Toothbrush head or brush carrier

Abstract

The present disclosure relates to a toothbrush head or brush carrier having at least one carrier element, at least one deformation tuft mounted on the carrier element such that the deformation tuft rises from a mounting end on a mounting surface of the carrier element generally along an extension direction towards a free end of the deformation tuft, the deformation tuft having a length from a mounting base to the free end, the deformation tuft comprising a plurality of fibers, and the deformation tuft having a first cross section having a first cross sectional area and a first cross sectional shape at a first length along the extension direction and a second cross section having a second cross sectional area and a second cross sectional shape at a second length along the extension direction, wherein the first cross sectional area and the second cross sectional area are substantially the same and the first cross sectional shape and the second cross sectional shape are different such that the first cross sectional shape does not match the second cross sectional shape independent of an angle of rotation of the first cross sectional shape and independent of a displacement of the first cross sectional shape.

Description

Technical Field

[0001] This disclosure relates to a toothbrush head or brush carrier comprising a cluster having two cross-sections along its length that do not match when overlapped. This disclosure also relates to a method of manufacturing such a toothbrush head. Background Technology

[0002] A known head for an oral care appliance may include a mounting surface, at least one twisted cluster comprising multiple fibers and having a base mounted on the mounting surface, the twisted cluster having an outer face, a longitudinal axis, a lower cross-sectional area extending in a plane perpendicular to the longitudinal axis and disposed at the base, and an upper cross-sectional area extending in a plane perpendicular to the longitudinal axis and disposed at the free end of the twisted cluster, the lower and upper cross-sectional areas having substantially the same shape and size, wherein at least the fibers forming the outer face are each substantially straight and inclined clockwise or counterclockwise relative to the longitudinal axis, and the upper cross-sectional area is twisted relative to the lower cross-sectional area at a twist angle α, and wherein the upper and lower cross-sectional areas are not identical when projected orthogonally to each other along the longitudinal axis. Such a head for an oral care appliance is disclosed in its entirety in document EP 2 910 143 B1.

[0003] There is interest in toothbrush heads or brush carriers, and toothbrushes including clusters formed in an even more general manner to allow for more advanced toothbrush head or brush carrier or toothbrush designs, each meeting advanced requirements for the toothbrush head or brush carrier or toothbrush. A method for manufacturing such advanced clusters and a toothbrush head or brush carrier including such advanced clusters also need to be provided. Summary of the Invention

[0004] According to one aspect, a toothbrush head or brush carrier is provided, comprising at least one carrier element and at least one deformable cluster mounted on the carrier element such that the deformable cluster rises from a mounting end on a mounting surface of the carrier element generally along an extending direction toward a free end of the deformable cluster. The deformable cluster has a length from a mounting base to the free end, the deformable cluster includes a plurality of fibers, and the deformable cluster has a first cross-section and a second cross-section. The first cross-section has a first cross-sectional area and a first cross-sectional shape at a first length along the extending direction, and the second cross-section has a second cross-sectional area and a second cross-sectional shape at a second length along the extending direction, wherein the cross-section is cut... The planes are parallel to each other, preferably wherein the plane located at the first length coincides with or is at least as close as possible to the mounting surface, and the first cross section does not pass through the mounting surface, and more preferably wherein the plane located at the second length coincides with or is at least as close as possible to the free end, such that the second cross section still passes through all the fibers that also pass through the first cross section, and the area of ​​the first cross section and the area of ​​the second cross section are substantially the same, and the shape of the first cross section and the shape of the second cross section are different, such that the shape of the first cross section does not match the shape of the second cross section, regardless of the angle of rotation of the shape of the first cross section and regardless of the displacement of the shape of the first cross section.

[0005] According to one aspect, a toothbrush comprising such a toothbrush head or brush carrier is provided.

[0006] According to one aspect, a method for manufacturing a toothbrush head is provided, the method comprising the following steps:

[0007] • A mold insert is provided having at least one cavity for defining a deformable cluster, the cavity having a length and extending along an extension direction from a first side of the mold insert to a second side of the mold insert opposite to the first side.

[0008] The cavity has a first cross-section (having a first cross-sectional shape and a first cross-sectional area) at a first length and a second cross-section (having a second cross-sectional shape and a second cross-sectional area) at a second length.

[0009] The planes that cut the cross-section are parallel to each other. Preferably, the plane located at the first length coincides with or is at least as close as possible to the first side, and the first cross-section does not pass through the first side. More preferably, the plane located at the second length coincides with or is at least as close as possible to the second side.

