Oral care implement

Abstract

An oral care implement includes a head detachably coupled to a handle. The head has a neck portion and a head portion. The head portion has a laminated configuration whereby the base structure is enclosed by the sheet structure and the protective structure. A plurality of bristle tufts extend from the front surface of the sheet structure, and the bristle tufts are formed by a plurality of filament bristles. The base structure may be a material having a greater vibration transmissibility that is plastically deformable to form a desired head shape.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of priority from U.S. Provisional Application No. 63 / 477,251, filed on December 27, 2022, U.S. Provisional Application No. 63 / 477,259, filed on December 27, 2022, and U.S. Provisional Application No. 63 / 477,265, filed on December 27, 2022, the respective contents of which are hereby incorporated herein by reference in their entirety. Background of the invention

[0003] Oral care, particularly the care of an individual's teeth and gums, is extremely important for ensuring overall health. However, typical oral care procedures are time - consuming. For example, most dentists recommend brushing for a minimum of two minutes. Individuals who may have dexterity issues or who may not wish to spend the required time brushing their teeth may suffer from poor oral health. Accordingly, there is a need for oral care appliances that can compensate for the deficiencies in existing products. Summary of the invention

[0004] The present invention relates to an oral care appliance having a handle and a head removably coupled to the handle. The head has a neck portion and a head portion coupled to the neck portion. The head portion has a base structure, a sheet structure, and a protective structure. The sheet structure contacts the base structure and has a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet structure. The protective structure has a front surface and a rear surface. The front surface of the protective structure is connected to at least a portion of the rear surface of the sheet structure to encapsulate the base structure between the sheet structure and the protective structure.

[0005] In one aspect, the present invention can be a head of an oral care appliance, the head having a neck portion and a head portion coupled to the neck portion. The head portion has a base structure, a sheet structure, and a protective structure. The sheet structure contacts the base structure and has a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet structure. The protective structure contacts a portion of the rear surface of the sheet structure and the rear surface of the base structure.

[0006] In another aspect, the present invention can be a method of manufacturing an oral care appliance. The method has a first step of providing a sheet structure having a plurality of bristle clusters extending from the front surface of the sheet structure. The method has a second step of encapsulating a base structure between the sheet structure and a protective structure to form a head portion.

[0007] In another aspect, the present invention can be an oral care appliance having a handle and a head detachably coupled to the handle. The head has a neck portion and a head portion coupled to the neck portion. The head portion has a sheet-like structure. The sheet-like structure has a first film layer, a second film layer, and a plurality of bristle clusters. The first film layer has a front surface and a rear surface, and the front surface forms the front surface of the sheet-like structure. The second film layer has a front surface and a rear surface, and the rear surface forms the rear surface of the sheet-like structure. The plurality of bristle clusters extend from the front surface of the first film layer.

[0008] In one aspect, the present invention can be a head of an oral care appliance, the head having a neck portion and a head portion coupled to the neck portion. The head portion has a base structure and a sheet-like structure. The sheet-like structure has a first film layer, a second film layer, and a plurality of bristle clusters. The front surface of the first film layer forms the front surface of the sheet-like structure. The second film layer is connected to the first film layer, and the rear surface of the second film layer forms the rear surface of the sheet-like structure. The plurality of bristle clusters extend from the front surface of the first film layer.

[0009] In another aspect, the present invention can be a method of manufacturing a sheet-like structure for an oral care appliance. The method has a first step of inserting a plurality of brush filaments into a plurality of hair implanting holes of a hair implanting tool to form a plurality of bristle clusters. The method has a second step of fusing a first film layer to a base portion of the plurality of bristle clusters. Finally, the method has a third step of fusing a second film layer to the first film layer.

[0010] In another aspect, the present invention can be an oral care appliance having a handle and a head detachably coupled to the handle, the handle having a vibration generating device. The head has a neck portion and a head portion coupled to the neck portion. The head portion has a base structure formed of a metallic material and a sheet-like structure in contact with the base structure. The sheet-like structure has a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet-like structure.

[0011] In one aspect, the present invention can be a head of an oral care appliance, the head having a neck portion and a head portion coupled to the neck portion. The head portion has a base structure formed of a first material and a sheet-like structure in contact with the base structure. The sheet-like structure has a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet-like structure. The sheet-like structure is formed of a second material. The first vibration transmission rate of the first material is greater than the second vibration transmission rate of the second material.

[0012] In another aspect, the present invention can be a method for exciting the bristle filaments. The method has a first step of providing an oral care implement having a handle and a head, the head having a neck portion and a head portion, the head portion being coupled to the neck portion, and the neck portion being coupled to the handle. The method has a second step of generating vibrations with a vibration generating device. In a third step, the method requires transmitting the vibrations from the handle to the bristle filaments via the neck portion, a metallic base structure of the head portion coupled to the neck portion, and a sheet-like structure of the head portion in contact with the base structure. The bristle filaments extend from the sheet-like structure.

