Patent Document

FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to an oral care implement and method of manufacturing the same, and specifically to a handle of an oral care implement having a decorative member that is protected against wear and methods of manufacturing the same. 
       BACKGROUND OF THE INVENTION 
       [0002]    Decorative members, such as logos, symbols, or other designs, are often applied to the handles of oral care implements. Such decorative members are used for a wide variety of reasons, including: to attract the attention of children; to identify the source and/or trade name of the oral care implement; to display a desired message and/or visual indicia; and/or to create a desired visual effect to the user. In some existing oral care implements, the decorative member is formed by providing a raised portion directly on the exterior surface of the toothbrush. However, this raised portion can be uncomfortable to a user, can be difficult to see, and/or can become easily worn during the natural use of the oral care implement. 
         [0003]    It also known to embed a decorative member within the oral care implement so that it is viewable and protected against wear. In such known embodiment, the decorative member is embedded and completely encapsulated within the handle of the oral care implement. However, the decorative member is still viewable to the user by utilizing a transparent material to completely encapsulate the decorative member thereunder. While embedding and completely encapsulating the decorative member within the handle protects the decorative member against any damage due to wear, it also decreases and distorts the visibility of the decorative member. Such distortion is caused by: (1) the decorative member being viewed through the curved surfaces of the handle; and/or (2) the transparent material having a less than perfect transparency quality. Such distortion of the decorative member may make it difficult for a user to clearly view the decorative member. Furthermore, these oral care implements require additional materials in order to fully encapsulate the decorative member, which results in an added cost. 
         [0004]    Thus, a need exists for an oral care implement having a decorative member wherein the decorative member is viewable without distortion, is protected against damage and wear and tear, and/or has a lower material cost. 
       BRIEF SUMMARY OF THE INVENTION 
       [0005]    The present invention is directed to an oral care implement with a handle having a decorative member recessed therein and having at least a portion of the decorative member exposed via an aperture. 
         [0006]    In one aspect, the invention can be an oral care implement comprising: a handle having a longitudinal axis and a head connected to the handle; the handle comprising a first transverse section and a second transverse section, the first transverse section coupled to the second transverse section; a decorative member disposed between the first transverse section and the second transverse section; and an aperture extending through the first transverse section that exposes at least a portion of the decorative member. 
         [0007]    In another aspect, the invention can be a method of forming an oral care implement comprising: a) forming a first transverse section of a handle of the oral care implement, the first transverse section comprising an aperture extending therethrough; b) applying a decorative member to the first transverse section so that at least a portion of the decorative member covers the aperture; and c) forming a second transverse section of the handle on the first transverse section, the decorative member disposed between the first and second transverse sections. 
         [0008]    In yet another aspect, the invention can be a method of forming an oral care implement comprising: a) forming a first transverse section of a handle of the oral care implement; b) applying a decorative member to the first transverse section; c) forming a second transverse section of the handle on the first transverse section, the decorative member disposed between the first and second transverse sections, and the second transverse section comprising an aperture through which at least a portion of the decorative member is exposed. 
         [0009]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0011]      FIG. 1  is a front view of an oral care implement in accordance with one embodiment of the present invention; 
           [0012]      FIG. 2  is a longitudinal cross-sectional view of the oral care implement of  FIG. 1  taken along line II-II; 
           [0013]      FIG. 3  is a transverse cross-sectional view of the oral care implement of  FIG. 1  taken along line III-III; 
           [0014]      FIG. 4  is a transverse cross-sectional view of the oral care implement of  FIG. 1  taken along line IV-IV; and 
           [0015]      FIG. 5  is a longitudinal cross-sectional view of an oral care implement in accordance with a second embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0016]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of the exemplary embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are described by reference to the exemplary embodiments illustrated herein. Accordingly, the invention expressly should not be limited to such exemplary embodiments, even if indicated as being preferred. The discussion herein describes and illustrates some possible non-limiting combinations of features that may exist alone or in other combinations of features. The scope of the invention is defined by the claims appended hereto. 