[0010] The area of ​​the first cross section and the area of ​​the second cross section are substantially the same, and the shape of the first cross section and the shape of the second cross section are different, so that the shape of the first cross section does not match the shape of the second cross section, and is independent of the angle of rotation of the shape of the first cross section and the displacement of the shape of the first cross section;

[0011] • Multiple fibers are introduced into the cavity, each fiber having a first end and a second end, and the second end of these fibers remains outside the mold insert;

[0012] • At least one of the following operations: melting the second ends of the fibers together to form a joint end of the plurality of fibers, or connecting the second ends of the fibers by applying a bonding material such as an adhesive to form a joint end of the plurality of fibers, in each case the plurality of fibers and the joint end form a deformable cluster;

[0013] • Preferably, the joint end is connected to the carrier element by injection molding of the carrier element around the joint end; and

[0014] • Remove the multiple fibers from the cavity. Attached Figure Description

[0015] This disclosure will be further illustrated by a detailed description of exemplary embodiments and with reference to the accompanying drawings. In the drawings,

[0016] Figure 1A This is a first exemplary embodiment of an exemplary variant cluster according to the present disclosure;

[0017] Figure 1B yes Figure 1A The diagram shows the cross-sectional shapes of the first and second sections of the deformable cluster, which are cut in a plane that coincides with the mounting end and the free end of the cluster.

[0018] Figure 2A This is a second exemplary embodiment of an exemplary variant cluster according to this disclosure;

[0019] Figure 2B yes Figure 2A A schematic diagram of the cross-sectional shapes of the first and second sections of the deformed cluster shown;

[0020] Figure 3A This is a third exemplary embodiment of an exemplary variant cluster according to the present disclosure;

[0021] Figure 3B yes Figure 3A A schematic diagram of the cross-sectional shapes of the first and second sections of the deformed cluster shown;

[0022] Figure 4AThis is a side view of an exemplary brush carrier for a brush head according to the present disclosure, wherein three deformable clusters are mounted on a carrier element;

[0023] Figure 4B yes Figure 4A A top view of the brush carrier shown;

[0024] Figure 5 This is a top view with the carrier elements of the deformable cluster removed;

[0025] Figure 6A In such Figure 4A The section cut at point AA shown passes through Figure 4A A top view of the cross-section of the brush carrier shown;

[0026] Figure 6B In such Figure 4A The cut-off point at plane BB shown Figure 4A A top view of the cross-section of the brush carrier shown;

[0027] Figure 6C In such Figure 4A The cut-off point at plane CC shown Figure 4A A top view of the cross-section of the brush carrier shown;

[0028] Figure 7 It is an illustration of a toothbrush including the toothbrush head according to this disclosure; and

[0029] Figure 8 This is a flowchart of the manufacturing process for producing a toothbrush head or brush carrier according to the present disclosure. Detailed Implementation

[0030] In this disclosure, novel types or categories of clusters are discussed, which are referred to herein as “variant clusters” for the purpose of distinguishing these novel categories of clusters from other cluster types. Therefore, the term “cluster” alone encompasses all possible kinds of clusters, including variant clusters.

[0031] It should be understood that a cluster comprises multiple fibers, such as 10, 47, or 98 fibers, or any other number of fibers, which are joined together in some way, usually but not necessarily by fusing the lower ends of the fibers together or by using a connecting material (such as an adhesive or thermoplastic material). While the ends of the joined fibers are referred to as the lower ends, the opposite upper ends of the fibers are referred to as the free ends, as they are not joined and are intended to contact the tooth surface alone during dental cleaning procedures. Fibers can be made by cutting natural or synthetic filaments to the desired length. Synthetic filaments can be made from a variety of plastic materials such as nylon (polyamides, such as PA6, PA6.6, PA6.10, PA6.12, or PA12), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene (PP), low-density polyethylene (LDPE), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), or any other suitable material. The filaments can have any suitable diameter, such as between 0.075 mm (often also referred to as about 3 mils, where 1 mil is 0.0254 mm) and 0.5 mm, preferably between 0.1 mm and 0.3 mm, for example 0.1 mm, 0.125 mm, 0.15 mm, 0.175 mm, 0.2 mm, 0.25 mm, 0.3 mm, etc. The rayon can have various cross-sectional shapes, such as circular, elliptical, X-shaped, star-shaped, etc. The filaments can be co-extruded from two or more materials with different material parameters (such as colorant additives) and can have a core-sheath structure or an island structure. The filaments can contain any suitable additives, such as colorants, abrasives, antimicrobial materials, active substances such as sodium fluoride (NaF), etc. The filaments can be twisted along their length or include indentations, etc. Filaments used in oral hygiene products such as toothbrushes can be obtained from various suppliers, such as Pedex GmbH, Wald-Michelbach, Germany, or Dupont, Wilmington, Delaware, USA.

[0032] The characteristics of a deformable cluster are as follows:

[0033] -It consists of multiple fibers;

[0034] - It extends from the mounting base toward the free end along the extension direction, wherein the mounting base coincides with the mounting surface of the carrier element, and the deformable cluster is mounted on the mounting surface;

[0035] -It has a length measured along the extension direction from the mounting base toward the free end;

[0036] It includes a first section cut at a first length and a second section cut at a second length different from the first length, wherein the two sections are each cut in a plane and the two planes are parallel to each other;

[0037] - The first cross section has a first cross section area and a first cross section shape, and the second cross section has a second cross section area that is substantially the same as the first cross section area and a second cross section shape that is different from the first cross section shape and cannot be matched with the first cross section shape by rotation and / or displacement.

