NUM> J/m (<NUM> ft-lb/in) - including all values and sub-ranges there-between. In some embodiments, the second hard plastic may have a second impact strength of about <NUM> J/m (<NUM> ft-1b/in).

According to the present invention, a ratio between the first notched izod impact strength of the first hard plastic and the second notched izod impact strength (also referred to as a "ductility ratio") may range from about <NUM>:<NUM> to about <NUM>:<NUM> - including all ratios and sub-ranges there-between. According to the present invention, the ductility ratio may range from about <NUM>:<NUM> to about <NUM>:<NUM> - including all ratios and sub-ranges there-between. According to the present invention, the ductility ratio may range from about <NUM>:<NUM> to about <NUM>:<NUM> - including all ratios and sub-ranges there-between. In some embodiments, the ductility ratio may be about <NUM>:<NUM>.

Additionally, a ratio of the first hardness to the second hardness (also referred to as a "hardness ratio") may range from about <NUM>:<NUM> to about <NUM>:<NUM>. The first hardness may be substantially equal to the second hardness.

The second component <NUM> may be formed from the second hard plastic material that is a copolymer of polyolefin. Thus, the outer surface <NUM>, inner surface <NUM>, and core <NUM> of the second component <NUM> may comprise the copolymer of polyolefin. In a preferred embodiment, the second component <NUM> may be formed from the second hard plastic material that is a copolymer of polypropylene. Thus, the outer surface <NUM>, inner surface <NUM>, and core <NUM> of the second component <NUM> may comprise copolymer of polypropylene.

In some embodiments, the second hard plastic material may be a blend of polyolefin homopolymer and an impact modifier polymer. In a non-limiting embodiment, the impact modifier polymer may be metallocene polyolefin. In a non-limiting embodiment, the metallocene polyolefin may be polyethylene homopolymer, copolymer, or blends thereof. In a non-limiting embodiment, the impact modifier polymer may be polyethylene homopolymer, copolymer, or blends thereof. The impact modifier polymer may have a specific gravity of about <NUM> to about <NUM>. The impact modifier polymer may have a Shore D hardness of about <NUM> to about <NUM> - including all hardness values and sub-ranges there-between. A ratio of the first hardness to the third hardness may range from about <NUM>:<NUM> to about <NUM>:<NUM> - including all hardness values and sub-ranges there-between. A ratio of the first hardness to the second hardness may range from about <NUM>:<NUM> to about <NUM>:<NUM> - including all hardness values and sub-ranges there-between.

The impact modifier polymer may be present in an amount ranging from about <NUM> wt. % to about <NUM> wt. % based on the total weight of second hard plastic material - i.e., based on the total weight of the homopolymer and impact modifier polymer present in the second hard plastic material.

According to some embodiments of the present invention, the first and second hard plastics may be chemically compatible. The phrase "chemically compatible" may refer to materials that for a cohesive bond at the interface of the two materials during processing - for instance a polypropylene homopolymer may be chemically compatible with an impact-modified polypropylene polymer. In other arrangements useful for the understanding of the present invention, the first and second hard plastics may chemically incompatible. The phrase "chemically incompatible" may refer to materials that fail to create a cohesive bond at the interface of the two materials during processing - for instance a polypropylene homopolymer may be chemically incompatible with an inorganic polymer or a rubber polymer (e.g., nitrile polymer).

In some embodiments, the second component <NUM> may continuously extend from the handle <NUM> to the neck <NUM> such that the distal end <NUM> of the second component <NUM> is located at a distance beyond distal end <NUM> of the handle <NUM> that is equal to at least <NUM>% of the third length L3. In other embodiments, the second component <NUM> may continuously extend from the handle <NUM> to the neck <NUM> such that the distal end <NUM> of the over-molded portion <NUM> is located at a distance beyond distal end <NUM> of the handle <NUM> that is equal to about <NUM>% to about <NUM>% of the third length L3 - including all percentages and sub-ranges there-between. In other embodiments, the over-molded portion <NUM> may continuously extend from the handle <NUM> to the neck <NUM> such that the distal end <NUM> of the second component <NUM> is located at a distance
beyond distal end <NUM> of the handle <NUM> that is equal to about <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or <NUM>% of the third length L<NUM>.

