Oral care implement and method of forming the same

Abstract

An oral care implement having a multi-colored interface. In one embodiment, the invention can be an oral care implement comprising: a handle; and a head comprising: a pre-formed cleaning element assembly having a head plate and a plurality of tooth cleaning elements mounted to the head plate, the head plate formed of a material having a first color; a support body having a socket, the support body formed of a material having a second color; a multi-colored interface formed between a perimeter of the socket and a perimeter of the head plate; and the head plate fused to the support body along at least a portion of the multi-colored interface.

1 . A method of forming a head of an oral care implement, the method comprising:
 a) forming a head plate of a material of a first color,   b) mounting a plurality of tooth cleaning elements to the head plate, thereby forming a cleaning element assembly;   c) forming a support body of a material of a second color, the second color being different than the first color, the support body comprising a socket;   d) forming a multi-colored interface between a perimeter of the head plate and a perimeter of the socket by positioning the head plate of the cleaning element assembly in the socket of the support body; and   e) securing the head plate to the support body thereby forming the head of the oral care implement.   
     
     
         2 . The method according to  claim 1  wherein step e) further comprises fusing the head plate to the support body along at least a portion of the multi-colored interface. 
     
     
         3 . The method according to  claim 2  wherein step e) further comprises sonically welding the head plate to the support body. 
     
     
         4 . The method according to  claim 1  wherein the plurality of tooth cleaning elements comprise bristle tufts, and wherein step b) further comprises:
 b-1) inserting first portions of the bristle tufts through holes in the head plate, second portions of the bristle tufts protruding from a front surface of the head plate; and 
 b-2) fusing the first portions of the bristle tufts together to form a matte adjacent a rear surface of the head plate. 
 
     
     
         5 . The method according to  claim 4  wherein step d) further comprises positioning the head plate of the cleaning element assembly in the socket of the support body so that the matte is located between the head plate and the support body. 
     
     
         6 . The method according to  claim 4  wherein the second portions of the bristle tufts are formed of a material having a third color, the third color being different than the first color. 
     
     
         7 . The method according to  claim 6  wherein at least one of the bristle tufts comprises a third portion forming a distal end of the at least one bristle tuft, the third portion being a fourth color, the fourth color is different than the third color. 
     
     
         8 . The method according to  claim 7  wherein the fourth is the same as the first color. 
     
     
         9 . The method according to  claim 1  wherein the plurality of tooth cleaning elements comprise elastomeric elements, and wherein step b) further comprises injection molding the elastomeric elements onto the head plate. 
     
     
         10 . The method according to  claim 9  wherein the elastomeric elements are formed of a material of a fifth color, the fifth color being different than the first color. 
     
     
         11 . The method according to  claim 1  wherein the perimeter of the head plate is formed by an inwardly stepped surface and the perimeter of the socket is formed by an outwardly stepped surface, and wherein step d) further comprises forming the multi-colored interface by mating the inwardly stepped surface and the outwardly stepped surface. 
     
     
         12 . The method according to  claim 11  wherein the outwardly stepped surface comprises an inclined ledge surface and the inwardly stepped surface comprises a grooved ledge surface, and wherein step d) further comprises positioning the grooved ledge surface adjacent the inclined ledge surface. 
     
     
         13 . An oral care implement comprising:
 a handle; and   a head comprising:
 a pre-formed cleaning element assembly having a head plate and a plurality of tooth cleaning elements mounted to the head plate, the head plate formed of a material having a first color; 
 a support body having a socket, the support body formed of a material having a second color, 
 a multi-colored interface formed between a perimeter of the socket and a perimeter of the head plate; and 
 the head plate fused to the support body along at least a portion of the multi-colored interface. 
   
     
     
         14 . The oral care implement according to  claim 13  wherein the head plate is sonically welded to the support body along at least a portion of the multi-colored interface. 
     
     
         15 . The oral care implement according to  claim 13  wherein the plurality of tooth cleaning elements comprise bristle tufts having first portions that are inserted through holes in the head plate and fused together to form a matte adjacent a rear surface of the head plate and second portions protruding from a front surface of the head plate. 
     
     
         16 . The oral care implement according to  claim 15  wherein the matte is located between the head plate and a floor of the socket. 
     
     
         17 . The oral care implement according to  claim 15  wherein the second portions of the bristle tufts are formed of a material having a third color, the third color being different than the first color. 
     
     
         18 . The oral care implement according to  claim 15  wherein the plurality of tooth cleaning elements further comprise elastomeric elements, and wherein the matte covers a base portion of the elastomeric elements. 
     
     
         19 . The oral care implement according to  claim 18  wherein at least one of the bristle tufts comprises a third portion forming a distal end of the at least one bristle tuft, the third portion being a fourth color, and wherein the fourth color is different than the third color. 
     
     
         20 . The oral care implement according to  claim 19  wherein the fourth color is the same as the first color. 
     
     
         21 . The oral care implement according to  claim 13  wherein the plurality of tooth cleaning elements comprise elastomeric elements that are injection molded onto the head plate. 
     
     
         22 . The oral care implement according to  claim 21  wherein the elastomeric elements are formed of a material of a fifth color, the fifth color being different than the first color. 
     
     
         23 . The oral care implement according to  claim 13  wherein the perimeter of the head plate comprises an inwardly stepped surface and the perimeter of the socket comprises an outwardly stepped surface, and wherein the inwardly stepped surface of the perimeter of the head plate mates with the outwardly stepped surface of the perimeter of the socket when the multi-colored interface is formed. 
     
     
         24 . The oral care implement according to  claim 23  wherein the outwardly stepped surface comprises an inclined ledge surface and the inwardly stepped surface comprises a grooved ledge surface, and wherein the grooved ledge surface is positioned adjacent the inclined ledge surface when the multi-colored interface is formed. 
     
     
         25 . The oral care implement according to  claim 24  wherein a gap exists between the grooved ledge surface and the inclined ledge surface.