[0038] Regarding the "mismatch" feature, it should be understood that this refers to the following: the second section is projected parallel to the plane it intercepts onto the parallel plane intercepted by the first section. Therefore, it is impossible to match the first and second sections by displacement and rotation within this joining plane; that is, the first and second sections cannot be made identical through displacement and rotation operations.

[0039] The deformable cluster may have an outer surface extending between a first length and a second length, the outer surface being defined by a straight line connecting each point on the outer edge of the first section to a point on the outer edge of the second section, such that each point on one edge has one and only one corresponding point connected on the other edge.

[0040] As will be explained in more detail below regarding the method of manufacturing deformable clusters, deformable clusters may include connecting ends that can be connected to a carrier element, and the connecting ends may not extend beyond the mounting surface. For example, the connecting ends may be molten blocks of fibrous material generated by heating the corresponding ends of the deformable clusters, such that the fibrous material melts and, once cooled and solidified, forms a substantially homogeneous block of material.

[0041] The deformable cluster is connected to a carrier element having a mounting surface, the visible portion of which rises from the mounting end coinciding with the mounting surface to the free end of the deformable cluster. The deformable cluster typically extends along an extension direction. The mounting surface can be planar, curved (i.e., it can have a three-dimensional shape), or even stepped; that is, the mounting surface may include at least one step, wherein the surface is substantially discontinuous.

[0042] A circular cluster cut by two parallel planes at two far distances has the same cross-section in both cutting planes—the cross-sectional area and cross-sectional shape are always the same. This is independent of the angle of the cutting planes relative to the extension direction of the circular cluster. The same applies to any other cluster with a constant cross-section. Therefore, the angle of the cutting planes relative to the extension direction is irrelevant, because the deformable cluster will always have two mismatched cross-sectional shapes in the two far cutting planes. Therefore, precisely defining the extension direction of the cluster is irrelevant. However, the extension direction can be defined as follows: the deformable cluster is cut by two parallel planes, the distance between these two parallel planes such that the first and second planes pass through the same number of fibers. The center point of area for each cross-section is then determined. The straight line drawn to connect these two center points of area can be said to start from the mounting end and pass through the extension direction of the free end. Although the relationship between the extension direction and the cutting planes may be irrelevant to defining the deformable cluster, the planes in which the cross-sections are cut can be chosen, for example, substantially perpendicular to the extension direction of the deformable cluster, or they can be parallel to the planar mounting surface of the carrier element, or they can be parallel to the planar free end of the deformable cluster.

[0043] As mentioned above, the free ends of the deformable cluster can be planar, that is, the free ends of all the fibers forming the deformable cluster terminate in a plane. However, this should not preclude the free ends of the deformable cluster from having a non-planar topology, wherein the free ends of the fibers forming the deformable cluster terminate on a three-dimensional surface, or wherein the free ends of the fibers forming the deformable cluster terminate in an irregular manner.

[0044] As described above, the deformable cluster has two cross-sections at two different length values ​​along the extension direction, and these two cross-sections have two different cross-sectional shapes. The cross-sectional shape of the deformable cluster can preferably be deformed smoothly from the first cross-sectional shape to the second cross-sectional shape; that is, multiple cross-sectional cuts can be made at multiple planes, each parallel to the planes of the first and second cross-sections, and the difference between the cross-sectional shapes becomes smaller as the parallel planes are positioned closer together along the extension direction. This means that the change in cross-sectional shape occurs without any steps or abrupt changes, i.e., the transition occurs smoothly. In some embodiments, straight lines can be drawn from each point on the edge of the first cross-section to a point on the second cross-section, such that each point on each of the two edges has one and only one corresponding point on the other of the two edges. The multiple straight lines then define the external shape of the deformable cluster at least between the two planes that cut the first and second cross-sections.

[0045] According to some aspects, at least one of the cross-sectional shapes has at least one concave surface, preferably at least one second cross-sectional shape. The free end of the cluster including the concave surface can support good cleaning of the tooth surface because debris can be collected in the concave surface. Since the first cross-sectional shape may not include a concave surface, but may be, for example, circular or without a concave surface, the mounting end of the deformable cluster can benefit from a more stable construction that cannot be provided by a cross-sectional shape with a concave surface, because the fibers around the concave surface can bend more easily, i.e., bend under lower forces, and therefore may provide a less noticeable cleaning effect. Thus, the deformable cluster can achieve both good bending stability and good cleaning properties. However, this should be understood as merely an example. In another example, multiple deformable clusters are arranged on a carrier element such that their mounting bases are optimally held by the carrier element due to their compressed shape, but wherein the free ends of the clusters may have elongated and / or concave shapes.

