Patent Description:
The hard plastic and the resilient soft plastic are selected so that they bond with one another at the surface where the two plastic parts touch. In comparison with a toothbrush made of only one plastic material, this provides greater scope for design. Since, however, the two plastic materials have to bond with one another during the injection-molding operation, there are restrictions in the selection of the plastic materials and consequently in the design of the toothbrush.

One solution to the limitation that two plastic materials must bond with one another during the injection molding operation has been introduced by which a handle can be formed by two plastics that do not chemically bond within one another during the injection molding operation but rather utilize a mechanical connection, such as by inter-fitting portions of the two plastic components or by shrinking one plastic component about the other.

A need exists for an oral care implement, and method of manufacturing the same, that has a handle having greater design flexibility, is more cost-effective to mass produce, and/or affords comfort and control to the user during use.

<CIT> describes a toothbrush comprising a handle with an elongated handle body that is integral/unitary with a head, a core structure and a grip cover. The elongated handle body is constructed of an opaque rigid material and the core structure is constructed of a transparent hard plastic. The elongated handle body has a through slot within which the core structure is located. The grip cover is a U-shaped member formed of a resilient material that is fixed to the elongated handle body to provide a gripping surface to improve performance during use. Further relevant prior art can be found in <CIT> and <CIT>.

Exemplary embodiments according to the present disclosure are directed to oral care implements having a multi-component handle.

An example useful for understanding the invention can be an oral care implement comprising: a handle extending along a longitudinal axis; a head at a distal end of the handle; at least one tooth cleaning element extending from the head; the handle comprising: a first component constructed of a first hard plastic, the first component comprising a first component aperture; a second component constructed of a second hard plastic, the second component comprising the head and an anchor, the anchor located within the first component aperture and comprising a second component aperture; and a third component constructed of a first elastomeric material, the third component located within the second component aperture.

Another example useful for understanding the invention can be an oral care implement comprising: a handle extending along a longitudinal axis; a head coupled to the handle; at least one tooth cleaning element extending from the head; the handle comprising: a first component constructed of a first hard material, the first component comprising a first component aperture; a second component constructed of a second hard material, the second component comprising the head and an anchor, the anchor located within the first component aperture and comprising a second component aperture; and a third component disposed within the second component aperture.

Yet another example useful for understanding the invention can be a method of forming an oral care implement comprising: forming a first component of a first hard plastic, the first component having a first component aperture; forming a second component of a second hard plastic on the first component so that an anchor of the second component is located within the first component aperture, the anchor comprising a second component aperture; and forming a third component of a first elastomeric material in the second component aperture.

The invention is provided in the feature combination of claim <NUM>, including an oral care implement comprising: a handle extending along a longitudinal axis; a head at the distal end of the handle; at least one tooth cleaning element extending from the head; the handle comprising: a first component constructed of a first hard plastic; and a second component constructed of a second hard plastic, the second component comprising a body portion and a plurality of strips extending from the body portion and forming a strap network that wraps around the first component.

Therefore, the above defined invention particularly includes an oral care implement comprising: a handle; a head coupled to the handle; at least one tooth cleaning element extending from the head; the handle comprising: a first component constructed of a first hard material; and a second component constructed of a second hard material, the second component comprising a plurality of strips that collectively form a strap network that wraps around the first component.

An example useful for understanding the invention can be a method of forming an oral care implement comprising: forming a first component of a first hard plastic; and forming a second component of a second hard plastic on the first component, the second component comprising: a plurality of strips that form a strap network that wraps around the first component; and a portion extending from a distal end of the first component, the portion comprising a head of the oral care implement.

In the following description, the invention is discussed in terms of a manual toothbrush, and method of manufacturing the same, having the inventive multi-component handle. However, in other forms, the invention could be in the form of other oral care implements including a soft-tissue cleansing implement, an inter-proximal pick, a flossing tool, a plaque scraper, a powered toothbrush, or other ansate implement designed for oral care. It is also to be understood that other embodiments may be utilized, and that structural and functional modifications may be made without departing from the scope of the present invention.