         [0017]    Preferred embodiments of the present invention will now be described herein with respect to one possible embodiment of an oral care implement, namely a manual toothbrush. However, in other forms, the invention could be in the form of other oral care implements including a soft-tissue cleansing implement, a powered toothbrush, or other ansate implements designed for oral care. 
         [0018]    Referring now to  FIG. 1 , an oral care implement  100  is illustrated according to one embodiment of the present invention. The oral care implement  100  generally comprises a handle  120  and a head  110 . The handle  120  provides the user with a mechanism by which he/she can readily grip and manipulate the oral care implement  100 . The handle  120  includes ergonomic features which provide a high degree of control for the user while maintaining comfort. The head  110  is connected to the handle  120  by a neck  115 . The head  110  includes a set of teeth cleaning elements  119  which are generically illustrated. 
         [0019]    Generally, the oral care implement  100  extends from a proximal end  101  (which is also the proximal end of the handle  110 ) to a distal end  102  along a longitudinal axis A-A. Conceptually, the longitudinal axis A-A is a reference line that is generally coextensive with the three-dimensional center line of the handle  120  and the head  110 . Because the handle  120  is a non-linear structure (as can be seen in  FIG. 2  as viewed laterally) in the illustrated embodiment, the longitudinal axis A-A for the oral care implement  100  is also non-linear in the illustrated embodiment. However, the invention is not so limited, and in certain embodiments the oral care implement  100  may have a simple linear arrangement and thus a substantially linear longitudinal axis A-A. 
         [0020]    As noted above, the head  110  is coupled to the handle  120  via the neck  115 . As discussed in greater detail below, the head  120 , the neck  115 , and an upper transverse section  122  of the handle  120  of the oral care implement  100  are formed as an integral structure using an injection molding process in the exemplified embodiment of  FIGS. 1-4 . Furthermore, as discussed in greater detail below, in the exemplified embodiment of  FIG. 5 , the head  220 , the neck  215 , and a lower transverse section  221  of the handle  220  of the oral care implement  200  are formed as an integral structure using an injection molding process. However, in other embodiments, the handle  120  and the head  110  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  110  and the handle  120  (or a transverse section thereof) are constructed as an integral piece or a multi-piece assembly (including connection techniques) is not limiting of the present invention in all embodiments. Furthermore, other manufacturing techniques may be used in place of and/or in addition to injection molding to create the handle  110  (of transverse sections thereof) and/or the head  120  (or components thereof), such as milling and/or machining 
         [0021]    Referring now to  FIGS. 1 and 2  concurrently, the head  110  generally comprises a front surface  111  and a rear surface  112 . The front surface  111  and the rear surface  112  of the head  110  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  111 ,  112  can be planar, contoured or combinations thereof. The front surface  111  and rear surface  112  are bound by a peripheral or lateral surface  113 . 
         [0022]    A set of cleaning elements  119 , which are generically illustrated as a plurality of circular tufts of bristles, are provided on and extend outward from the front surface  111  of the head  110  for cleaning contact with an oral surface, preferably teeth. While the set of cleaning elements  119  is particularly suited for brushing teeth, the set of cleaning elements  119  can also be used to clean oral soft tissue, such as a tongue, gums, or cheeks instead of or in addition to teeth. As used herein, the term “cleaning element” is used in a generic sense to refer to any structure that can be used to clean or massage an oral surface through relative surface contact. 
         [0023]    Common examples of “cleaning elements” include, without limitation, filament bristles, fiber bristles, nylon bristles, spiral 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. 
         [0024]    The set of cleaning elements  119  can be connected to the head  110  in any manner known in the art. For example, anchor free tufting (AFT) could be used to mount the cleaning elements. In AFT, a plate or membrane is secured to the brush head such as by ultrasonic welding. The bristles (or other elastomeric elements) extend through the plate or membrane. The free ends of the bristles on one side of the plate or membrane perform the cleaning function. The ends of the bristles on the other side of the plate or membrane are melted together by heat to be anchored in place. Any suitable form of cleaning elements may be used in the broad practice of this invention. Alternatively, the bristles could be mounted to tuft blocks or sections by extending through suitable openings in the tuft blocks so that the base of the bristles is mounted within or below the tuft block. Staple technology may also be used. 