[0046] Depending on some aspects, the deformable clusters may have an extension direction that is inclined relative to the normal on the mounting surface at the mounting base of the deformable cluster. In the case of two or more deformable clusters, these clusters may have different inclinations; that is, in the case of two deformable clusters, their extension directions may not be parallel, but they may be inclined toward or away from each other, such that the free ends of the clusters may be closer to or further away from each other than their mounting ends.

[0047] As described above, the brush carrier or toothbrush head may include more than one deformable cluster, for example, it may include two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, etc., deformable clusters, wherein each of these deformable clusters may be substantially the same as the other deformable clusters, or each of these deformable clusters may be different from all the other deformable clusters, or at least one subgroup of deformable clusters may have substantially the same shape, while at least one other deformable cluster has a different shape. The deformable clusters may be provided together with at least one other cluster, such as a standard circular cluster or a cluster with a constant cross-sectional shape, or a twisted cluster as described in EP 2 910 143 B1. Instead of one such non-deformable cluster, multiple such non-deformable clusters may be provided. The deformable clusters may be provided in groups, for example, they may be arranged in a ring-shaped cluster arrangement. Figure 4A , Figure 4B , Figure 5 , Figure 6A , Figure 6B and Figure 6C An exemplary brush carrier or toothbrush head with three deformable clusters and one standard circular cluster is discussed.

[0048] According to some aspects, an exemplary toothbrush head or brush carrier may have at least two deformable clusters, preferably at least three deformable clusters, which are tilted such that their free ends are closer to each other than their mounting bases. Preferably, the deformable clusters (e.g., their center points on the mounting surface) are arranged generally in a circular, elliptical, or oval shape. More preferably, a straight central cluster is mounted in the center of a circle. Even more preferably, the free ends of the deformable clusters surround the central cluster. And even more preferably, each of the three deformable clusters has a first cross-sectional shape that is elongated and oriented such that the major axis of the elongated first cross-sectional shape points to the center point of the circle, ellipse, or oval shape or to the tangent of the central region of the circle, ellipse, or oval shape. Each of the deformable clusters has a second cross-sectional shape at its free end that is curved ("curved" in the sense of partially surrounding) around the central cluster.

[0049] Exemplary variant clusters

[0050] Figure 1A , Figure 1B , Figure 2A , Figure 2B and Figure 3A , Figure 3B Three different exemplary deformable clusters 100, 110 and 120 are shown, in which Figure 1A , Figure 2A and Figure 3A Perspective views of the corresponding deformable clusters 100, 110, and 120 are shown. In these examples, it is assumed that the mounting surface is flat and the free ends of the deformable clusters are also flat, such that the first section is always taken at the level of the mounting surface (i.e., at length value 0), and the second section is always taken at the level of the free ends of the plane (i.e., at length value Ls), where Ls is the free length of the deformable cluster.

[0051] Deformable cluster 100 has a mounting end 101 and a free end 109, deformable cluster 110 has a mounting end 111 and a free end 119, and deformable cluster 120 has a mounting end 121 and a free end 129. It should be understood that the mounting ends 101, 111, and 121 rise from a carrier element, which is assumed herein to have the previously mentioned flat mounting surface. Any portion of the deformable clusters 100, 110, and 120 that may be disposed in or beneath the carrier element is not shown (the carrier element is obviously not shown either). Figure 1B , Figure 2B and Figure 3BThe outlines of first cross-sections 102, 112, and 122, respectively, taken in a first plane coinciding with the horizontal plane of the mounting surfaces of deformable clusters 100, 110, and 120, are shown. The outlines of second cross-sections 108, 118, and 128, respectively, taken in a second plane parallel to the first plane and coinciding with the horizontal plane of the free ends 109, 119, and 129 of these deformable clusters, are also shown. According to this disclosure, the cross-sectional area of ​​the first cross-section in each example is substantially the same as the cross-sectional area of ​​the second cross-section in the same example, while the cross-sectional shape of the first cross-section in each example differs from the cross-sectional shape of the second cross-section in the same example.

[0052] In all three examples, the first cross-section is circular or similar to a circle (e.g., as shown in the image). Figure 3A , Figure 3B The first cross-sectional shape can be a dodecagon (as opposed to a dodecagon), but this should not be construed as limiting, as it can take any practical shape. The first cross-sectional shape can preferably be one that provides, for example, a bending stiffness higher or lower than the bending stiffness of the deformable cluster at its free end. For example, an elongated, V-shaped, or +-shaped free end has a generally low bending stiffness while providing certain cleaning properties, such as a residue-collecting concave surface or a wide cleaning edge that provides a beneficial cleaning effect. This low bending stiffness can be balanced by the cross-sectional shape of the deformable cluster closer to its mounting base, which can be circular or similarly circular. However, those skilled in the art will also see the benefits of low bending stiffness at the base and compressed fiber arrangement at the free end, or the benefits of an elongated cross-sectional shape at the base and a V-shape at the free end, etc.

