Toothbrush with injection-moulded bristles and method and apparatus for producing the same

Abstract

A toothbrush having a brush body and a bristle carrier that is produced from a hard material using an injection molding method and having injection-molded bristles that protrude from the bristle carrier. The injection molded bristles are produced from a bristle material using the injection molding method. The bristles have a bristle stem and the bristle carrier has a small carrier plate or is formed by the small carrier plate that is produced from a hard material using the injection molding method and fastened on the brush body. The hard material of the bristle carrier or the hard material of the small carrier plate is harder than the bristle material.

The invention claimed is: 
     
         1 . A toothbrush comprising:
 a brush body; and   a bristle carrier that is produced from a hard material using an injection molding method and having injection-molded bristles that protrude from the bristle carrier,   wherein the injection-molded bristles are produced from a bristle material using the injection molding method, and have a bristle stem,   wherein the bristle carrier comprises a small carrier plate produced from a hard material using the injection molding method and fastened on the brush body in a small carrier plate accommodating recess in a head region of the brush body into which the small carrier plate is inserted in its assembled state, and   wherein the hard material of the bristle carrier or the hard material of the small carrier plate is harder than the bristle material,   the toothbrush further comprising a massaging and cleaning element protruding on the same side of the bristle carrier as the injection-molded bristles, injected on the bristle carrier and made from a soft material wherein a Shore hardness of the soft material massaging and cleaning element is lower than a Shore hardness of the bristle material.   
     
     
         2 . The toothbrush as claimed in  claim 1 , wherein the small carrier plate contains a distributing channel or a passage for the bristle material. 
     
     
         3 . The toothbrush as claimed in  claim 1 , wherein the small carrier plate has a hard material and the brush body has an identical or at least affine hard material at the connecting point between the small carrier plate and the brush body. 
     
     
         4 . The toothbrush as claimed in  claim 1 , wherein the small carrier plate on the brush body is fastened by means of ultrasonic welding, bonding, snapping-in, or latching. 
     
     
         5 . The toothbrush as claimed in  claim 4 , wherein, in the case of ultrasonic welding, channel walls of the small carrier plate form the welding support and an offset TPE layer serves for centering the small carrier plate in a trough-shaped recess in the head part of the brush body. 
     
     
         6 . The toothbrush as claimed in  claim 1 , wherein the small carrier plate is connected over a portion of an entire circumferential length of the small carrier plate to the brush body to achieve flexibility of the small carrier plate. 
     
     
         7 . The toothbrush as claimed in  claim 1 , wherein the bristle material does not form a material bond with the hard material during the injection molding process and the bristle material and the hard material are connected together mechanically. 
     
     
         8 . The toothbrush as claimed in  claim 1 , wherein the bristle material is distributed such that it enters into positive locking or friction locking with the material of the bristle carrier. 
     
     
         9 . The toothbrush as claimed in  claim 8 , wherein the positive locking takes place as a result of the brush body being penetrated by the bristle material and the bristle material, prior to and after penetration of the brush body, is spread out in a wider manner than the penetration, or as a result of the bristle material wrapping around the brush body from an outside or through openings of the brush body. 
     
     
         10 . The toothbrush as claimed in  claim 1 , wherein a distributing channel, on a rear side of the bristle carrier facing away from the injection-molded bristles, is realized on the bristle carrier and the bristle carrier has passages for the bristle material that extend from the bottom of the distributing channel to a front side of the bristle carrier facing the injection-molded bristles. 
     
     
         11 . The toothbrush as claimed in  claim 1 , wherein further cleaning elements made from soft material using the injection molding method are arranged on the carrier plate. 
     
     
         12 . The toothbrush as claimed in  claim 1 , wherein a distributing channel containing the bristle material is over-molded with a soft or hard material. 
     
     
         13 . The toothbrush as claimed in  claim 1 , wherein the bristle carrier has a surface layer produced from the bristle material. 
     
     
         14 . The toothbrush as claimed in  claim 13 , wherein the injection-molded bristles are realized integrally with the surface layer and protrude from the surface layer. 
     
     
         15 . The toothbrush as claimed in  claim 1 , wherein there is no contact between the bristle material and the soft material. 
     
     
         16 . The toothbrush as claimed in  claim 1 , wherein the soft material can cover certain positions of the bristle material. 
     
     
         17 . The toothbrush as claimed in  claim 1 , wherein the soft material is located on both faces of the bristle carrier. 
     