Referring first to <FIG> concurrently, a toothbrush <NUM> is illustrated according to one embodiment of the present invention. The toothbrush <NUM> generally comprises a handle <NUM> and a head <NUM>. The handle <NUM> provides the user with a mechanism by which he/she can readily grip and manipulate the toothbrush <NUM>. The handle <NUM> includes ergonomic features which provide a high degree of control for the user while maintaining comfort. The head <NUM> is connected to a distal end <NUM> of the handle <NUM> and includes a set of teeth cleaning elements <NUM>, which are generically illustrated.

Generally, the toothbrush <NUM> extends from a proximal end <NUM> (which is also the proximal end of the handle <NUM>) to a distal end <NUM> along a longitudinal axis A-A (illustrated in <FIG>). Conceptually, the longitudinal axis A-A is a reference line that is generally coextensive with the three-dimensional center line of the handle <NUM> (and the body of the head <NUM>). Because the handle <NUM> is a non-linear structure (as can be seen in <FIG> and <FIG>) in the illustrated embodiment, the longitudinal axis A-A for toothbrush <NUM> is also non-linear in the illustrated embodiment. However, the invention is not so limited, and in certain embodiments, the toothbrush may have a simple linear arrangement and thus a substantially linear longitudinal axis A-A. As best visible in <FIG>, the handle <NUM> has a generally elliptical transverse cross-sectional shape along its longitudinal length. Other transverse cross-sectional shapes can be used in other embodiments.

The head <NUM> is connected to the distal end <NUM> of the handle <NUM>. As discussed in greater detail below, the head <NUM> and the handle <NUM> of the toothbrush <NUM> are preferably formed as a single-component integral structure using an injection molding process, which in the exemplified embodiment is the second component <NUM>. More specifically, in the exemplified embodiment, the head <NUM> is integrally formed as part of the second component <NUM> of the handle <NUM>. The second component <NUM> also comprises the neck <NUM> of the toothbrush <NUM>. As exemplified, the neck is a portion of the handle <NUM> of the toothbrush <NUM> that is narrowed relative to the head <NUM> and the gripping portion of the handle <NUM>.

In other embodiments, the handle <NUM> and the head <NUM> may 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 head <NUM> is integrally formed as part of the second component <NUM> of the handle <NUM> or is 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 handle <NUM> and/or the head <NUM> (or components thereof), such as milling and/or machining.

The head <NUM> generally comprises a front surface <NUM> and a rear surface <NUM>. The front surface <NUM> and the rear 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 front and rear surfaces <NUM>, <NUM> can be planar, contoured or combinations thereof. The front surface <NUM> and rear surface <NUM> are bound by a peripheral surface <NUM>.

The set of tooth cleaning elements <NUM>, which are generically illustrated as a block, are provided on and extend outward from the front surface <NUM> of the head <NUM> for cleaning contact with an oral surface, preferably teeth. While the set of tooth cleaning elements <NUM> is particularly suited for brushing teeth, the set of tooth cleaning elements <NUM> can also be used to clean oral soft tissue, such as a tongue, gums, or cheeks instead of or in addition to teeth. Common examples of "tooth cleaning elements" include, without limitation, filament bristles, fiber bristles, nylon bristles, spiral bristles, core-sheath bristles, rubber bristles, elastomeric protrusions, flexible polymer protrusions, co-extruded filaments, flag bristles, crimped bristles, anti-bacterial bristles and combinations thereof and/or structures containing such materials or combinations.

The set of tooth cleaning elements <NUM> can be connected to the head <NUM> in any manner known in the art. In the exemplified embodiment (see <FIG>), anchor free tufting (AFT) is used to mount the cleaning elements. In this embodiment, the body of the head <NUM> comprises a depression (or basin) <NUM> for receiving a cleaning element assembly that comprises a carrier plate to which the tooth cleaning elements <NUM> are connected prior to being coupled to the body of the head <NUM>. The carrier plate is then positioned within the depression <NUM> and secured to the body of the head <NUM>, such as by ultrasonic welding, thermal fusion, mechanical fit or adhesion. The bristles (or other elastomeric elements) of the set of tooth cleaning elements <NUM> extend through the carrier. The free ends of the set of tooth cleaning elements <NUM> on one side of the carrier plate perform the cleaning function. The ends of the set of tooth cleaning elements <NUM> on the other side of the carrier plate are melted together by heat, thereby retaining the set of tooth cleaning elements <NUM> in place.

In other embodiments, the set of tooth cleaning elements <NUM> can 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. In still another embodiment, tuft holes may be formed in the body of the head and staples, or other anchors, can be sued to secure the bristles tufts therein.