[0053] for Figure 1A and Figure 1B The deformed cluster 100 shown has a cross-sectional shape of essentially V-shaped second section 108. Figure 2A and Figure 2B The deformed cluster 110 shown has a second section 118 with a cross-sectional shape shaped like an elongated wedge with rounded edges, and for Figure 3A and Figure 3B The deformed cluster 120 shown has a cross-sectional shape of + (i.e., shaped like the mathematical symbol "+"). It should be understood that these cross-sectional shapes, as shown, can only be approximated by a finite number of fibers per cluster (e.g., less than about 500 fibers, or less than about 350 fibers, or less than about 200 fibers, or less than about 150 fibers, or less than about 100 fibers, preferably between 20 and 500 fibers). It should also be understood that the fibers of the cluster tend to diverge slightly from each other from the mounting base to the free end (so-called "flowering" of the cluster), such that the cross-sectional area of ​​the second section can, in practice, be slightly larger than the first cross-sectional area of ​​the first section, even if this is not intentional.

[0054] exist Figure 1A , Figure 1B , Figure 2A , Figure 2B , Figure 3A and Figure 3B In the example not shown, the free ends of the deformable cluster can have a three-dimensional topology; that is, the free ends of the individual fibers do not terminate in essentially a single plane (whether or not they are inclined relative to the mounting surface), but rather the free ends of the fibers can terminate on a three-dimensional surface or can terminate irregularly. This means that the individual fibers of the cluster terminate at different lengths. As an example, see [reference]. Figure 4A The central cluster has a protruding free end. In this case, the second section will be cut in a second plane that intersects all the fibers that also pass through the first plane, i.e., the second plane will be located exactly below the protruding free end.

[0055] For completeness, it should be noted that all sections taken in the intermediate plane, which is parallel to the first plane but closer to the first plane than the second plane, will also pass through all the fibers passing through the first plane, and the cross-sectional area of ​​the corresponding intermediate section will be substantially the same as the cross-sectional area of ​​the first or second section. Then, the cross-sectional shape of the intermediate section taken at the plane at an increasing distance from the first plane will smoothly transform from the first cross-sectional shape to the second cross-sectional shape.

[0056] Although Figure 1A , Figure 2A and Figure 3A The exemplary embodiments shown employ a planar mounting surface; however, it should be understood that the mounting surface can be non-planar (e.g., Figure 4A As shown), for example, the mounting surface may be curved or may include steps. In the context of this disclosure referring to the normal of the mounting surface, it should be understood that this refers to the normal on a mounting surface that is smoothly interpolated at the center of the area of ​​the base of the deformable cluster. The extension direction of the cluster may be inclined relative to such mounting surface normals. The cluster may be circumferentially inclined, for example, in a clockwise or counterclockwise direction relative to a center point (e.g., the actual physical center point of the carrier element), or the cluster may be inclined in a radially inward or outward orientation. The cluster can, of course, be arbitrarily inclined to meet any need. The inclination angle should not be construed as limited, but is generally in the range between and including 0 degrees and 20 degrees, such as 5 degrees or 7 degrees or 11 degrees or 14 degrees or 15 degrees or 16 degrees or 17 degrees or 18 degrees or any other value. In the case of a curved mounting surface, the clusters may be inclined differently relative to the mounting surface normal, while the extension directions of the clusters may still be all parallel to each other.

[0057] Exemplary toothbrush head including deformable clusters

[0058] Figure 4A , Figure 4B , Figure 5 , Figure 6A , Figure 6B , Figure 6C All of these relate to an exemplary brush carrier 11A, which includes three deformable clusters 100A, 110A, 120A and another cluster 130A, all of which are mounted on a carrier element 150A including a mounting surface 151A. Although only the brush carrier 11A including clusters 100A, 110A, 120A, 130A and carrier element 150A is shown herein, it should be understood that the brush carrier 11A can be mounted on a brush housing to form a toothbrush head; as... Figure 7 The toothbrush head 10 shown is an example, but it should be understood that the toothbrush head can also be a non-removable part of the toothbrush. For example, the toothbrush head of a manual toothbrush is usually non-removable, while the toothbrush head of an electric toothbrush is usually replaceable.