         [0025]    Furthermore, if desired, the rear surface  112  of the head  110  may also comprise additional structures for oral cleaning, such as a soft tissue cleanser. Such soft tissue cleansers are typically constructed of a thermoplastic elastomer (“TPE”) and include one or more projections, such as nubs and/or ridges, for engaging and massaging soft oral tissue, such as the tongue. 
         [0026]    Still referring to  FIGS. 1 and 2 , the handle  120  is formed of a lower transverse section  121  and an upper transverse section  122 , which are coupled together. The upper transverse section  122 , which comprises an outer surface  123  and a bottom surface  126 , is integrally formed with the neck  115  and the head  110  to form a unitary structure. The lower transverse section  121 , which comprises a top surface  125  and an outer surface  124 , is coupled to the upper transverse section  122 . More specifically, the top surface  125  of the lower transverse section  121  is coupled to the bottom surface  126  of the upper transverse section  122 . The coupling of the lower and upper transverse sections  121 ,  122  can be achieved in any manner known in the art such as, for example, thermal welding, sonic welding, a tight-fit assembly, a coupling sleeve, adhesion, fasteners or other techniques. In one exemplary embodiment, the coupling of the upper and lower transverse sections  121 ,  122  are coupled together via a bond that is formed between the materials of the upper and lower transverse sections  121 ,  122  during an injection molding process. 
         [0027]    It should be noted that while the exemplary embodiments of the handles  120 ,  220  of the oral care implements  100 ,  200  of  FIGS. 1-5  include two transverse sections, in other embodiments of the invention, more than two transverse sections may used to create the handles  120 ,  220 . Moreover, gripping overlays, such as TPE overlays, can be included on one or all of the transverse sections as desired. Furthermore, while the transverse sections of the handles are arranged in an upper-lower relative arrangement in the exemplary embodiments of the invention, the invention is not so limited and the transverse sections may be arranged in a side-by-side (i.e., left-right) or angled relative arrangement. 
         [0028]    The outer surface  124  of the lower transverse section  121  and the outer surface  123  of the upper transverse section  122  collectively form the outer surface of the handle  120  that enables a user to manipulate the oral care implement  100  during use. As can be seen in  FIG. 4 , the outer surfaces  124 ,  123  collectively form an elliptical transverse cross-sectional profile for the handle  120 . 
         [0029]    In one embodiment, one of the lower and upper transverse sections  121 ,  122  is formed of a rigid material while the other one of the lower and upper transverse sections  121 ,  122  is formed of an elastomeric material. In one such embodiment, the lower transverse section  121  is formed of an elastomeric material while the upper transverse section  122  is formed of a rigid material. In another such embodiment, the lower transverse section  121  is formed of a rigid material while the upper transverse section  122  is formed of an elastomeric material. In another embodiment, both the lower and upper transverse sections  121 ,  122  are formed of a rigid material. 
         [0030]    Suitable rigid materials include hard plastics, such as, without limitation, polyethylene, polypropylene (PP), polyamide, polyester, cellulosics, SAN, acrylic, ABS or any other of the commonly known hard thermoplastics used in toothbrush manufacturing. One suitable elastomeric material is a thermoplastic elastomer (“TPE”). In certain embodiments, the TPE has a hardness in a range of 8 to 65 shore A. However, the exact hardness of the TPE used in any specific embodiment of the invention will be dictated by the percentage of the transverse cross-sectional area of the handle occupied by the transverse section formed of TPE. 
         [0031]    For reasons that will become apparent from the discussion below, the material selected for the upper transverse section  122  is preferably a transparent material, irrespective of whether the upper transverse section  122  is a rigid material or an elastomeric material. It should be understood that as used herein, the term “transparent” includes both colored transparency and colorless transparency, and is intended to include any material through which an embedded feature is visible therethrough as described below. 