While not in the exemplified embodiment, the rear surface <NUM> of the head <NUM> may also comprise additional structures for oral cleaning, such as a soft tissue cleanser, in other embodiments. Such soft tissue cleansers are typically constructed of a TPE and include one or more projections, such as nubs and/or ridges, for engaging and massaging soft oral tissue, such as the tongue.

As shown in <FIG>, the handle <NUM> can be conceptually delineated in longitudinal sections comprising a proximal section <NUM>, a middle section <NUM> and a neck section <NUM>. The proximal section <NUM> is the portion or segment of the handle <NUM> that generally fits comfortably within the palm of the user. The middle section <NUM> forms the portion or segment of the handle <NUM> that generally fits comfortably between the user's thumb and index finger. The neck portion <NUM> forms the portion or segment of the handle <NUM> that connects to the head <NUM>.

The proximal section <NUM> longitudinally extends from the proximal end <NUM> of the toothbrush <NUM> to the middle section <NUM>. The middle section <NUM> longitudinally extends from the proximal section <NUM> to the neck section <NUM>. The neck section <NUM> extends from the middle section <NUM> to the head <NUM>. While the head <NUM> is illustrated as being widened relative to the neck section <NUM> of the handle <NUM>, the head <NUM> could in some constructions simply be a continuous extension or narrowing of the neck section <NUM> of the handle <NUM>.

As discussed in greater detail below, the first component <NUM> is located within (and forms a part of) both the proximal section <NUM> and the middle section <NUM>. The second component <NUM> is located within (and forms part of) each of the proximal section <NUM>, the middle section <NUM> and the neck section <NUM>. Moreover, in the exemplified embodiment, the first and third components <NUM>, <NUM> are not located within the neck section <NUM>. The third component <NUM> is located (and forms part of) the middle section <NUM>. As exemplified, the third component is only located (and forms part of) in the middle section <NUM>.

Referring now to <FIG> concurrently, the handle <NUM> is illustrated in an exploded state so that its three components are visible. The three components of the handle <NUM> include a first component <NUM>, a second component <NUM> and a third component <NUM>. In certain embodiments, the first component <NUM> can be considered a core structure, the second component can be considered an elongated handle body, and the third component can be considered a grip body. While three components <NUM>, <NUM>, <NUM> are exemplified as forming the multi-component handle <NUM> of the toothbrush <NUM> in the illustrated embodiment, in other embodiments of the multi-component handle <NUM> of the toothbrush <NUM>, the third component <NUM> may be omitted if desired. In one such embodiment, the second component <NUM> can be modified to assume the volume of the omitted third component <NUM>. In still another such embodiment, the first component <NUM> can be modified to assume the volume of the omitted third component <NUM>. In still other embodiments, the multi-component handle <NUM> of the toothbrush <NUM> may further comprise an additional component (in addition to the first, second and third components <NUM>, <NUM>, <NUM>), such as a thermoplastic elastomer overlay, which is commonly referred to in the art as a grip cover.

In one embodiment, each of the first, second and third components <NUM>, <NUM>, <NUM> is an integrally formed single-component structure. One suitable forming method for forming the first, second and third components <NUM>, <NUM>, <NUM> is injection molding. Of course, in certain other embodiments, other forming techniques may be utilized, such as machining and/or milling. In one embodiment, the first component <NUM> is formed of a first hard plastic, the second component <NUM> is formed of a second hard plastic, and the third component <NUM> is formed of an elastomeric material.

Suitable first hard plastics for formation of the first component <NUM> include polyethylene, polyethylene terephthalate, polypropylene (PP), polyamide, polyester, cellulosics, SAN, acrylic, ABS, BR or any other of the hard plastics used in toothbrush manufacture. Suitable second hard plastics include polyethylene, polypropylene (PP), polyamide, polyester, cellulosics, SAN, acrylic, ABS, BR or any other of the hard plastics used in toothbrush manufacture. As used herein, the term "plastic" may include a blend of different plastics or a copolymer. The third component <NUM> is constructed of a first elastomeric material, such as a thermoplastic elastomer (TPE). In certain embodiments, the first elastomeric material of the third component may have a hardness durometer in a range of A11 to A15 Shore hardness. Of course, materials outside this hardness range could be used. As an example, one potential first elastomeric material for the third component <NUM> can be styrene-ethylene/butylene-styrene (SEBS) manufactured by GLS Corporation. Nevertheless, other manufacturers can supply the SEBS material and other materials could be used.