[0013] In yet another aspect, the present invention can be a method for forming an oral piece. The method has a first step of forming a flat laminate structure having a plurality of bristle clusters extending from a front surface of the flat laminate structure. The method has a second step of bending the flat laminate structure into a three-dimensional oral piece.

[0014] In one aspect, the present invention can be a head of an oral care implement, the head having a head portion, the head portion having a base structure formed of a first material and a plurality of cluster blocks in contact with a front surface of the base structure. Each of the plurality of cluster blocks has a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface. The plurality of cluster blocks are formed of a second material. A first vibration transmission rate of the first material is greater than a second vibration transmission rate of the second material.

[0015] In another aspect, the present invention can be an oral care implement having a handle and a head coupled to the handle. The head has a neck portion and a head portion coupled to the neck portion. The head portion has a base structure, a sheet-like structure, and a protective structure. The base structure extends from a proximal end coupled to the neck portion to a distal end. The sheet-like structure is in contact with the base structure and includes a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet-like structure. The protective structure covers the base structure and is in contact with the sheet-like structure.

[0016] In yet another aspect, the present invention can be a head of an oral care implement. The head can have a neck portion and a head portion coupled to the neck portion. The head portion has a base structure, a sheet-like structure, and a protective structure. The base structure has a front surface and an opposite rear surface. The base structure can be formed of a metallic material. The sheet-like structure is in contact with the base structure and has a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet-like structure. The protective structure covers the rear surface of the base structure.

[0017] In another aspect, the present invention can be a method for manufacturing the head of an oral care appliance. First, a plurality of brush filaments are connected to a flexible sheet to form a sheet-like structure having a front surface, a rear surface, and a plurality of brush tufts extending from the front surface of the sheet-like structure. Second, the sheet-like structure is positioned in direct contact with the front surface of the base structure. Third, the rear surface of the base structure is covered with a protective structure. The protective structure is in direct contact with the perimeter of the sheet-like structure and covers a portion of the front surface of the base structure.

[0018] Other applicable fields of the present invention will become apparent from the detailed description provided below. It should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will be more fully understood from the detailed description and the accompanying drawings, in which:

[0020] Figure 1 is a perspective view of an oral care appliance according to an embodiment of the present invention;

[0021] Figure 2 is Figure 1 a perspective view of the head of the oral care appliance;

[0022] Figure 3 is Figure 2 an exploded perspective view of the head;

[0023] Figure 4 is Figure 2 a front view of the head;

[0024] Figure 5 is a sectional view taken along line V-V of Figure 2 ;

[0025] Figure 6 is a sectional view taken along line VI-VI of ​ ;

[0026] ​ is ​ a rear view of the head;

[0027] ​ is ​ a left side view of the head;

[0028] ​ is ​ a right side view of the head;

[0029] ​ is ​ a top view of the head;

[0030] ​ yes ​ Bottom view of the head;

[0031] ​ It can be used for ​ A perspective view of the lamellar structure of the head;

[0032] ​ It can be used for ​ A top view of the hair transplanting tool on the head;

[0033] ​ yes ​ Detailed diagram of the plurality of implant holes of the tool;

[0034] ​ is shown in the first step of making a sheet structure ​ diagram of the tool;

[0035] ​ is a diagram of a tool used in a second step of manufacturing a sheet-like structure;

[0036] ​ is a diagram of a tool in the third step of manufacturing a sheet-like structure;

[0037] ​ is a diagram of a tool in a fourth step of manufacturing a sheet-like structure;

[0038] ​ is a diagram of a tool in the fifth step of manufacturing a sheet-like structure;

[0039] ​ is a diagram of a tool in a fifth alternative step of manufacturing a sheet-like structure;

[0040] ​ is a diagram of a tool in a fifth second alternative step of making a sheet-like structure;

[0041] ​ is a diagram of a tool in a sixth step of manufacturing a sheet-like structure;

[0042] ​ is a diagram of a tool in the seventh step of manufacturing a sheet-like structure;

[0043] ​ is a diagram of a tool in the eighth step of manufacturing a sheet-like structure;

[0044] ​ is a diagram of a tool shown in a first step of manufacturing a sheet-like structure;

[0045] ​ is a diagram of a tool in the fifth step of manufacturing a sheet-like structure;

[0046] ​ It is a diagram of a tool in the seventh step of manufacturing a sheet structure, which shows the connection of bristles to the first film layer;

[0047] ​ It is a diagram of a tool in another seventh step of manufacturing a sheet structure, which shows the connection of the second film layer to the first film layer;

[0048] ​ It is a diagram of a tool before the eighth step of manufacturing a sheet structure, which shows a molten cushion layer;

[0049] ​ It is a perspective view of the sheet structure before trimming;

[0050] ​ It is an exploded view of the sheet structure and the trimmed excess material after trimming;

[0051] ​ It is for forming ​ a perspective view of a flat laminated structure of the head portion;

[0052] ​ It is ​ an exploded view of the flat laminated structure;

