Oral care products and methods of using and making the same

Abstract

An oral care implement may include a base portion sized for insertion into an oral cavity and a plurality of flexible, elastomeric elements extending from the base portion, wherein each of the plurality of flexible, elastomeric elements comprises an edge, wherein at least one of the edges comprises a micro edge, and wherein the plurality of flexible, elastomeric elements comprises an element density of less than about 5 mm. Another embodiment of an oral care implement may include a base portion sized for insertion into an oral cavity and a plurality of flexible, elastomeric elements extending from the base portion, wherein at least one of the plurality of flexible, elastomeric elements comprises a first section having a first section edge and a first transverse cross sectional area, and a second section disposed adjacent to the first section along a longitudinal axis of the at least one of the plurality of flexible, elastomeric elements, the second section having a second section edge and a second transverse cross sectional area different from the first transverse cross sectional area. Yet another embodiment of an oral care implement includes a base portion sized for insertion into an oral cavity, the base portion having a base wall and two opposed, side walls connected to the base wall that form a channel for receiving teeth within an oral cavity and a plurality of flexible, elastomeric elements extending into the channel from the base and two opposed, side walls.

What is claimed is: 
     
         1 . An oral care implement comprising:
 a base portion sized for insertion into an oral cavity; and   a plurality of flexible, elastomeric elements extending from the base portion, wherein:
 each of the plurality of flexible, elastomeric elements comprises an edge, 
 at least one of the edges comprises a micro edge, and 
 the plurality of flexible, elastomeric elements comprises an element density of less than about 5 mm. 
   
     
     
         2 . The oral care implement of  claim 1 , wherein the element density is from about 0.1 mm to about 3.0 mm. 
     
     
         3 . The oral care implement of  claim 2 , wherein the element density is from about 0.1 to about 2.0 mm. 
     
     
         4 . The oral care implement of  claim 1 , wherein the micro edge comprises a tip radius (R) that is less than 0.02 mm. 
     
     
         5 . The oral care implement of  claim 4 , wherein the micro edge comprises a tip radius (R) that is less than or equal to about 0.015 mm. 
     
     
         6 . The oral care implement of  claim 1 , wherein the micro edge comprises a tip radius (R) that is from about 0.015 mm to about 0.0015 mm. 
     
     
         7 . The oral care implement of  claim 1 , wherein at least one of the edges comprises an out-gassed edge. 
     
     
         8 . The oral care implement of  claim 1 , wherein the plurality of flexible, elastomeric elements are not extruded elastomeric elements. 
     
     
         9 . The oral care implement of  claim 1 , wherein the plurality of flexible, elastomeric elements comprise a material having a Shore Hardness of from about 8 Shore A to about 75 Shore D. 
     
     
         10 . The oral care implement of  claim 9 , wherein the plurality of flexible, elastomeric elements comprise a material comprising a Shore Hardness of from about 35 Shore A to about 55 Shore D. 
     
     
         11 . The oral care implement of  claim 10 , wherein the material further comprises a wet friction greater than about 0.05. 
     
     
         12 . The oral care implement of  claim 11 , wherein the plurality of flexible, elastomeric elements have a length from about 0.05 mm to about 10 mm. 
     
     
         13 . The oral care implement of  claim 12 , wherein the length comprises from about 2.0 mm to about 6 mm. 
     
     
         14 . The oral care implement of  claim 11 , wherein the material further comprises:
 a hardness from about 55 Shore A to about 55 Shore D,   a wet friction greater than about 0.1,   a surface tension greater than about 500 Nm −1 ×10 4 , and   a material density from about 0.05 g/cm 3  to about 3.0 g/cm 3 .   
     
     
         15 . The oral care system of  claim 14 , wherein the surface tension is greater than about 600 Nm −1 ×10 4  and the material density is from about 0.5 g/cm 3  to about 2.0 g/cm 3 . 
     
     
         16 . An oral care implement comprising:
 a base portion sized for insertion into an oral cavity; and   a plurality of flexible, elastomeric elements extending from the base portion;   wherein at least one of the plurality of flexible, elastomeric elements comprises
 a first section having a first section edge and a first transverse cross sectional area, and 
 a second section disposed adjacent to the first section along a longitudinal axis of the at least one of the plurality of flexible, elastomeric elements, the second section having a second section edge and a second transverse cross sectional area different from the first transverse cross sectional area. 
   