     
         18 . The toothbrush as claimed in  claim 1 , wherein the injection-molded bristles form bristle bundles. 
     
     
         19 . The toothbrush as claimed in  claim 18 , wherein the number of injection-molded bristles in each case forming a bristle bundle is between 2 and 15. 
     
     
         20 . The toothbrush as claimed in  claim 1 , wherein a ratio between the diameter of the injection-molded bristles—measured at the usage-side end of the bristle stem—and the exposed length of the injection-molded bristles is at least 1:35. 
     
     
         21 . The toothbrush as claimed in  claim 1 , wherein a diameter of the injection-molded bristles on the bristle-carrier-side end is between 0.5 and 1 mm. 
     
     
         22 . The toothbrush as claimed in  claim 1 , wherein between 100 and 500 injection-molded bristles are provided. 
     
     
         23 . The toothbrush as claimed in  claim 1 , wherein the soft material is comprised of thermoplastic polyurethane elastomer (TPE-U), thermoplastic styrene elastomers (TPE-S), thermoplastic polyamide elastomer (TPE-A), thermoplastic polyolefin elastomer (TPE-O), thermoplastic polyester elastomers (TPE-E), thermoplastic polyethylene (PE) or polyurethane (PU), and a hardness of the soft material is less than 90 Shore A. 
     
     
         24 . The toothbrush as claimed in  claim 1 , wherein the hardness of the soft material for the bristle-free, flexible massaging and cleaning elements is less than 40 Shore A. 
     
     
         25 . The toothbrush as claimed in  claim 1 , wherein the bristle carrier consists of at least one hard material and the bristle material differs from the hard material. 
     
     
         26 . The toothbrush as claimed in  claim 1 , wherein the hard material for the bristle carrier or for the small carrier plate and, where applicable, for the brush body, is at least one of the following thermoplastics: styrene polymer; polyolefin; polyester; cellulose derivative; polyamides (PA); polymethyl methacrylate (PMMA); polycarbonate (PC); polyoxymethylene (POM); polyvinyl chloride (PVC); and polyurethane (PUR). 
     
     
         27 . The toothbrush as claimed in  claim 1 , wherein the bristle material is an elastomer with a Shore D hardness of between 10 and 100. 
     
     
         28 . The toothbrush as claimed in  claim 1 , wherein the bristle carrier is connected to an electric drive element and can be set into an oscillating, pivoting or translatory movement by the latter. 
     
     
         29 . The toothbrush as claimed in  claim 28 , wherein the bristle carrier is driven at a movement frequency of between 6,000 and 20,000 movement cycles per minute and a path of the usage-side ends of the injection-molded bristles-per movement cycle-is smaller than 5 mm per direction. 
     
     
         30 . The toothbrush as claimed in  claim 1 , wherein the front side of the small carrier plate is flat or is in a three-dimensional form and/or is produced using the two-component or multiple-component injection molding method. 
     
     
         31 . A toothbrush comprising:
 a brush body; and   a bristle carrier that is produced from a hard material using an injection molding method and having injection-molded bristles that protrude from the bristle carrier,   wherein the injection-molded bristles are produced from a bristle material using the injection molding method, and have a bristle stem,   wherein the bristle carrier comprises a small carrier plate produced from a hard material using the injection molding method and fastened on the brush body in a small carrier plate accommodating recess in a head region of the brush body into which the small carrier plate is inserted in its assembled state, and   wherein the hard material of the bristle carrier or the hard material of the small carrier plate is harder than the bristle material,   the toothbrush further comprising a tongue cleaner on the side facing away from the bristles, injected on the bristle carrier and made from a soft material wherein a Shore hardness of the tongue cleaner is lower than a Shore hardness of the bristle material.   
     
     
         32 . A toothbrush comprising:
 a brush body; and   a bristle carrier that is produced from a hard material using an injection molding method and having injection-molded bristles that protrude from the bristle carrier,   wherein the injection-molded bristles are produced from a bristle material using the injection molding method, and have a bristle stem,   wherein the bristle carrier comprises a small carrier plate produced from a hard material using the injection molding method and fastened on the brush body in a small carrier plate accommodating recess in a head region of the brush body into which the small carrier plate is inserted in its assembled state,   wherein the hard material of the bristle carrier or the hard material of the small carrier plate is harder than the bristle material, and   wherein extruded, conventional bristles being arranged on the bristle carrier are provided.   
     
