Brush head manufacturing methods with protective coatings

Abstract

A method for manufacturing a brush head includes the steps of providing a plurality of bristle tuft retention elements, and inserting at least one bristle tuft into each of the bristle tuft retention elements. The proximal end of each bristle tuft is secured into each bristle tuft retention element. The platen portion of the brush neck is positioned in relation to the proximal ends of the bristle tufts in the retaining elements to define a space in relation to the proximal ends of the bristle tufts. A flexible material is injected into the space to create a flexible material matrix that at least partially encompasses the neck and the proximal ends of the bristle tufts. At least a portion of an exterior of the flexible material matrix is coated with a protective coating.

1 . A method for manufacturing a brush head, the method comprising the steps of:
 providing a plurality of bristle tuft retention elements and a plurality of bristle tufts;   inserting a respective bristle tuft into each of the bristle tuft retention elements;   securing a proximal end of each respective bristle tuft into each of the bristle tuft retention elements;   positioning a platen portion of a neck of the brush head in relation to the proximal ends in a mold, wherein the positioning of the platen portion of the neck defines a space in relation to the proximal ends for injection of a flexible material;   injecting the flexible material into the space in the mold to create a flexible material matrix that at least partially encompasses the platen, retention elements, and the proximal ends; and   coating at least a portion of an exterior of the flexible material matrix with a protective coating.   
     
     
         2 . The method of  claim 1 , wherein the step of securing the proximal ends of the bristle tufts comprises the step of:
 applying heat to the proximal ends of the bristle tufts at a temperature sufficient to at least partially melt the proximal ends, or partially melt the proximal ends and a portion of the bristle tuft retention elements to create a proximal head portion.   
     
     
         3 . The method of  claim 1 , wherein the flexible material matrix is made from a vulcanized thermoplastic elastomer (TPE-V or TPV), or a Polyether Block Amide (PEBA) material, a thermoplastic elastomer (TPE), a silicone or other flexible material. 
     
     
         4 . The method of  claim 1 , wherein each of the neck, platen, and retention elements are made from a material with a higher elastic modulus value than the flexible material, such as a thermoplastic polymer such as polypropylene (PP), or a polyamide-acrylonitrile-butadiene-styrene blend (PA/ABS). 
     
     
         5 . The method of  claim 1 , wherein the protective coating provides increased resistance to one or more chemical compositions, oils or water. 
     
     
         6 . The method of  claim 1 , wherein the protective coating is a thermoplastic vulcanisate (TPV) material, an ultraviolet (UV) curable acrylate, a urethane-based heat curable coating, or a silicone. 
     
     
         7 . The method of  claim 1 , wherein the neck further comprises a gate for injection of the flexible material into said space. 
     
     
         8 . The method of  claim 1 , wherein the coating has a thickness within the range of 50-200 μm. 
     
     
         9 . A method for manufacturing a brush head, the method comprising the steps of:
 providing a plurality of bristle tuft retention elements and a plurality of bristle tufts;   inserting a respective bristle tuft into each of the bristle tuft retention elements;   securing a proximal end of each respective bristle tuft into each of the bristle tuft retention elements;   positioning a platen portion of a neck of the brush head in relation to the proximal ends in a mold, wherein the positioning of the platen portion of the neck defines a space in relation to the proximal ends for injection of a flexible material;   coating at least a portion of the mold with a protective coating; and   injecting the flexible material into the space in the mold to create a flexible material matrix that at least partially encompasses the platen, retention elements, and the proximal ends and forming a layer on top of the flexible material matrix with the protective coating from the mold.   
     
     
         10 . The method of  claim 9 , wherein the coating is applied to an interior surface of the mold prior to injection of the flexible material. 
     
     
         11 . The method of  claim 9 , wherein the flexible material matrix is made from a vulcanized thermoplastic elastomer (TPE-V or TPV), or a Polyether Block Amide (PEBA) material, a thermoplastic elastomer (TPE), a silicone or other flexible material. 
     
     
         12 . The method of  claim 9 , wherein each of the neck, platen, and retention elements are made from a material with a higher elastic modulus value than the flexible material, such as a thermoplastic polymer such as polypropylene (PP), or a polyamide-acrylonitrile-butadiene-styrene blend (PA/ABS). 
     
     
         13 . The method of  claim 9 , wherein the protective coating is a thermoplastic vulcanisate (TPV) material, an ultraviolet (UV) curable acrylate, a urethane-based heat curable coating, or a silicone. 
     
     
         14 . The method of  claim 9 , wherein the neck further comprises a gate for injection of the flexible material into said space. 
     
     
         15 . A brush head, comprising:
 a neck having a platen portion;   a plurality of bristle tufts, each of which comprises a plurality of bristle strands;   a plurality of retention elements, each configured to receive at least one of the plurality of bristle tufts, wherein after the bristle tufts are inserted into the retention elements, the proximal ends of the bristle tufts are secured into the retention elements;   a flexible material matrix formed by injection molding a flexible material around least a portion of the brush neck platen, the plurality of retention elements, and the proximal ends to secure the components together; and   a protective coating ( 60 ) around at least a portion of an exterior of the flexible material matrix ( 30 ).