In one embodiment, the first hard plastic is different than the second hard plastic. In an even more specific embodiment, the first hard plastic and the second hard plastic are different hard plastics that are chemically incompatible with one another such that they do not form a chemical bond with each other during an injection molding process.

In certain embodiments, the hard plastic that forms one of the first and second components is an opaque hard plastic while the hard plastic that forms the other one of the first and second components is a transparent (or light transmissive) hard plastic. As used herein, the term "transparent hard plastic" includes hard plastics that are color tinted but still allow light to transmit therethrough. Suitable transparent hard plastics include without limitation clarified PP and clear polyesters, such as polyethylene terephthalate or a copolyester, such as poly-cyclohexylene dimethylene terephthalate, acid modified, polyester (PCTA) or styrene acrylonitrile (SAN), acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA) or a cellulosic plastic, such as cellulose acetate propionate (CAP). One suitable opaque hard plastic is opaque PP. However, opaque versions of the hard plastics listed above for the first and second hard plastics may also be used.

In one specific embodiment, the first hard plastic of the first component <NUM> is a transparent hard plastic while the second hard plastic of the second component <NUM> is an opaque hard plastic. In one such embodiment, the first hard plastic of the first component <NUM> can be a transparent BR while the second hard plastic of the second component <NUM> can be an opaque PP.

In one embodiment, the first elastomeric material of the third component <NUM> and the second hard plastic of the second component <NUM> are selected so as to be chemically compatible with one another such that so that a chemical bond is formed between the first elastomeric material and the second hard plastic during an injection molding process. In one such specific embodiment, the first elastomeric material can be a TPE while the second hard plastic can be PP.

Referring now to <FIG> concurrently, the first component <NUM> and its structural cooperation with the second and third components <NUM>, <NUM> will be described in greater detail. The first component <NUM> is an elongated structure that, when assembled within the handle <NUM> of the toothbrush, extends along the longitudinal axis A-A (see <FIG>). The first component <NUM> extends longitudinally from a proximal end <NUM> to a distal end <NUM>. The first component <NUM> comprises a front outer surface <NUM>, a rear outer surface <NUM>, a left-side outer surface <NUM>, and a right-side outer surface <NUM>. As will be discussed in greater detail below, when the handle <NUM> of the toothbrush <NUM> is fully assembled (as shown in <FIG>) portions of each of the front outer surface <NUM>, the rear outer surface <NUM>, the left-side outer surface <NUM>, and the right-side outer surface <NUM> remain exposed. Moreover, in certain embodiments where the first hard plastic is a transparent hard plastic, a first window may be formed through the handle <NUM> via exposed portions <NUM>, <NUM> of the first component <NUM> from the first and second opposing outer surfaces <NUM>, <NUM> of the handle <NUM> (which are the lateral surfaces) (see <FIG>). Additionally, a second window may be formed through the handle <NUM> via exposed portions <NUM>, <NUM> of the first component <NUM> from the third and fourth opposing outer surfaces <NUM>, <NUM> of the handle <NUM> (which are the front and rear surfaces) (see <FIG>).

The first component <NUM> comprises a first component aperture <NUM>. As discussed in greater detail below, the first component aperture <NUM> is provided to receive an anchor <NUM> of the second component <NUM> when the handle <NUM> is assembled. As will become apparent from the below discussion, the mechanical cooperation between the anchor <NUM> of the second component <NUM> and a sidewall <NUM> that defines the first component aperture <NUM> assists in ensuring a secure coupling between the first and second components <NUM>, <NUM>, especially when the first and second components <NUM>, <NUM> are formed of chemically incompatible hard plastics as described above.

In the exemplified embodiment, the first component aperture <NUM> is a through-hole that extends between the front outer surface <NUM> and the rear outer surface <NUM> of the first component <NUM>. In other embodiments, the first component aperture <NUM> may be a blind hole extending into the front outer surface <NUM> of the first component <NUM> or a blind hole extending into the rear outer surface <NUM> of the first component <NUM>.

