Method of manufacturing toothbrushes with common core

Abstract

A dental implement includes a rigid plastic core handle and an overmold. The overmold may have different exterior configurations for different users with the different configurations altered to anatomically fit the targeted user's hands and to appeal to the targeted user. The method for manufacturing the dental implement includes forming a plastic core in a first mold, removing the plastic core from the first mold, selecting one of a plurality of second molds, with each of the plurality of second molds having a different mold cavity such that an overmold formed by one of the plurality of the second modes and an overmold formed by another one of the plurality of second molds have different configurations, placing the plastic core into the selected one of the plurality of second molds, forming an overmold about the plastic core by injecting an material into the mold cavity, and removing the plastic core and overmold from the mold cavity.

1 . A method of manufacturing a dental implement, the dental implement having a shaft with a plastic core, and an overmold, the method comprising:
 a) forming a plastic core in a first mold;   b) removing the plastic core from the first mold;   c) selecting one of a plurality of second molds, each of the plurality of second molds having a different mold cavity such that an overmold formed by one of the plurality of the second molds and an overmold formed by another one of the plurality of second molds have different configurations;   d) placing the plastic core into the selected one of the plurality of second molds;   e) forming an overmold about the plastic core by injecting a material into the mold cavity of the selected one of the plurality of second molds; and   f) removing the plastic core and overmold from the mold cavity.   
     
     
         2 . The method of  claim 1 , further comprising, after Step e), chemically blending the injected material with the plastic core, and cooling the overmold with the chemically blended injected material and the plastic core forming a chemical bond therebetween. 
     
     
         3 . The method of  claim 2 , wherein the injected material has a temperature that softens the plastic core for chemically blending the core with the injected material. 
     
     
         4 . The method of any one of  claims 1 , further comprising arranging electrically functional elements within the plastic core, the electrically functional elements including an electrically operated functional unit and an electric supply unit connectable to an energy source for energizing the electrically operated functional unit. 
     
     
         5 . The method of any one of  claims 1 , wherein Step d) includes enclosing portions of the plastic core within the mold cavity with the plastic core between the enclosed portions. 
     
     
         6 . The method of any one of  claims 1 , the plastic core including a distal end defining a channel extending into the core, and further comprising inserting electrically functional elements into the channel, and attaching an end cap at the distal end of the plastic core to close the channel. 
     
     
         7 . The method of any one of  claims 1 , the dental implement including a head member and a neck located between the head member and the plastic core, and further comprising attaching a plurality of bristles to the head member to form a brush head. 
     
     
         8 . The method of any one of  claims 1 , wherein the injected material is an elastomer. 
     
     
         9 . The method of any one of  claim 1 , wherein the configurations include one or more of shapes, sizes, colors, patterns, designs and motifs. 
     
     
         10 . A method of manufacturing a dental implement, the dental implement having a shaft with a plastic core, and an overmold, the method comprising:
 a) providing a first plastic core formed from a first mold;   b) selecting a first one of a plurality of second molds, each of the plurality of second molds having a different mold cavity such that an overmold formed by one of the plurality of the second molds and an overmold formed by another one of the plurality of second molds have different configurations;   c) placing the first plastic core into the first one of the plurality of second molds;   d) forming a first overmold about the first plastic core by injecting a material into the mold cavity of the first one of the plurality of second molds;   e) removing the first plastic core and the first overmold from the mold cavity;   f) providing a second plastic core formed from the first mold;   g) selecting a second one of a plurality of second molds;   h) placing the second plastic core into the second one of the plurality of second molds;   i) forming a second overmold about the second plastic core by injecting a material into the mold cavity of the second one of the plurality of second molds; and   j) removing the second plastic core and the second overmold from the mold cavity.   
     
     
         11 . The method of  claim 10 , further comprising,
 after Step d), chemically blending the injected material with the first plastic core, and cooling the first overmold with the chemically blended injected material and the first plastic core forming a chemical bond therebetween; and   after Step i), chemically blending the injected material with the second plastic core, and cooling the second overmold with the chemically blended injected material and the second plastic core forming a chemical bond therebetween;   
     
     
         12 . The method of any one of  claims 10 , wherein the configurations include one or more of shapes, sizes, colors, patterns, designs and motifs. 
     
     
         13 . A dental implement kit, the kit comprising:
 a first dental implement with a first plastic core formed of a first mold;   a first overmold formed of a first one of a plurality of second molds, each of the plurality of second molds having a different mold cavity such that an overmold formed by one of the plurality of the second molds and an overmold formed by another one of the plurality of second molds have different configurations;   a second dental implement with a second plastic core formed of the first mold; and   a second overmold formed of a second one of a plurality of second molds;   wherein the first overmold and the second overmold have different configurations.   
     
     
         14 . The kit of  claim 13 , wherein the first and second overmolds are formed about the plastic core by injecting a material into the mold cavity of the first and second ones of the plurality of second molds respectively. 
     
     
         15 . The kit of  claim 14 , wherein the first and second overmolds are formed about the plastic core by chemically blending the injected material with the first and second plastic cores, and cooling the first and second overmolds with the chemically blended injected material and the first and second plastic cores respectively, forming a chemical bond therebetween. 
     
     
         16 . The kit of  claim 13 , wherein the configurations include one or more of shapes, sizes, colors, patterns, designs and motifs.