         [0032]    Suitable transparent materials include, without limitation, clarified PP, SAN, copolyester, transparent TPE, PET, ABS, CAP, PU. While not preferred, in some embodiments, the upper transverse section  122  can be formed of an opaque or other non-transparent material, irrespective of whether the upper transverse section  122  is a rigid material or an elastomeric material. The lower transverse section  121  can be formed of a transparent material or an opaque material, irrespective of whether the lower transverse section  121  is a rigid material or an elastomeric material 
         [0033]    In the embodiment of  FIGS. 1-4 , the lower transverse section  121  is formed of a transparent elastomeric material and the upper transverse section  122  is formed of a transparent rigid material. However, in another embodiment, the lower transverse section  121  is formed of an elastomeric rigid material and the upper transverse section  122  is formed of a transparent elastomeric material. In still another embodiment, the lower transverse section  121  is formed of a transparent rigid material and the upper transverse section  122  is formed of a transparent rigid material. In a further embodiment, the lower transverse section  121  is formed of an opaque rigid material and the upper transverse section  122  is formed of a transparent elastomeric material. In an even further embodiment, the lower transverse section  121  is formed of an opaque rigid material and the upper transverse section  122  is formed of a transparent rigid material. In a yet further embodiment, the lower transverse section  121  is formed of an opaque elastomeric material and the upper transverse section  122  is formed of a transparent rigid material. 
         [0034]    Referring still to  FIGS. 1 and 2  concurrently, the handle  120  of the oral care implement  100  further comprises a decorative member  150  disposed between the lower transverse section  121  and the upper transverse section  122 . The decorative member  150  comprises a top surface  153  and a bottom surface  154 . The decorative member  150  can be any type of element that can be used to effectuate and/or include a visual indicia. For example, the decorative member  150  can be a layer of ink (or other colorant or pigment) printed directly onto one of the upper and/or lower transverse sections  121 ,  122 . In other embodiments, the decorative member  150  may be a decal, which can be a single or multi-layer laminate, that is positioned between the lower and upper transverse sections  121 ,  122  as illustrated. When the decorative member  150  is a decal, the visual indicia can be on one or both surfaces of the decal. Examples of visual indicia include, without limitation, logos, alphanumeric symbols, characters, animals, plants, patterns, symbols, combinations thereof, and/or other graphical elements. 
         [0035]    In the illustrated embodiment, the bottom surface  154  of the decorative member  150  is in contact with the top surface  125  of the lower transverse section  121  while a portion of the top surface  153  of the decorative member  150  is in contact with the bottom surface  126  of the upper transverse section  122 . As a result, the decorative member  150  is “sandwiched” between the lower and upper transverse sections  121 ,  122 . As can be seen, the entirety of the top surface  153  of the decorative member  150  is not in contact with the bottom surface  126  of the upper transverse section  122 . Therefore, the decorative member  150  can be conceptually divided into a covered portion  152  that is in contact with the bottom surface  126  of the upper transverse section  122  and an exposed portion  151  that is not in contact with the bottom surface  126  of the upper transverse section  122 . Thought of another way, the upper transverse section  122  overlies the covered portion  152  of the decorative member  150  while the exposed portion  151  is exposed via an aperture  140 , as will be discussed in more detail below. 
         [0036]    As mentioned above, the upper transverse section  122  comprises an aperture  140  extending therethrough. The aperture  140  forms a transverse passageway through the upper transverse section  122  extending from outside of the oral care implement  100  to the exposed portion  151  of the decorative member  150 . In one embodiment, the aperture  140  occupies between 5% to 95% of the transverse cross-sectional area of the upper transverse section  122  (for at least one axial position). In a more specific embodiment, the aperture  140  occupies between 25% to 75% of the transverse cross-sectional area of the upper transverse section  122  (for at least one axial position). Of course, the invention is not to be limited by the size of the aperture  140  and may occupy more or less of the transverse cross-sectional area of the upper transverse section  122  as desired. Furthermore, in the exemplified embodiment, the aperture  140  is an oval that is elongated along the longitudinal axis A-A. Other shapes and sizes of the aperture  140  can be used to expose different sizes and shapes of the decorative member  150  or portions thereof as would be known to persons skilled in the art. 