In other embodiments, the second component <NUM> may continuously extend from the handle <NUM> to the head <NUM> such that the distal end <NUM> of the second component <NUM> is located at a distance beyond distal end <NUM> of the neck <NUM> that is equal to at least <NUM>% of the second length L<NUM>. In other embodiments, the second component <NUM> may continuously extend from the handle <NUM> to the head <NUM> such that the distal end <NUM> of the over-molded portion <NUM> is located at a distance beyond distal end <NUM> of the neck <NUM> that is equal to about <NUM>% to about <NUM>% of the second length L<NUM> - including all percentages and sub-ranges there-between. In other embodiments, the second component <NUM> may continuously extend from the handle <NUM> to the head <NUM> such that the distal end <NUM> of the second component <NUM> is located at a distance beyond distal end <NUM> of the neck <NUM> that is equal to about <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%), or <NUM>% of the second length L<NUM>.

The outer surface <NUM> of the body <NUM> may comprise the first component <NUM>. The outer surface <NUM> of the body <NUM> may comprise the outer surface <NUM> of the first component <NUM>. The outer surface <NUM> of the body <NUM> may comprise the second component <NUM>. The outer surface <NUM> of the body <NUM> may comprise the outer surface <NUM> of the second component <NUM>.

The exposed front surface <NUM> of the body <NUM> may comprise the first component <NUM>. Specifically, the exposed front surface <NUM> of the body <NUM> may comprise the front exposed surface <NUM> of the first component <NUM>. The exposed rear surface <NUM> of the body <NUM> may comprise the first component <NUM>. Specifically, the exposed rear surface <NUM> of the body <NUM> may comprise the rear exposed surface <NUM> of the first component <NUM>. In some embodiments, the second component <NUM> forms a portion of the exposed front surface <NUM> of the body <NUM> and a portion of the exposed rear surface <NUM> of the body <NUM>.

The first exposed side surface <NUM> of the body <NUM> may comprise the first component <NUM>. Specifically, the first exposed side surface <NUM> of the body <NUM> may comprise the outer surface <NUM> of the first component <NUM>. The second exposed side surface <NUM> of the body <NUM> may comprise the first component <NUM>. Specifically, the second exposed side surface <NUM> of the body <NUM> may comprise the outer surface <NUM> of the first component <NUM>. In some embodiments, the first component <NUM> forms a portion of an exposed first side surface <NUM> of the body <NUM> and a portion of an exposed second side surface <NUM> of the body <NUM>.

The exposed front surface <NUM> of the body <NUM> may comprise the second component <NUM>. Specifically, the exposed front surface <NUM> of the body <NUM> may comprise the front exposed surface <NUM> of the second component <NUM>. The exposed rear surface <NUM> of the body <NUM> may comprise the second component <NUM>. Specifically, the exposed rear surface <NUM> of the body <NUM> may comprise the rear exposed surface <NUM> of the second component <NUM>.

The outer surface <NUM> of the head <NUM> may comprise the first component <NUM>. The outer surface <NUM> of the head <NUM> may comprise the outer surface <NUM> of the first component <NUM>. The outer surface <NUM> of the head <NUM> may comprise the second component <NUM>. The outer surface <NUM> of the head <NUM> may comprise the outer surface <NUM> of the second component <NUM>.

The outer surface <NUM> of the handle <NUM> may comprise the second component <NUM>. The outer surface <NUM> of the handle <NUM> may comprise the outer surface <NUM> of the second component <NUM>. As described further herein, the outer surface <NUM> of the handle <NUM> may further comprise the first component <NUM>. Specifically, the outer surface <NUM> of the handle <NUM> may further comprise the outer surface <NUM> of the first component <NUM>. The outer surface <NUM> of the neck <NUM> may comprise a portion of the first component <NUM> and a portion of the second component <NUM>. The outer surface <NUM> of the neck <NUM> may comprise the outer surface <NUM> of the first component <NUM> and the outer surface <NUM> of the second component <NUM>.