     
         33 . The toothbrush as claimed in  claim 32 , wherein the extruded, conventional bristles are guided through passages of the bristle carrier and are melted on the rear side of the bristle carrier on their end facing away from the usage-side end, to form a melt carpet for fastening the extruded, conventional bristles on the bristle carrier. 
     
     
         34 . The toothbrush as claimed in  claim 33 , wherein the melt carpet covers a distributing channel for the bristle material at least in part. 
     
     
         35 . The toothbrush as claimed in  claim 32 , wherein the extruded, conventional bristles are arranged in further bristle bundles each with between 20 and 300 bristle ends on the usage side. 
     
     
         36 . A toothbrush comprising:
 a brush body; and   a bristle carrier that is produced from a hard material using an injection molding method and having injection-molded bristles that protrude from the bristle carrier,   wherein the injection-molded bristles are produced from a bristle material using the injection molding method,   wherein the bristles have a bristle stem and a bristle end and the bristle carrier comprises a small carrier plate that is produced from a hard material using the injection molding method and fastened on the brush body,   wherein bundles with extruded, conventional bristles are arranged on the bristle carrier or the small carrier plate, the number of bristles with extruded, conventional bristles being greater than the number of bristle ends of injection-molded bristles, and   wherein further bristle bundles, which do not stand at right angles with respect to the surface of the bristle carrier, can be formed of extruded, conventional bristles, wherein the further bristle bundles form a so-called X position or protrude laterally beyond the brush head.   
     
     
         37 . The toothbrush as claimed in  claim 36 , wherein a ratio between the number of bristle ends of injection-molded bristles and the number of bristles with extruded, conventional bristles is between 1:2 and 1:40. 
     
     
         38 . The toothbrush as claimed in  claim 36 , wherein the extruded, conventional bristles are longer than the injection molded bristles. 
     
     
         39 . The toothbrush as claimed in  claim 36 , wherein zones with bristle bundles of injection-molded bristles alternate with zones with bristle bundles of extruded, conventional bristles wherein the alternating rows are in the longitudinal or transverse direction. 
     
     
         40 . The toothbrush as claimed in  claim 36 , wherein zones with bristle bundles made of injection-molded bristles are surrounded by bristle-free, flexible cleaning and massaging elements. 
     
     
         41 . A toothbrush comprising:
 a brush body;   a bristle carrier that is produced from a hard material using an injection molding method and having injection-molded bristles that protrude from the bristle carrier; and   a massaging and cleaning element protruding on the same side of the bristle carrier as the injection-molded bristles,   wherein the injection-molded bristles are produced from a bristle material using an injection molding method and the massaging and cleaning element is injection molded on the bristle carrier and is made from a soft material, a Shore hardness of the soft material massaging and cleaning element being lower than a Shore hardness of the bristle material,   wherein the bristle carrier comprises a small carrier plate that is produced from a hard material using the injection molding method and fastened on the brush body in a small carrier plate accommodating recess in a head region of the brush body into which the small carrier plate is inserted in its assembled state,   wherein bundles with extruded, conventional bristles are arranged on the bristle carrier or the small carrier plate, and   wherein the bristles with extruded, conventional bristles are melted on their end facing away from the usage-side end.   
     
     
       42. A toothbrush comprising:
 a brush body including a handle part, a neck part and a head part, the head part having a front side and a rear side; and   a bristle carrier that is produced from a hard material using an injection molding method and having injection-molded bristles that protrude from the bristle carrier,   wherein the injection-molded bristles are produced from a bristle material using the injection molding method,   wherein the bristle carrier comprises a small carrier plate fastened in a corresponding recess in the head part or wherein the bristle carrier is formed by the head part,   wherein on the rear side of the head part a distribution channel is situated, the distribution channel being fluidly connected to the front side of the head part via multiple passages, and   wherein the bristle material is non-releasably connected by means of positive and/or friction locking to the bristle carrier without forming a material bond with the hard material of the bristle carrier,   the toothbrush further comprising at least one of (a) a tongue cleaner on a side facing away from the injection-molded bristles, injected on the bristle carrier and made from a soft elastomeric material, and (b) a massaging and cleaning element protruding on a same side of the bristle carrier as the injection-molded bristles and made from a soft elastomeric material.   
     
     
       43. The toothbrush as claimed in  claim 42 , wherein the front side and the rear side of the head part being in a three-dimensional form. 
     