         [0037]    As noted above, in a preferred embodiment, the upper transverse section  122  is formed of a transparent material so that the covered portion  152  of the decorative member  150 , in addition to the exposed portion  151 , are visible to user. Specifically, the covered portion  152  of the decorative member  150  is visible through the transparent material of the upper transverse section  122  while the exposed portion is visible through the aperture  140 . While the visibility of the covered portion  152  of the decorative member  150  may be distorted or otherwise altered due to being viewed through the transparent material, the exposed portion  151  of the decorative member  150  will be clearly viewable without any distortion as it is viewed in an unimpeded manner via the aperture  140 . 
         [0038]    The exposed portion  151  of the decorative member  150  is circumferentially surrounded by the covered portion  152  of the decorative member  150 . Thus, in the exemplified embodiment, the covered portion  152  of the decorative member  150  is a perimeter portion of the decorative member  150 . In other embodiment, the covered portion  152  of the decorative member  150  may only consist of a portion (or portions) of the perimeter of the decorative member  150  so that at least a part of the peripheral edge of the decorative member  150  is exposed through the aperture  140 . In other embodiments, the entirety of the decorative member  150  may be located within and exposed via the aperture  140 . In such an embodiment, the entirety of the decorative member  150  is the exposed portion  151 . 
         [0039]    In certain embodiments, the visual indica are located, at least in part, on the exposed portion  151  of the decorative member  150 . Such positioning of the visual indicia enhances visibility of the visual indicia because it is not covered by the upper transverse section  122 . However, as will be described below, the exposed portion  151  of the decorative member  150  is still protected against wear and other contact damage because it is recessed with respect to the outer surface  123  of the handle  120 . 
         [0040]    Referring now to  FIGS. 2 and 3  concurrently, the details of the aperture  140  (and its forming structure) will be described in more detail. When the handle  120  of the oral care implement  100  is assembled (as illustrated in  FIGS. 2 and 3 ), the aperture  140  forms a basin  145  in the outer surface  123  of the upper transverse section  122 . The floor of the basin  145  is formed by a top surface  153  of the decorative member  150  and, more specifically, the top surface  153  of the exposed portion  151  of the decorative member  150 . An upstanding wall  141  extends upward from the top surface  153  of the exposed portion  151  of the decorative member  150  and terminates at the outer surface  123  of the upper transverse section  122 . In the illustrated embodiment, the upstanding wall  141  extends from the top surface  153  of the decorative member  150  in an inclined manner relative thereto. In one embodiment, the upstanding wall  141  is inclined at an angle Θ relative to the top surface  153 , wherein the angle Θ is in a range between 93° to 135°. However, the invention is not so limited and, in other embodiments, the upstanding wall  141  may extend from the top surface  153  of the decorative member  150  in a substantially normal manner. 
         [0041]    As mentioned above, the exposed portion  151  of the decorative member  150  is recessed relative to the outer surface  123  of the upper transverse section  122 . Thus, a user can grip the handle  120  without coming into contact with the decorative member  150 . This structure protects the decorative member  150  against wear and other contact-induced damage. Moreover, even if the oral care implement  100  is placed against a flat surface, such as a countertop, the decorative member  150  will not contact the flat surface because it is recessed relative to the outer gripping surface of the handle  120 . 
         [0042]    Referring now to  FIG. 4 , a transverse cross-section of a portion of the oral care implement  100  that does not include the aperture  140  is illustrated. While the cross-sectional view of  FIG. 4  is taken at a location near the proximal end  101  of the handle  120 , the description below is also applicable to the other portions of the handle  120  that do not include the aperture  140  but include the decorative member  150 . In these sections of the handle  120 , the covered portions  152  of the decorative member  150  are “sandwiched” between the lower and upper transverse sections  121 ,  122  . In embodiments where the upper transverse section  122  is transparent, the decorative member  150  is visible through the upper transverse section  122 . 