[0059] Figure 4A and Figure 4B Side and top views of an exemplary brush carrier 11A are shown. Three deformable clusters 100A, 110A, and 120A are generally arranged around another cluster 130A on a circle 400A, which may also be referred to as the central cluster 130A due to its position. Clusters 100A, 110A, 120A, and 130A are all mounted on the mounting surface 151A of the carrier element 150A. The three deformable clusters 100A, 110A, and 120A are arranged along the circle 400A, with an equiangular distance of 120 degrees between each adjacent cluster. The central cluster 130A is mounted in the center of the circle 400A, which is also the center of the carrier element 150A. The central cluster 130A is shown here as a straight circular cluster, but the central cluster can also have many other cross-sectional shapes, such as a triangular shape. The deformable clusters 100A, 110A, and 120A are identical in shape and all slope towards the central cluster 130A. Deformed cluster 100A has a mounting end 101A and a free end 109A, deformed cluster 110A has a mounting end 111A and a free end 119A, deformed cluster 120A has a mounting end 121A and a free end 129A, and central cluster 131 has a mounting end 131A and a free end 139A, wherein the free end 139A of central cluster 130A has a non-planar free end profile with a spherical shape, that is, the end of the fiber of central cluster 130A terminates on a portion of a sphere. However, this is merely an example and should not be construed as limiting. Deformed cluster 110A generally extends along the extension direction 113A, deformed cluster 120A generally extends along the extension direction 123A, and central cluster 130A generally extends along the extension direction 133A. Figure 4A Three parallel planes AA, BB, and CC are shown, through which the area is intercepted. Figure 6A , Figure 6B and Figure 6CThe cross-sectional cut is shown in the figure. Plane AA is shown here at a first length along the extension direction, which is close to the mounting surface 151A and therefore close to the mounting ends 101A, 111A and 121A of the deformable clusters 100A, 110A and 120A, and plane CC is shown at a second length along the extension direction, which is close to the free ends 109A, 119A and 129A of these deformable clusters.

[0060] Figure 5 This is a top view of the carrier element 150A with the clusters removed. Cluster holes 200A, 210A, and 220A are shown as having an elongated rhomboid shape in the mounting surface 151A. Similarly, a circular cluster hole 230A for the central cluster is visible. The major axes 201A, 211A, and 221A of the rhomboid cluster holes are indicated by dashed lines; these major axes are tangent at a circle 401A around the center of the carrier element 150A as they extend beyond the corresponding cluster holes. Figure 4B In contrast, it is clear that the circle 401A defines a relatively small central region at the center of the carrier element 150A. In other examples, the long axis of the cluster aperture of the deformable cluster may point to the center or another extended central region.

[0061] Figure 6A , Figure 6B and Figure 6C It shows the respective directions as follows Figure 4A The parallel planes AA, BB, and CC shown represent the cross-sectional cuts through the brush carrier 11A. Figure 6A The diagram shows a cross-sectional cut taken in plane AA in the viewing direction on carrier element 150A. First cross-sections 102A, 112A, and 122A of the three deformed clusters can be seen, each having an elongated, generally rhomboid cross-sectional shape. The central cluster has a circular first cross-section 132A. Figure 6C A cross-sectional cut taken in plane CC in the viewing direction on carrier element 150A is shown. Second cross-sections 108A, 118A, and 128A of three deformable clusters can be seen, each having a curved, bean-shaped cross-section, wherein the concave surface of the bean-shaped cross-section partially surrounds a central cluster, which in turn has a circular cross-sectional shape 138A. These specific second cross-sectional shapes of the deformable clusters enable a high fiber density in the central free-end region of the brush carrier 11A, allowing for the cleaning of specific interdental areas of the dental arch using a large number of fibers arranged in a relatively small area. Figure 6BA cross-sectional cut is shown in plane BB along the viewing direction on carrier element 150A. Intermediate sections 105A, 115A, and 125A of the three deformed clusters can be seen, providing an impression of how the elongated first cross-sectional shape of the rhombus is deformed into a bean-shaped second cross-sectional shape. The cross-sectional shape 135A of the central cluster, of course, remains unchanged.

[0062] Exemplary toothbrush

[0063] Figure 7 This is an illustration of an exemplary toothbrush 1 including a handle portion 20 and a toothbrush head 10 according to the present disclosure, the toothbrush head being detachably attached to the handle portion 20. The toothbrush head 10 includes a brush carrier 11 mounted to be driven to move relative to the toothbrush head housing 12.

[0064] Methods for manufacturing deformable clusters

[0065] Figure 8 The process steps of a method for manufacturing a brush carrier or toothbrush head including at least one deformable cluster are shown.

[0066] At step 500, a mold insert having at least one cavity for defining a deformable cluster is provided. The cavity has a length and extends along an extension direction from a first side of the mold insert to a second side of the mold insert opposite the first side. Furthermore, the cavity has a first cross-section (having a first cross-sectional shape and a first cross-sectional area) at a first length and a second cross-section (having a second cross-sectional shape and a second cross-sectional area) at a second length, wherein the planes cutting these cross-sections are parallel to each other, preferably wherein the plane located at the first length coincides with or is at least as close as possible to the first side, and the first cross-section does not pass through the first side, and more preferably wherein the plane located at the second length coincides with or is at least as close as possible to the second side, and the first cross-sectional area and the second cross-sectional area are substantially the same, and the first cross-sectional shape and the second cross-sectional shape are different, such that the first cross-sectional shape does not match the second cross-sectional shape, regardless of the angle of rotation of the first cross-sectional shape and regardless of the displacement of the first cross-sectional shape. The mold insert may have multiple cavities that define additional deformable or non-deformable clusters, such as circular clusters or other constant or torsional cross-section clusters.