In some embodiments, the neck <NUM> of the body <NUM> may comprise the portion of the exposed front surface <NUM> of the body <NUM> formed by the second component <NUM> and the portion of the exposed rear surface <NUM> of the body <NUM> formed by the second component <NUM>. In some embodiments, the handle <NUM> of the body <NUM> comprises the portion of the exposed front surface <NUM> of the body <NUM> formed by the second component <NUM> and the portion of the exposed rear surface <NUM> of the body <NUM> formed by the second component <NUM>.

The first component <NUM> of the present invention may be substantially free of TPE. The second component <NUM> of the present invention may be substantially free of TPE. The body <NUM> of the present invention may be substantially free of TPE.

Although not limited to, the body <NUM> of the present invention may be formed by a method that includes injection molding the first hard plastic material into a mold to form the first component <NUM>. Subsequently, after providing the first component <NUM> formed from a first hard plastic material, over-molding the second hard plastic material onto the first component <NUM> such that the second hard plastic material spans the handle <NUM> and neck <NUM> - as previously discussed.

In such methodology, the inner surface <NUM> of the second component <NUM> may directly contact the outer surface <NUM> of the first component <NUM>.

According to the present disclosure the body <NUM> may have a handle <NUM> formed entirely from the first and second hard plastic material - whereby the second hard plastic material of the second component <NUM> is over-molded onto the first hard plastic material of the first component <NUM>. According to the present invention the body <NUM> may have a neck <NUM> formed entirely from the first and second hard plastic material - whereby the second hard plastic material of the second component <NUM> is over-molded onto the first hard plastic material of the first component <NUM>. According to the present disclosure, the body <NUM> may have a head <NUM> formed entirely from the first and second hard plastic material - whereby the second hard plastic material of the second component <NUM> is over-molded onto the first hard plastic material of the first component <NUM>.

According to the present disclosure, by over-molding the second material of the second component <NUM> onto the first material of the first component <NUM>, the resulting body <NUM> exhibits superior hygiene characteristics by withstanding fungal growth (mold) as compared to a body formed with over-molded TPE portions. Furthermore, as demonstrated in the examples section, the second component being formed from the second hard plastic material into the neck area avoids breakage issues by using a second hard plastic material that is more ductile than the first hard plastic material. By making the surface of the second component <NUM> more ductile, it is much less prone to allow cracks to develop.

The second component <NUM> may be over-molded onto the first component <NUM> such that at least a portion of the second component <NUM> is located within the first recess cavity <NUM>. The second component <NUM> may be over-molded to the first component <NUM> such that at least a portion of the second component <NUM> is located within the second recess cavity <NUM>. The second component <NUM> may be over-molded to the first component <NUM> such that at least a portion of the second component <NUM> is located within the open passage formed by the aperture <NUM>.

The second component <NUM> may extend beyond the front surface <NUM> of the first component <NUM> such that the outer surface <NUM> of the of the second component <NUM> extends beyond the outer surface <NUM> of the first component <NUM> in a radial direction from the longitudinal axis A-A. The second component <NUM> may extend beyond the rear surface <NUM> of the body <NUM> such that the outer surface <NUM> of the of the second component <NUM> extends beyond the outer surface <NUM> of the first component <NUM> in a radial direction from the longitudinal axis A-A.

Referring now to <FIG> and <FIG>, the second material may be over-mold to the first component <NUM> such that the inner surface <NUM> of the second component <NUM> directly contacts at least one of the first cavity floor <NUM> of the first recess cavity <NUM> and/or the second cavity floor <NUM> of the second recess cavity <NUM>. The second material may be over-mold to the first component <NUM> such that the inner surface <NUM> of the second component <NUM> directly contacts at least one of the first cavity wall <NUM> of the first recess cavity <NUM> and/or the second cavity wall <NUM> of the second recess cavity <NUM>. The second material may be over-mold to the first component <NUM> such that the inner surface <NUM> of the second component <NUM> directly contacts aperture walls <NUM> of the aperture <NUM>.