         [0043]    On the portions of the handle  120  that do not include the aperture  140  and do not include the decorative member  150 , the first transverse section  121  is coupled directly to the upper transverse section  122  through direct contact and coupling between the top surface  125  of the first transverse section  121  to the bottom surface  126  of the upper transverse section  122  in the manner discussed above. Of course, an intervening layer and/or material may be used in certain embodiments. Moreover, while the top and bottom surfaces  125 ,  126  of the upper and lower transverse sections  122 ,  121  are substantially planar in the exemplified embodiment, the invention is not so limited. In other embodiments, one or both of the top and bottom surfaces  125 ,  126  of the upper and lower transverse sections  122 ,  121  can be contoured and/or can include mating topography in the form of protrusions and depressions if desired. 
         [0044]    Referring to  FIG. 5 , a second embodiment of an oral care implement  200  in accordance with the present invention is illustrated. The oral care implement  200  will be described using a similar numbering scheme as used for the oral care implement  100  discussed above, with the exception that the “ 200 ” series of numbers will be used. The oral care implement  200  is substantially similar to the oral care implement  100  except for differences discussed below. In order to avoid redundancy, only those aspects of the oral care implement  200  that differ from the oral care implement  100  will be described below with the understanding that the discussion above with respect to the oral care implement  100  is applicable in all other regards. 
         [0045]    The oral care implement  200  comprises a handle  220  and a head  210 , the head  210  is connected to the handle  220  by a neck  215 . The handle  220  comprises a lower transverse section  221  and an upper transverse section  222 . In this embodiment, the lower transverse section  221  is integral with the neck  215  and the head  210  to form a unitary structure. The upper transverse section  222  is a separate component from the lower transverse section  221 , the neck  215  and the head  210 . The upper transverse section  222  is coupled to the lower transverse section  221  in the manner described above with reference to  FIGS. 1 and 2 . In both the embodiment of  FIG. 2  and the embodiment of  FIG. 5 , when the selected transverse section is integral with the neck and head, it is preferred that the selected transverse section be constructed of a suitable rigid material so that the head and neck have sufficient structural integrity. 
         [0046]    A first method of forming the oral care implement  100  according to one embodiment of the present invention will now be described. While the method will be described below with respect to one particular embodiment of the oral care implement  100  regarding particular materials of construction of the transverse sections  121 ,  122  and the decorative label  150 , it is to be understood that any of the material permutations described above can be utilized in the manufacturing process through suitable substitution. 
         [0047]    At an initial step, the upper transverse section  122  of the handle  120  is formed. The upper transverse section  122  includes the aperture  140 . In one embodiment, the upper transverse section  122  is formed via a molding process, such as injection molding. In one embodiment of the injection molding process, a first mold half and second mold half are positioned together that collectively form an internal space/volume that corresponds to the size and shape of the upper transverse section  122 . A transparent rigid plastic, in molten form, is injected into the space/volume formed by the first mold half and the second mold half to form the upper transverse section  122 . 
         [0048]    The decorative member  150  is applied to the bottom surface  126  of the upper transverse section  122  to at least partially cover (i.e., overlie) the aperture  140 . In this embodiment, the decorative member is preferably a decal, or other type of label, as described above. In one embodiment, the decorative member  140  is applied to the bottom surface  126  of the upper transverse section  122  to cover the entirety of the aperture  140 . The decorative member  150  is applied to the upper transverse section  122  subsequent to its injection molding formation and after adequate cooling of the molten transparent rigid plastic in one embodiment. In another embodiment, the decorative member  150  is positioned within the space/volume formed by the first and second mold halves prior to the injection of the molten transparent rigid plastic. In such an embodiment, the application of the decorative member  150  to the upper transverse section  122  occurs concurrently with the formation of the upper transverse section  122 . 
         [0049]    While an injection molding process is described above to form the upper transverse section  122  with the aperture therein  140 , it is possible to form the aperture  140  in the upper transverse section  122  at a subsequent processing step, such as by milling, machining or drilling the previously formed upper transverse section  122 . Moreover, it is possible to form the upper transverse section  122  using other manufacturing techniques, such as stamping, machining, milling, and/or combinations thereof. Finally, while not required in all embodiments of the inventive method, during the formation of the upper transverse section  122 , the neck  115  and the head  120  of the oral care implement  100  are also concurrently and integrally formed as a unitary structure with the upper transverse section  122  using one of the techniques disclosed above, and preferably injection molding. 
         [0050]    Once the upper transverse section  122  is formed and the decorative member  150  is applied thereto as described above, the lower transverse section  121  of the handle  120  is formed and coupled to the upper transverse section  122  so that the decorative member  150  is disposed therebetween and at least a portion  151  of the decorative member  150  is exposed via the aperture  140 . In one embodiment, the lower transverse section  121  is formed via a molding process, such as injection molding. In one embodiment, the lower transverse section  121  injection molding process is accomplished by leaving the recently formed upper transverse section  122  (with the applied decorative member  150 ) in the first mold half, removing the second mold half, and positioning a third mold half into contact with the first mold half. In this embodiment, the third mold half will have a cavity/space formed therein that corresponds in size and shape to the lower transverse section  121  and the third mold half will be aligned with the first mold half so that the cavity/space will be in properly aligned spatial communication with the recently formed upper transverse section  122  (with the applied decorative member  150 ). Once properly aligned, a transparent TPE, in molten form, is injected into and fills the cavity/space of the third mold half, thereby contacting and covering the rear surface  154  of the decorative member  150  and the exposed portions of the bottom surface  126  of the upper transverse section  122 . 
         [0051]    While an injection molding process is described above to form the lower transverse section  121 , it is possible to form the lower transverse section  121  using other manufacturing techniques, such as stamping, machining, milling, and/or combinations thereof. Furthermore, while the upper transverse section  122  (with the applied decorative member  150 ) remains in-situ within the first mold half while the second and third mold halves are alternated in the above-desired injection molding process, in certain embodiments, the upper transverse section  122  (with the applied decorative member  150 ) will be transferred out of the first mold half after adequate cooling and positioned in an appropriate space of two different mating mold halves. 
         [0052]    Preferably, when an injection molding process is used, the transparent TPE of the lower transverse section  121  and the transparent rigid plastic of the upper transverse section  122  are selected so that a suitable chemical bond develops therebetween. Of course, materials can be selected that do not chemically bond. In such circumstances, the lower and upper transverse sections  121 ,  122  will be designed so that a mechanical coupling will be effectuated between the lower and upper transverse sections  121 ,  122 , with the decorative member  150  secured therebetween. Alternatively, an intermediate layer can be disposed between the lower and upper transverse sections  121 ,  122  to effectuate a suitable chemical bond and/or mechanical fit. 
         [0053]    A second method of forming the oral care implement  200  according to another embodiment of the present invention will now be described. While the method will be described below with respect to one particular embodiment of the oral care implement  200  regarding particular materials of construction of the transverse sections  221 ,  222  and the decorative label  250 , it is to be understood that any of the material permutations described above can be utilized in the manufacturing process through suitable substitution. 
         [0054]    At an initial step, the lower transverse section  221  of the handle  220  is formed. In one embodiment, the lower transverse section  221  is formed via a molding process, such as injection molding. In one embodiment of the injection molding process, a first mold half and second mold half are positioned together that collectively form an internal space/volume that corresponds to the size and shape of the lower transverse section  221 . A transparent rigid plastic, in molten form, is injected into the space/volume formed by the first mold half and the second mold half to form the lower transverse section  221 . 
         [0055]    The decorative member  250  is applied to the top surface  225  of the lower transverse section  222 . The decorative member  250  in this embodiment can be a decal or a layer of ink printed on the top surface  225 . The decorative member  250  is applied to the lower transverse section  221  subsequent to its injection molding formation and after adequate cooling of the molten transparent rigid plastic in one embodiment. In another embodiment, the decorative member  250  is positioned within the space/volume formed by the first and second mold halves prior to the injection of the molten transparent rigid plastic. In such an embodiment, the application of the decorative member  250  to the lower transverse section  221  occurs concurrently with the formation of the lower transverse section  221 . 
         [0056]    While an injection molding process is described above to form the lower transverse section  221 , it is possible to form the lower transverse section  221  using other manufacturing techniques, such as stamping, machining, milling, and/or combinations thereof. Finally, while not required in all embodiments of the inventive method, during the formation of the lower transverse section  221 , the neck  215  and the head  220  of the oral care implement  200  are also concurrently and integrally formed as a unitary structure with the lower transverse section  222  using one of the techniques disclosed above, and preferably injection molding. 
         [0057]    Once the lower transverse section  221  is formed and the decorative member  150  is applied thereto as described above, the upper transverse section  222  of the handle  220  is formed and coupled to the lower transverse section  221  so that the decorative member  250  is disposed therebetween and at least a portion  251  of the decorative member  250  is exposed via an aperture  240  in the upper transverse section  222 . In one embodiment, the upper transverse section  222  is formed via a molding process, such as injection molding. In one embodiment, the upper transverse section  222  injection molding process is accomplished by leaving the recently formed lower transverse section  221  (with the applied decorative member  150 ) in the first mold half, removing the second mold half, and positioning a third mold half into contact with the first mold half. In this embodiment, the third mold half will have a cavity/space formed therein that corresponds in size and shape to the upper transverse section  222  and the third mold half will be aligned with the first mold half so that the cavity/space will be in properly aligned spatial communication with the recently formed lower transverse section  221  (with the applied decorative member  250 ). Once properly aligned, a transparent TPE, in molten form, is injected into and fills the cavity/space of the third mold half, thereby contacting and covering a portion  252  of the top surface  253  of the decorative member  250  and the exposed portions of the top surface  225  of the lower transverse section  221 . The third mold has a plug portion that corresponds in size and shape to the aperture  240  and contacts the upper surface  253  of the decorative member  250 . As a result, the aperture  240  is formed in alignment with a portion  251  of the decorative member  250  that will remain exposed via the resulting aperture  240 . 
         [0058]    While an injection molding process is described above that forms the upper transverse section  222 , it is possible to form the upper transverse section  222  using other manufacturing techniques, such as stamping, machining, milling, and/or combinations thereof. Furthermore, while the lower transverse section  221  (with the applied decorative member  150 ) remains in-situ within the first mold half while the second and third mold halves are alternated in the above-desired injection molding process, in certain embodiments, the lower transverse section  221  (with the applied decorative member  250 ) will be transferred out of the first mold half after adequate cooling and positioned in an appropriate space of two different mating mold halves. 
         [0059]    Preferably, when an injection molding process is utilized, the transparent TPE of the upper transverse section  222  and the transparent rigid plastic of the lower transverse section  221  are selected so that a suitable chemical bond develops therebetween. Of course, materials can be selected that do not chemically bond. In such circumstances, the lower and upper transverse sections  221 ,  222  will be designed so that a mechanical coupling will be effectuated between the lower and upper transverse sections  221 ,  222 , with the decorative member  250  secured therebetween. Alternatively, an intermediate layer can be disposed between the lower and upper transverse sections  221 ,  222  to effectuate a suitable chemical bond and/or mechanical fit. 
         [0060]    While a number of embodiments of the current invention have been described and illustrated in detail, various alternatives and modifications will become readily apparent to those skilled in the art without departing from the spirit and scope of the invention. As various changes could be made in the above methods, compositions and structures without departing from the scope of the invention, it is intended that all matter contained in this application, including all mechanisms and/or modes of interaction described above, shall be interpreted as illustrative only and not limiting in any way the scope of the appended claims. 
         [0061]    As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

Technology Category: 3