[0067] At step 501, which is an optional step, the cavity is closed on the second side by a closing element that can define a planar or non-planar fiber abutment surface, or the closing element is positioned close to the second side, for example at a distance in the range of 0.01 mm to 10 mm, such that the free end of the fiber that can be introduced into the cavity from the first side abuts the fiber abutment surface of the closing element, the closing element defining the planar or non-planar free end of the cluster defined by the cavity.

[0068] At step 502, fibers are introduced into the cavity from the first side, each fiber having a first end (which will become a free end) and a second end, with the second end of the fiber remaining outside the mold insert on the first side. As the fibers are introduced into the cavity, they will orient themselves to adapt to the deformed cluster cavity. Some rocking or vibration of the mold insert can be used to support the arrangement of the fibers and prevent the individual fibers from being arranged in a prestressed manner. Due to the deformable form of the cavity and potentially due to the topology of the free ends of the cluster defined by the closing element, the fibers will have different lengths in the cavity and therefore they can extend at different heights on the first side. A cutting step can be applied to cut the fibers to a common length. In the filling step, the cluster cavity can be highly filled, for example, the cavity filling can exceed 50%, 60%, 65%, 70%, or 75%.

[0069] At step 503, at least one of the following operations is performed: the second ends of the fibers are melted together to form a joint end of multiple fibers, or the second ends of the fibers are joined by applying a bonding material such as an adhesive to form a joint end of multiple fibers. In each case, the multiple fibers and the joint end form a deformable cluster. The step of melting the second ends together or joining the second ends by a bonding material ideally does not introduce any new prestress, but rather relieves any prestress that still exists.

[0070] At step 504, the joint end of the deformable cluster is preferably connected to the carrier element by injection molding around the joint end. Then, a mold insert may form a first half-mold or a component of the first half-mold, such that the mold insert and the other half-mold define a mold cavity for the carrier element. Typically, the mold insert may include multiple sets of cluster cavities, each set relating to a carrier element.

[0071] At step 505, multiple fibers (i.e., the at least one deformable cluster) are removed from the cluster-defined cavity along with the carrier element demolded from the molding cavity. As the fibers temporarily bend during removal, they will spring back to the orientation imparted to the multiple fibers by the cavity after removal, due to the fact that their orientation is substantially fixed by the joint ends. Since the fiber introduction and the connection at the second end have avoided introducing any prestress, the shape of the removed deformable cluster will substantially conform to the shape defined by the cavity. As previously mentioned, some unavoidable blooming may occur, such that the cross-sectional area may increase slightly towards the free end of the deformable cluster. Where some prestress still exists for individual fibers, the corresponding fibers may spring back to a stress-free position, allowing the shape of the deformable cluster to be slightly deformed; however, it is assumed that for most embodiments discussed herein, the described technique will avoid prestress.

[0072] In step 510, which is an optional step, cavities are formed by line etching, in which fine straight lines cut through the material of the mold insert. Thus, the lines can move along the edges of the cross-sectional shape on the first and second sides, and therefore the shape of the deformable cluster is defined by the straight lines, as explained in the previous paragraph. Other techniques for forming cavities can also be employed. For example, the mold insert can be assembled from sheets, in which cavities are formed in each sheet by etching, laser cutting, laser ablation, or other electrical discharge machining (EDM), in addition to line etching. Another technique that can be used is 3D printing, such as direct metal laser sintering, selective laser sintering, selective laser melting, or electron beam melting. The mold insert can also be made from ceramic or polymer materials using 3D printing technology.

[0073] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​cited. Rather, unless otherwise specified, each such dimension is intended to represent the stated value and a range around which it is functionally equivalent. For example, a dimension disclosed as “40 mm” is intended to represent “approximately 40 mm”.

Claims

1. A brush carrier, comprising: At least one carrier element; At least one deformable cluster is mounted on the carrier element such that the deformable cluster rises from the mounting end on the mounting surface of the carrier element generally along the extension direction toward the free end of the deformable cluster. The deformable cluster has a length from the mounting base to the free end; The deformable cluster comprises multiple fibers; and The deformable cluster has a first cross-section at a first length along the extension direction and a second cross-section at a second length along the extension direction, the first cross-section having a first cross-sectional shape and a first cross-sectional area, and the second cross-section having a second cross-sectional shape and a second cross-sectional area; The planes that cut the first and second sections are parallel to each other, wherein the plane located at the first length coincides with the mounting surface, or is at least as close as possible to the mounting surface, without the first section passing through the mounting surface, and wherein the plane located at the second length coincides with the free end, or is at least as close as possible to the free end, such that the second section still passes through all the fibers that also pass through the first section. The first cross-sectional area and the second cross-sectional area are substantially the same, and the first cross-sectional shape and the second cross-sectional shape are different, such that the first cross-sectional shape does not match the second cross-sectional shape, regardless of the rotation angle of the first cross-sectional shape and regardless of the displacement of the first cross-sectional shape.