The second material may be over-mold to the first component <NUM> such that second component <NUM> is present in the first recess cavity <NUM>, the second recess cavity <NUM>, and at least one aperture <NUM> of the first component <NUM> - whereby the second component <NUM> forms a single integrally formed structure. State otherwise, the core <NUM> of the second component <NUM> may extend continuously from the first recess cavity <NUM>, through at least one aperture <NUM>, to the second recess cavity <NUM> - see <FIG>. In such configurations, the second material may extend continuously from opposite outer surfaces <NUM> of the body <NUM> along a direction that is substantially parallel to the second transverse axis C-C. In such configuration, the second material may form a portion of the front surface <NUM> and the rear surface <NUM> of the body <NUM>, whereby the second material extends continuously from the front surface <NUM> to the rear surface <NUM> in a direction that is substantially parallel to the second transverse axis C-C.

The second material may be over-molded to the first component <NUM> such that at least a portion of the first layer <NUM> of the second component <NUM> is located within the first recess cavity <NUM>, at least a portion of second layer <NUM> of the second component <NUM> is located within the second recess cavity <NUM>, and post <NUM> connecting the first layer <NUM> to the second layer <NUM> is located within the open passage formed by the aperture <NUM>. In such embodiments, the post <NUM> may occupy a volume that is substantially equal to the third volume created by the aperture <NUM>. The first layer <NUM>, the second layer <NUM>, and the post <NUM> may be integrally formed as a monolithic structure.

The second component <NUM> may extend beyond the front exposed surface <NUM> of the first component <NUM> such that the outer surface <NUM> of the of the second component <NUM> formed by the first layer <NUM> extends beyond the exposed front surface <NUM> of the first component <NUM> in a direction substantially parallel to the second transverse axis C-C. The second component <NUM> may extend beyond the rear exposed surface <NUM> of the first component <NUM> such that the outer surface <NUM> of the of the second component <NUM> extends beyond the exposed rear surface <NUM> of the second component in a direction substantially parallel to the second transverse axis C-C.

Referring now to <FIG>, the second material may also be over-molded to the first component <NUM> such that second component <NUM> is present in the second recess cavity <NUM>. In such configuration, the exposed front surface <NUM> of the body <NUM> may be formed by the front exposed surface <NUM> of the first component <NUM> and the exposed rear surface <NUM> of the body <NUM> may be formed by the outer surface <NUM> of the second component <NUM>.

A first test was performed to measure fracture strength of a body at the neck, whereby a first component of the body was formed from the polypropylene homopolymer and a second component formed from impact modified polypropylene copolymer was over-molded onto the first component along the neck. The materials used in this experiment have the following characteristics as set forth in Table <NUM>. (<NUM> lbf = <NUM> Newton; <NUM> psi = <NUM> Bar; <NUM> ft-lbs/in = <NUM> J/m).

Additionally, the hardness of the polypropylene homopolymer was substantially equal to the hardness of the impact-modified polypropylene copolymer.

Each neck was subjected to a pendulum impact drop test with the resulting impact force measured for each drop - the results are provided in Table <NUM>. (<NUM> lbf = <NUM> Newton; <NUM> psi = <NUM> Bar; <NUM> ft-lbs/in = <NUM> J/m).

When the force exceeded <NUM> lbf, no break or fracture in the neck area resulted. Comparative necks were also tested formed exclusively from polypropylene homopolymers - whereby such necks exhibited break and/or fracture during testing.

A second test was performed to measure fracture strength of a body at the head, whereby a first component of the body was formed from the polypropylene homopolymer and a second component formed from impact modified polypropylene copolymer was over-molded onto the first component along the neck. The polypropylene homopolymer and the impact modified polypropylene copolymer being the same as used in Experiment <NUM>. Each head was subjected to a pendulum impact drop test with the resulting impact force measured for each drop.

Claim 1:
An oral care implement (<NUM>) comprising:
a body (<NUM>) having a head portion (<NUM>), a gripping portion (<NUM>), and a neck portion (<NUM>) located between the head and gripping portions;
a plurality of tooth engaging elements (<NUM>) extending from the head portion (<NUM>);
the body (<NUM>) comprising:
a first component (<NUM>) formed of a first hard plastic having a first ductility; and
a second component (<NUM>) formed of a second hard plastic having a second ductility that is greater than the first ductility;
wherein each of the first component (<NUM>) and the second component (<NUM>) comprises a portion of the neck portion (<NUM>) of the body (<NUM>);
characterized in that the first hard plastic is polypropylene homopolymer and the second hard plastic is impact modified polypropylene.