The first component aperture <NUM> extends along a first axis B-B. When the handle <NUM> is assembled, the first axis B-B is transverse to the longitudinal axis A-A. In one specific embodiment, the first axis B-B may be substantially orthogonal to the longitudinal axis A-A. In the exemplified embodiment, the sidewall <NUM> comprises an annular structure that circumferentially surrounds the first component aperture <NUM> about the first axis B-B. This annular structure terminates in an upper annular surface <NUM> that remains exposed when the handle <NUM> is assembled.

The sidewall <NUM> of the first component <NUM> comprises a first transverse protuberance <NUM> and a second transverse protuberance <NUM> located adjacent the first component aperture <NUM> and extending from the rear outer surface <NUM> of the first component <NUM>. The first and second transverse protuberances <NUM>, <NUM> are circumferentially spaced apart from one another about the first axis B-B. In the exemplified embodiment, the first and second transverse protuberances <NUM>, <NUM> are located on opposite sides of the first component aperture <NUM> but may be at other locations in other embodiments. When the handle <NUM> is assembled, the first and second transverse protuberances <NUM>, <NUM> respectively extend into first and second transverse openings <NUM>, <NUM> of the anchor <NUM> (shown in <FIG>). Moreover, when the handle <NUM> the first and second transverse protuberances <NUM>, <NUM> are located on opposite sides of the second component aperture <NUM> of the second component <NUM>. As seen in <FIG>, the first and second transverse protuberances <NUM>, <NUM> extend through the first and second transverse openings <NUM>, <NUM> to form portions of an inner surface that defines the second component aperture <NUM> (discussed in greater detail below). As a result of the above mechanical cooperation, the first and second transverse protuberances <NUM>, <NUM> further assist in ensuring a secure coupling between the first and second components <NUM>, <NUM>. While in the exemplified embodiment, two transverse protuberances <NUM>, <NUM> are exemplified, in other embodiments more or less than two transverse protuberances may be used. In still other embodiments, the transverse protuberances may be omitted all together.

As can also be seen in <FIG> and <FIG>, the sidewall <NUM> of the first component nests within a groove <NUM> formed in an outer surface <NUM> of the anchor <NUM> of the second component <NUM>, thereby further assisting in ensuring a secure coupling between the first and second components <NUM>, <NUM>.

The first component <NUM> further comprises a longitudinal protuberance <NUM> extending from the distal end <NUM> of the first component <NUM>. When the handle <NUM> is assembled, the longitudinal protuberance <NUM> extends into a longitudinal recess <NUM> formed in a transverse wall <NUM> of the second component <NUM> (see <FIG>). When the handle <NUM> is assembled, the longitudinal protuberance <NUM> is embedded within the second component <NUM>.

Referring now to <FIG> and <FIG>, certain structural details of the second component <NUM> will be described, along with its structural cooperation with the first and third components <NUM>, <NUM>. The second component <NUM> is an elongated handle structure that generally comprises a body portion <NUM> and a strap network <NUM> extending longitudinally from the body portion <NUM>. The body portion <NUM> further comprises an anchor <NUM> which, as discussed above, extends into the first component opening <NUM> when the handle <NUM> is assembled.

The body portion <NUM> is located within (and forms part of) the middle section <NUM> and neck section <NUM> of the handle <NUM> while the strap network <NUM> is located within (and forms part of) the proximal middle section <NUM> of the handle <NUM> (see <FIG>). The body portion <NUM> also comprises the head <NUM> of the toothbrush <NUM> in the exemplified embodiment as discussed above.

The anchor of the second component <NUM> comprises a second component aperture <NUM>. In the exemplified embodiment, the second component aperture <NUM> is a through-hole that extends between a front outer surface <NUM> and a rear outer surface <NUM> of the second component <NUM>. In other embodiments, the second component aperture <NUM> may be a blind hole extending into the front outer surface <NUM> of the second component <NUM> or a blind hole extending into the rear outer surface <NUM> of the second component <NUM>.

The second component aperture <NUM> extends along a second axis C-C. When the handle <NUM> is assembled, the second axis C-C is transverse to the longitudinal axis A-A. In one specific embodiment, the second axis C-C may be substantially orthogonal to the longitudinal axis A-A. In certain embodiments, when the handle <NUM> is assembled, the first and second axes B-B, C-C may be substantially parallel to one another and/or substantially coextensive.

In the exemplified embodiment, the second component aperture <NUM> has a cross-sectional area (measured transverse to the second axis B-B) that tapers with increasing depth from the opposing front and rear outer surfaces <NUM>, <NUM> of the second component <NUM>. As a result an apex edge <NUM> is formed that is embedded by the third component <NUM> within the handle <NUM>. This structure assists with retaining the third component <NUM> within the second component aperture <NUM>. In other embodiments, however, the cross-sectional area of the second component aperture <NUM> (measured transverse to the second axis B-B) may be substantially constant, may be stepped, or may increase and decrease in a repetitive manner.

In the exemplified embodiment, the anchor <NUM> comprises a sidewall <NUM> that defines an annular structure that circumferentially surrounds the second component aperture <NUM> about the second axis C-C. The sidewall <NUM> comprises an inner surface <NUM> that defines the second component aperture <NUM> and an outer surface <NUM>. A groove <NUM> is formed into the outer surface <NUM> of the anchor <NUM>. As discussed above, the sidewall <NUM> of the first component <NUM> nests within the groove <NUM> when the handle <NUM> is assembled.

The sidewall <NUM> (which defines an annular structure in the exemplified embodiment) comprises an upper surface <NUM> that remains exposed on the front outer surface <NUM> of the handle <NUM>. Additionally, when the handle <NUM> is assembled, the sidewall <NUM> of the anchor <NUM> isolates the third component <NUM> from the first component <NUM> (best shown in <FIG>), with the exception of the terminal surfaces of the transverse protuberances <NUM>, <NUM> of the first component <NUM>.

As mentioned above, the sidewall <NUM> of the anchor <NUM> comprises first and second transverse openings <NUM>, <NUM> that extend from the inner surface <NUM> to the outer surface <NUM>. These first and second transverse openings <NUM>, <NUM> are provided to receive the first and second transverse protuberances <NUM>, <NUM> of the first component <NUM> when the handle <NUM> is assembled (see <FIG>). As can be seen, in this embodiment, the terminal surface of the first and second transverse protuberances <NUM>, <NUM> form portions of the inner surface that defines the second component aperture <NUM> of the anchor <NUM>. While in the exemplified embodiment, two transverse openings <NUM>, <NUM> are exemplified, in other embodiments more or less than two transverse openings may be used. In still other embodiments, the transverse openings may be omitted all together.

As shown in <FIG>, the second component <NUM> further comprises an internal transverse wall <NUM>. A longitudinal recess <NUM> is formed into the transverse wall <NUM> of the second component <NUM>. When the handle <NUM> is assembled, the longitudinal protuberance <NUM> of the first component <NUM> extends into and is located within the longitudinal recess <NUM>, thereby assisting in ensuring a secure coupling between the first and second components <NUM>, <NUM>. In the exemplified embodiment, the longitudinal protuberance <NUM> is embedded within the handle <NUM>.

Referring now to <FIG> and <FIG>, the second component <NUM> further comprises the strap network <NUM>. The strap network <NUM> is formed by a plurality of strips that, when the handle is assembled, wraps around the first component <NUM> to assist with ensuring that first and second components <NUM>, <NUM> are securely coupled together.

In the exemplified embodiment of the strap network <NUM>, the strap network <NUM> comprises a first longitudinal strip <NUM>, a second longitudinal strip <NUM> and a third longitudinal strip <NUM>. As can best be seen in <FIG>, when the handle <NUM> is assembled the first, second and third longitudinal strips <NUM>, <NUM>, <NUM> are arranged about the first component <NUM> in a circumferentially spaced-apart manner about the longitudinal axis A-A. In one embodiment, the first, second and third strips <NUM>, <NUM>, <NUM> may be substantially equi-spaced from one another. In another embodiment, the spacing between first, second and third strips <NUM>, <NUM>, <NUM> may not be substantially equal.

The first strip <NUM> extends longitudinally from the body portion <NUM> of the second component <NUM> toward the proximal end <NUM> of the handle <NUM> until it joins with the second strip <NUM> at the proximal end <NUM>. Similarly, the second strip <NUM> extends longitudinally from the body portion <NUM> of the second component <NUM> toward the proximal end <NUM> of the handle <NUM> until it joins with the first strip <NUM> at the proximal end <NUM>. As a result, the first and second strips <NUM>, <NUM> collectively form a first strap <NUM> that wraps around the proximal end <NUM> of the first component <NUM>, and also forms a portion of the proximal end <NUM> of the handle <NUM>.

The third strip <NUM> also extends longitudinally from the body portion <NUM> of the second component <NUM> toward the proximal end <NUM> of the handle <NUM>. However, as a distance from the proximal end <NUM> of the handle, the third strip divides/branches into a first branch <NUM> and a second branch <NUM>. The first branch <NUM> of the third strip <NUM> converges with the first strip <NUM> at a first strap node <NUM>. As a result, the third strip <NUM> and the first strip <NUM> collectively form a second strap <NUM> that forms a loop (in conjunction with the body portion <NUM>) on a first lateral surface <NUM> of the handle <NUM>. Similarly, the second branch <NUM> of the third strip <NUM> converges with the second strip <NUM> at a second strap node <NUM>. As a result, the third strip <NUM> and the second strip <NUM> collectively form a third strap <NUM> that forms a loop (in conjunction with the body portion <NUM>) on a second lateral surface <NUM> of the handle <NUM>. Additionally, as can be seen, the first, second and third strips <NUM>, <NUM>, <NUM> also collectively form a loop <NUM> on the rear outer surface <NUM> of the handle <NUM>. It is to be noted that while one embodiment of a strap network <NUM> is exemplified, the strap network <NUM> can take on a wide range of potential structural manifestations.

Referring now to <FIG> and <FIG> concurrently, when the first component <NUM> is constructed of a first hard plastic that is substantially transparent and the second component <NUM> is constructed of a second hard plastic that is substantially opaque, the plurality of strips <NUM>, <NUM>, <NUM> define a first window through the first component <NUM> from first and second lateral surfaces <NUM>, <NUM> of the handle <NUM> and a second window through the front and rear surfaces <NUM>, <NUM> of the handle <NUM>.

Referring now to <FIG> and <FIG> concurrently, the first component <NUM> is provided with a plurality of grooves <NUM> that are formed into the outer surface of the first component <NUM>. These grooves <NUM> are provided so that when the handle <NUM> is assembled, the plurality of strips <NUM>, <NUM>, <NUM> are located therein, thereby further assisting with ensuring that secure coupling is achieved between the first and second components <NUM>, <NUM>, even when chemically incompatible materials are used.

While the exemplified embodiment of the toothbrush <NUM> has a second component <NUM> that comprises both the anchor <NUM> and the strap network <NUM>, in certain embodiments the strap network <NUM> may be omitted. In still other embodiments, the anchor <NUM> may be omitted. In such embodiments, corresponding modifications can be made to the first component <NUM> to compensate for said omissions. For example, if the anchor <NUM> is omitted, the third component <NUM> may be located directly in the first component aperture <NUM>.

Turning now to <FIG>, <FIG> and <FIG> concurrently, the third component <NUM> will be described in greater detail. The third component <NUM> is a generally bulbous shaped body that bulges out of the apertures <NUM>, <NUM> of the first and second components <NUM>, <NUM>. The third component <NUM> fills the second component aperture <NUM> of the second component <NUM> and, thus, takes on the shape of the second component aperture <NUM>. The third component <NUM> has a convex front surface <NUM> and a convex rear surface <NUM>, which resemble an oval or elliptical shape. The bulbous shape of the third component <NUM> enables the user to reliably roll and control the handle <NUM> between the thumb and index fingers during use. The third component <NUM> may also be non-bulging or have any number of shapes, such as circular, a true oval shape and the like.

In one preferred construction, the third component <NUM> has a multiplicity of finger grip protrusions <NUM> projecting from the front and rear surfaces <NUM>, <NUM>. The finger grip protrusions <NUM> provide a tactile feature to increase the friction on the user's finger surfaces and thus enhance the user's ability to grip the handle <NUM>, particularly under wet conditions. The finger grip protrusions <NUM> are preferably provided in a desired conical or frusto-conical shape for improved grip performance. In other embodiments, other roughened surfaces and geometries could be used.