2. The brush carrier according to claim 1, wherein the free end of the deformable cluster has a non-planar topology.

3. The brush carrier according to claim 1 or 2, wherein the cross-sectional shape of the deformable cluster smoothly transitions from the first length to the second length.

4. The brush carrier according to claim 1 or 2, wherein at least the second cross-sectional shape has a recess.

5. The brush carrier according to claim 1 or 2, wherein the extending direction of the deformable cluster is inclined relative to the normal of the mounting surface at the mounting base.

6. The brush carrier according to claim 1 or 2, wherein when the center point of the area of ​​the second cross section is projected onto the first cross section along a direction determined by a surface orthogonal to the mounting surface at the mounting base of the deformable cluster, the center point of the area of ​​the second cross section does not coincide with the center point of the area of ​​the first cross section.

7. The brush carrier according to claim 1 or 2, wherein the distance between the first length and the second length is 50% or more of the total free length of the deformable cluster.

8. The brush carrier according to claim 7, wherein the distance between the first length and the second length is 60% or more of the total free length of the deformable cluster.

9. The brush carrier according to claim 8, wherein the distance between the first length and the second length is 70% or more of the total free length of the deformable cluster.

10. The brush carrier of claim 9, wherein the distance between the first length and the second length is 80% or more of the total free length of the deformable cluster.

11. The brush carrier according to claim 1 or 2, wherein each fiber has a base on the mounting surface, a free end, a length measured between the base and the free end, and an angle of inclination measured relative to the direction of extension, wherein at least the angles of inclination of the two fibers are different.

12. The brush carrier according to claim 1 or 2, wherein each point on the outer edge of the first cross section is connectable to a point on the outer edge of the second cross section by a straight line defining the outer shape of the deformable cluster between the first length and the second length.

13. The brush carrier according to claim 1 or 2, comprising at least two deformable clusters, which are tilted such that their free ends are closer to each other than their mounting bases.

14. The brush carrier of claim 13, comprising at least three deformable clusters, which are tilted such that their free ends are closer to each other than their mounting bases.

15. The brush carrier according to claim 13, wherein the deformable clusters are arranged on a circular, elliptical or oval shape.

16. The brush carrier according to claim 15, wherein the straight central cluster is mounted at the center of the circle.

17. The brush carrier of claim 13, wherein the free end of the deformable cluster surrounds the central cluster.

18. The brush carrier of claim 13, wherein each of the three deformable clusters has a first cross-sectional shape, the first cross-sectional shape being elongated and oriented such that the major axis of the elongated first cross-sectional shape points to the center point of a circle, ellipse, or oval shape or to the tangent of the central region of a circle, ellipse, or oval shape, and each of the deformable clusters has a second cross-sectional shape at its free end that bends around the central cluster.

19. A toothbrush comprising a brush carrier according to any one of claims 1 to 18.

20. The toothbrush of claim 19, wherein the toothbrush includes a brush portion that can be repeatedly detached and reattached, the brush portion including the brush carrier.

21. A method for manufacturing a brush carrier, comprising the following steps: A mold insert is provided having at least one cavity for defining a deformable cluster, the cavity having a length extending along an extension direction from a first side of the mold insert to a second side of the mold insert opposite to the first side. The cavity has a first cross-section at a first length and a second cross-section at a second length, the first cross-section having a first cross-sectional shape and a first cross-sectional area, and the second cross-section having a second cross-sectional shape and a second cross-sectional area. The planes that cut the first and second sections are parallel to each other, wherein the plane located at the first length coincides with the first side, or is at least as close as possible to the first side without the first section passing through the first side, and wherein the plane located at the second length coincides with the second side, or is at least as close as possible to the second side, and The first cross-sectional area and the second cross-sectional area are substantially the same, and the first cross-sectional shape and the second cross-sectional shape are different, such that the first cross-sectional shape does not match the second cross-sectional shape, regardless of the rotation angle of the first cross-sectional shape and regardless of the displacement of the first cross-sectional shape; Multiple fibers are introduced into the cavity, each fiber having a first end and a second end, and the second end of the fiber being held outside the mold insert. At least one of the following: melting the second ends of the fibers together to form a joint end of the plurality of fibers, or connecting the second ends of the fibers by applying a connecting material to form a joint end of the plurality of fibers, in each case the plurality of fibers and the joint end form a deformable cluster; Connect the connecting end to the carrier element; and Remove the plurality of fibers from the cavity.

22. The method of claim 21, wherein the connecting material is an adhesive.

23. The method of claim 21 or 22, wherein the joint end is connected to the carrier element by injection molding of the carrier element around the joint end.

24. The method of claim 21 or 22, comprising the step of forming the cavity by line etching.

25. The method of claim 21 or 22, further comprising the step of closing the distal end of the cavity opening on a second side of the mold insert with a forming element defining the shape of the free end of the cluster, or comprising the step of providing a forming element defining the shape of the free end of the cluster near the distal end of the cavity.

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