     
     
         17 . The oral care implement of  claim 16 , wherein the second transverse cross sectional area is less than the first transverse cross sectional area. 
     
     
         18 . The oral care implement of  claim 16 , wherein:
 the first transverse cross sectional area has a first shape;   the second transverse cross sectional area has a second shape; and   the first shape is different from the second shape.   
     
     
         19 . The oral care implement of  claim 16 , wherein the at least one of the plurality of flexible, elastomeric elements further comprises a third section having a third transverse cross sectional area that is disposed adjacent to the second section along the longitudinal axis, and wherein the third transverse cross sectional area is different than the first and second transverse cross sectional areas. 
     
     
         20 . The oral care implement of  claim 19 , wherein the third transverse cross sectional area is less than the first and second transverse cross sectional areas. 
     
     
         21 . The oral care implement of  claim 19 , wherein the at least one of the plurality of flexible, elastomeric elements further comprises a fourth section having a fourth transverse cross sectional area that is disposed adjacent to the third section along the longitudinal axis of the at least one of the plurality of flexible, elastomeric elements, and wherein the fourth transverse cross sectional area is different than the first, second, and third transverse cross sectional areas. 
     
     
         22 . The oral care implement of  claim 21 , wherein the third transverse cross sectional area is less than the first and second transverse cross sectional areas and the fourth transverse cross sectional area is less than the first, second, and third transverse cross sectional areas. 
     
     
         23 . The oral care implement of  claim 16 , wherein the first and second section edges comprise a tip radius (R) that is less than 0.0254 mm. 
     
     
         24 . The oral care implement of  claim 23 , wherein the first and second section edges comprise a tip radius (R) that is less than or equal to about 0.015 mm. 
     
     
         25 . The oral care implement of  claim 24 , wherein the first and second section edges comprise a tip radius (R) that is from about 0.015 mm to about 0.0015 mm. 
     
     
         26 . The oral care implement of  claim 14 , wherein the plurality of flexible elements are disposed on the base portion such that the base portion comprises an element density from about 0.1 to about 3.0 mm. 
     
     
         27 . The oral care implement of  claim 16 , wherein the first and second section edges comprise out-gassed edges. 
     
     
         28 . The oral care implement of  claim 16 , wherein the first and second section edges are transverse edges. 
     
     
         29 . The oral care implement of  claim 28 , wherein the second section further comprises a longitudinal edge. 
     
     
         30 . The oral care implement of  claim 16 , wherein the first and second section edges are longitudinal edges. 
     
     
         31 . The oral care implement of  claim 16 , wherein the base portion is substantially U-shaped such that upon insertion into a human mouth, the plurality of flexible, elastomeric elements are adjacent to surfaces of teeth within the mouth. 
     
     
         32 . The oral care implement of  claim 16 , further comprising a drive mechanism connected to the base for driving the plurality of flexible, elastomeric elements into engagement with the teeth and/or gums within an oral cavity. 
     
     
         33 . The oral care implement of  claim 32 , wherein the drive mechanism selected from the group consisting of a bladder, ultrasonic drive, vibrating drive, oscillating drive, electric motor, piezoelectric actuator, electrostrictive actuator, electromagnetic actuator, magnetostrictive actuator, acoustostrictive actuator, photostrictive actuator, and chemostrictive actuator. 
     
     
         34 . The oral care implement of  claim 32 , wherein the drive mechanism comprises a bladder connected to a side of the base portion opposite the plurality of flexible, elastomeric elements. 
     
     
         35 . The oral care implement of  claim 34 , further comprising a fluid source in fluid communication with an interior chamber of the bladder for providing a fluid to the bladder. 
     
     
         36 . The oral care implement of  claim 35 , wherein the fluid source comprises a pump and a vacuum for pumping fluid to the bladder and for evacuating the fluid from the bladder. 
     
     
         37 . An oral care implement comprising:
 a base portion sized for insertion into an oral cavity, the base portion having a base wall and two opposed, side walls connected to the base wall that form a channel for receiving teeth within an oral cavity; and   a plurality of flexible, elastomeric elements extending into the channel from the base and two opposed, side walls, wherein:
 each of the plurality of flexible, elastomeric elements comprises an edge and a longitudinal axis, 
 at least one of the plurality of flexible, elastomeric elements comprises a first section having a first transverse cross sectional area and a second section having a second transverse cross sectional area that is disposed adjacent to the first section along the longitudinal axis of the at least one flexible, elastomeric element, and 
 the second transverse cross sectional area is different than the first transverse cross sectional area. 
   