[0053] ​ It is a perspective view of the base structure;

[0054] ​ It is a top view of the base structure;

[0055] ​ It is a perspective view of the flat laminated structure in an unbent state;

[0056] ​ It is a perspective view of the flat laminated structure in a first partially bent state;

[0057] ​ It is a perspective view of the flat laminated structure in a second partially bent state;

[0058] ​ It is a perspective view of the flat laminated structure in a fully bent state;

[0059] ​ It is a schematic diagram of a first alternative configuration of the head portion, with the bristles omitted;

[0060] ​ It is a schematic diagram of a second alternative configuration of the head portion, with the bristles omitted;

[0061] ​ It is a schematic diagram of a third alternative configuration of the head portion, with the bristles omitted;

[0062] ​ It is a schematic view of the fourth alternative configuration of the head portion, with the bristles omitted;

[0063] ​ It is a schematic view of the fifth alternative configuration of the head portion, with the bristles omitted;

[0064] ​ It is a schematic view of the sixth alternative configuration of the head portion, with the bristles omitted;

[0065] ​ It is a schematic view of the seventh alternative configuration of the head portion, with the bristles omitted;

[0066] ​ It is a schematic view of the eighth alternative configuration of the head portion, with the bristles omitted;

[0067] ​ It is a schematic view of the ninth alternative configuration of the head portion;

[0068] ​ It is a schematic view of the tenth alternative configuration of the head portion;

[0069] ​ It is a schematic view of the eleventh alternative configuration of the head portion;

[0070] ​ It is a schematic view of the twelfth alternative configuration of the head portion;

[0071] ​ It is a schematic view of the thirteenth alternative configuration of the head portion;

[0072] ​ It is a schematic view of the fourteenth alternative configuration of the head portion;

[0073] ​ is ​ a perspective view of an alternative embodiment of the head of an oral care implement;

[0074] ​ is ​ an exploded view of the head;

[0075] ​ is ​ a cross-sectional view of the head taken along line XLII-XLII of

[0076] ​ is ​ a perspective view of another alternative embodiment of the head of an oral care implement;

[0077] ​ is ​ an exploded view of the head; and

[0078] ​ is a cross-sectional view of the head taken along line XLV-XLV ​ of the head. DETAILED DESCRIPTION

[0079] The following description of the preferred embodiments is exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0080] The description of the illustrative embodiments of the principles of the present invention is intended to be read in conjunction with the accompanying drawings, which are regarded as a part of the entire written description. In the description of the embodiments of the present invention disclosed herein, any reference to direction or orientation is for convenience of description only and is in no way intended to limit the scope of the present invention. Relative terms such as "lower", "upper", "horizontal", "vertical", "above", "below", "upward", "downward", "top", and "bottom" and their derivatives (e.g., "horizontally", "downwardly", "upwardly", etc.) should be construed to refer to the orientation as later described or as shown in the drawings in the discussion. Unless explicitly stated otherwise, these relative terms are for convenience of description only and do not require the device to be constructed or operated in a particular orientation. Unless otherwise explicitly described, terms such as "attached", "affixed", "connected", "coupled", "interconnected", and similar terms refer to a relationship in which structures are directly or indirectly fixed or attached to each other through an intermediate structure, and both are either movably or rigidly attached or related. In addition, the features and advantages of the present invention are illustrated by reference to the exemplary embodiments. Therefore, the present invention should clearly not be limited to such exemplary embodiments that show some possible non-limiting combinations of features that may exist alone or in other combinations of features; the scope of the present invention is defined by the appended claims of the present invention..

[0081] Referring to ​ , there is shown an oral care appliance 1000 according to an embodiment of the present invention. The oral care appliance 1000 is an electric device for cleaning a user's teeth and other oral tissues. The oral care appliance 1000 has a head 100 and a handle 200, and the head 100 has a neck portion 102 and a head portion 104. The handle 200 has a vibration generating device and a user interface 204 configured to control the operation of the vibration generating device. The vibration generating device is preferably a motor, but can be any known type of vibration generating device suitable for transmitting vibration from the handle 200 to the head 100 to excite the cleaning elements on the head 100. Optionally, the head 100 can be detachably coupled to the handle 200, or it can be permanently attached.

[0082] ​The head 100 is shown in more detail. As described above, the head 100 has a head portion 104 coupled to a neck portion 102. The neck portion 102 may engage the stem or other engagement features of the handle 200. The head portion 104 is coupled to the neck portion 102 and has a generally arcuate shape adapted to be inserted into a user's oral cavity. The head portion 104 is configured to engage a plurality of the user's teeth simultaneously. The head 100 extends along a longitudinal axis A-A.

[0083] The head portion 104 extends along a path P-P. Optionally, the path P-P may be an arcuate path. The path P-P may be selected to correspond to the user's dental arch. Optionally, the path P-P may be a continuous arc or may be formed by a series of linear segments or arcs, or a combination of arcs and linear segments. