Patent ID: 7448693

Claim:
A method of manufacturing a toothbrush, comprising the steps of: inserting a plurality of bristles into each of a plurality of through holes defined between an upper surface and a lower surface of a head insert, said lower surface being near to a bottom of the head insert, each of said bristles defining a non-tapered portion at a first end and a tapered portion at a second end opposite to the first end thereof, said non-tapered portion being received into the through hole; and maintaining the tapered portions of the bristles outside and away from the upper surface of the head insert and the non-tapered portion of the bristles to protrude from the lower surface of the head insert; thermally fusing the non-tapered portion of the bristles protruding from the lower surface of the head insert, thereby fixing the bristles to the head insert; attaching the bottom of the head insert to an upper metal mold; combining the upper metal mold with a lower metal mold; and injecting resin into the lower metal mold through an inlet, thereby attaching the head insert to a head of the toothbrush.