A method of manufacturing the toothbrush <NUM> according to one embodiment of the present invention will be described. The first component created in manufacturing the toothbrush <NUM> is the first component <NUM>. To create the first component <NUM>, a first mold is provided having a first mold cavity and at least one port/nozzle for injecting the first hard plastic in a liquefied state into the first mold cavity. In one embodiment, a single port is used to inject the liquefied first hard plastic, which may be BR. The first mold cavity has a volume that is sized and shaped to correspond to the first component <NUM> as described above and illustrated herein. The first mold may be two-part mold, as is known in the art. Once the first mold cavity is created/provided, liquefied first hard plastic is injected into the first mold so as to fill the first mold cavity. The liquefied first hard plastic is allowed to cool to an appropriate temperature so as to form the first component <NUM>, as described above and illustrated herein, for further handling.

Once the first component <NUM> is created (and allowed to adequately cool for further handling), the first component <NUM> is supported by one or more clamping members that engage one or more points of contact on first component <NUM> with at least one set of arms.

Once the clamping member is properly supporting the first component <NUM>, the first component <NUM> is positioned within a second mold cavity of a second mold. This positioning can be efFectuated by either moving the first component <NUM> into the second mold cavity or by creating the second mold cavity about the first component <NUM> while supporting the first component <NUM> in a stationary manner, which can be accomplished by translating and mating multiple pieces of the second mold into position so that the second mold cavity is formed about the first component <NUM>. The second mold cavity has a volume that is sized and shaped to correspond to the second component <NUM>. One or more ports are present in the second mold for injecting the second hard plastic in a liquefied state into the second mold cavity. In one embodiment, a single port is used to inject the liquefied PP.

Once the first component <NUM> is in proper position within the second mold cavity (and the second mold cavity is adequately sealed), the liquefied second hard plastic (which may be PP) is injected into the second mold cavity so as to fill the remaining volume of the second mold cavity that is not occupied by the first component <NUM>. The liquefied second hard plastic forms the strap network <NUM> about the first component <NUM> and the anchor <NUM> within the first component aperture <NUM> (as described above).

The liquefied second hard plastic is then allowed to cool to an appropriate temperature, thereby forming the second component <NUM> about the first component <NUM>, as described above. The first component <NUM> and second component <NUM> collectively form a handle assembly. If the first and second plastics are selected so as to be chemically incompatible with one another, the second hard plastic of second component <NUM> does not chemically bond with the first hard plastic of the first component <NUM> during the injection molding process.

Once the handle assembly is sufficiently cool for further handling, at least the middle section <NUM> is positioned within a third mold cavity of a third mold. When in the third mold cavity, the first elastomeric material in a liquefied state is injected therein to fill the second component aperture <NUM>, which is enclosed by an appropriate mold, via a port. The first elastomeric material, in one embodiment, chemically bonds with the second hard plastic of the second component <NUM> during this injection molding process.

The inventive aspects discussed above may be practiced for a manual toothbrush or a powered toothbrush. In operation, the previously described features, individually and/or in any combination, may improve the control, grip performance, aesthetics and cost point of oral implements. Other constructions of toothbrush are possible. For example, the head <NUM> may be replaceable or interchangeable on the handle <NUM>. The head <NUM> may include various oral surface engaging elements, such as inter-proximal picks, brushes, flossing element, plaque scrapper, tongue cleansers and soft tissue massages. While the various features of the toothbrush <NUM> work together to achieve the advantages previously described, it is recognized that individual features and sub-combinations of these features can be used to obtain some of the aforementioned advantages without the necessity to adopt all of these features in an oral care implement.

Claim 1:
An oral care implement (<NUM>) comprising:
a handle (<NUM>) extending along a longitudinal axis (A-A);
a head (<NUM>) at the distal end of the handle (<NUM>);
at least one tooth cleaning element (<NUM>) extending from the head (<NUM>);
the handle (<NUM>) comprising:
a first component (<NUM>) constructed of a first hard plastic; and
a second component (<NUM>) constructed of a second hard plastic, the second component (<NUM>) comprising a body portion (<NUM>) and a plurality of strips extending from the body portion (<NUM>) and forming a strap network (<NUM>) that wraps around the first component (<NUM>);
wherein the first hard plastic is substantially transparent and the second hard plastic is substantially opaque;
characterized in that the plurality of strips define a first window through the first component (<NUM>) from first and second opposing outer surfaces (<NUM>, <NUM>) of the handle (<NUM>); and the plurality of strips define a second window through the third and fourth opposing outer surfaces (<NUM>, <NUM>) of the handle (<NUM>).