     
     
         38 . A method of forming a micro edge of an flexible, elastomeric element, the method comprising:
 forming a mold cavity with a first mold plate and a second mold plate positioned adjacent to the first mold plate;   forming a mold corner of the mold cavity using an intersection of the first mold plate and second mold plate;   injecting an elastomer into the mold cavity; and   allowing gas contained within the mold cavity to out-gas through the intersection between the first and second mold plates to form a micro edge along the mold corner formed by the intersection.   
     
     
         39 . The method of  claim 38 , wherein the step of forming a mold cavity with a first mold plate and a second mold plate positioned adjacent to the first mold plate comprises forming a first mold cavity and a second mold cavity, and wherein the step of forming a mold corner of the mold cavity using an intersection of the first mold plate and second mold plate comprises forming a first mold corner of the first mold cavity and a second mold corner of the second mold corner using the intersection of the first mold plate and second mold plate. 
     
     
         40 . The method of  claim 39 , wherein the step of forming a mold cavity with a first mold plate and a second mold plate positioned adjacent to the first mold plate comprises forming a plurality of mold cavities with a first mold plate and a second mold plate adjacent to the first mold plate, and wherein the step of forming a mold corner of the mold cavity using an intersection of the first mold plate and second mold plate comprises forming a mold corner for each of the plurality mold cavities using the intersection of the first mold plate and second mold plate. 
     
     
         41 . The method of  claim 38 , wherein the step of forming a mold corner of the mold cavity using an intersection of the first mold plate and second mold plate comprises forming a first corner and a second corner of the mold cavity using an intersection of the first mold plate and the second mold plate. 
     
     
         42 . The method of  claim 38 , wherein the step of forming a mold cavity with a first mold plate and a second mold plate positioned adjacent to the first mold plate forming a plurality of mold cavities with a first mold plate and a plurality of mold plates adjacent to the first mold plate, and wherein the step of forming a mold corner of the mold cavity using an intersection of the first mold plate and second mold plate comprises forming a plurality of mold corners of the plurality of mold cavities using a plurality of intersections of the first mold plate and the plurality of mold plates. 
     
     
         43 . The method of  42 , wherein the step of forming a mold corner of the mold cavity using an intersection of the first mold plate and second mold plate further comprises forming a plurality of mold corners of the plurality of mold cavities using a plurality of intersections between the plurality of mold plates or of the plurality of mold plates and a plurality of mold separators. 
     
     
         44 . The method of  38 , further comprising:
 forming the mold cavity with a third mold plate positioned adjacent to the second mold plate;   forming a second mold corner of the mold cavity using a second intersection of the second mold plate and third mold plate; and   allowing gas contained within the mold cavity to out-gas through the second intersection between the second and third mold plates to form a second micro edge along the second mold corner formed by the second intersection.   
     
     
         45 . The method of  44 , further comprising:
 forming the mold cavity with a fourth mold plate positioned adjacent to the third mold plate;   forming a third mold corner of the mold cavity using a third intersection of the third mold plate and fourth mold plate; and   allowing gas contained within the mold cavity to out-gas through the third intersection between the third and fourth mold plates to form a third micro edge along the third mold corner formed by the third intersection.   
     
     
         46 . The method of  45 , wherein the first mold plate comprises a first plurality of longitudinal cavity mold plates assembled adjacent one another for forming a plurality of longitudinal mold corners using intersections between adjacent longitudinal cavity mold plates of the first plurality of longitudinal cavity mold plates. 
     
     
         47 . The method of  46 , wherein the fourth mold plate comprise a second plurality of longitudinal cavity mold plates adjacent one another for forming a plurality of longitudinal mold corners using intersections between adjacent longitudinal cavity mold plates of the second plurality of longitudinal cavity mold plates. 
     
     
         48 . The method of  claim 38 , wherein the intersection is a transverse intersection formed between the first and second mold plates. 
     
     
         49 . The method of  claim 38 , wherein the intersection is a longitudinal intersection formed between the first and second mold plates.