     
       44. The toothbrush as claimed in  claim 42 , wherein the multiple passages comprise at least two different shapes. 
     
     
       45. The toothbrush as claimed in  claim 42 , wherein the multiple passages are arranged symmetrically along a longitudinal extension of the head part. 
     
     
       46. The toothbrush as claimed in  claim 42 , wherein the multiple passages are arranged symmetrically along a transverse extension of the head part. 
     
     
       47. The toothbrush as claimed in  claim 42 , wherein in a central region of the head part there is provided a single passage being approximately in the form of an oval which extends transversely with respect to the longitudinal extension of the head part. 
     
     
       48. The toothbrush as claimed in  claim 42 , wherein the bristle material and the hard material are connected together mechanically. 
     
     
       49. The toothbrush as claimed in  claim 42 , wherein the positive locking takes place as a result of the head part being penetrated by the bristle material and the bristle material, prior to and after penetration of the head part, is spread out in a wider manner than the penetration, or as a result of the bristle material wrapping around the head part from an outside or through the passages of the head part. 
     
     
       50. The toothbrush as claimed in  claim 42 , wherein the injection-molded bristles form bristle bundles. 
     
     
       51. The toothbrush as claimed in  claim 50 , wherein the number of injection-molded bristles in each case forming a bristle bundle is between 2 and 15. 
     
     
       52. The toothbrush as claimed in  claim 42 , a ratio between the diameter of the injection-molded bristles, measured at a usage-side end of a bristle stem, and the exposed length of the injection-molded bristles is at least 1 : 35. 
     
     
       53. The toothbrush as claimed in  claim 42 , wherein a diameter of the injection-molded bristles on a bristle-carrier-side end is between 0.5 and 1 mm. 
     
     
       54. The toothbrush as claimed in  claim 42 , wherein between 100 and 500 injection-molded bristles are provided. 
     
     
       55. The toothbrush as claimed in  claim 42 , wherein the hard material for the bristle carrier and, where applicable, for the brush body, is at least one of the following thermoplastics: styrene polymer; polyolefin; polyester; cellulose derivative; polyamides (PA); polymethyl methacrylate (PMMA); polycarbonate (PC); polyoxymethylene (POM); polyvinyl chloride (PVC); and polyurethane (PUR). 
     
     
       56. The toothbrush as claimed in  claim 42 , wherein the bristle material is an elastomer with a Shore D hardness of between 10 and 100. 
     
     
       57. A toothbrush comprising:
 a brush body including a handle part, a neck part and a head part, the head part having a front side and a rear side; and   a bristle carrier that is produced from a hard material using an injection molding method and having injection-molded bristles that protrude from the bristle carrier,   wherein the injection-molded bristles are produced from a bristle material using the injection molding method,   wherein the bristle carrier comprises a small carrier plate fastened in a corresponding recess in the head part or wherein the bristle carrier is formed by the head part,   wherein the bristle carrier of the head part further comprises multiple passages,   wherein the bristle material wraps around the head part from an outside or through the passages of the head part, and   wherein the hard material of the bristle carrier is harder than the bristle material,   the toothbrush further comprising at least one of (a) a tongue cleaner on a side facing away from the injection-molded bristles, injected on the bristle carrier and made from a soft elastomeric material, and (b) a massaging and cleaning element protruding on a same side of the bristle carrier as the injection-molded bristles and made from a soft elastomeric material.   
     
     
       58. The toothbrush as claimed in  claim 57 , wherein the front side and the rear side of the head part are in a three-dimensional form. 
     
     
       59. The toothbrush as claimed in  claim 57 , wherein the bristle material is non-releasably connected by means of positive and/or friction locking to the bristle carrier without forming a material bond with the hard material of the bristle carrier. 
     
     
       60. The toothbrush as claimed in  claim 57 , wherein the multiple passages comprise at least two different shapes. 
     
     
       61. The toothbrush as claimed in  claim 57 , wherein the multiple passages are arranged symmetrically along a longitudinal extension of the head part. 
     
     
       62. The toothbrush as claimed in  claim 57 , wherein the multiple passages are arranged symmetrically along a transverse extension of the head part. 
     
     
       63. The toothbrush as claimed in  claim 57 , wherein in a central region of the head part there is provided a single passage being approximately in the form of an oval which extends transversely with respect to the longitudinal extension of the head part.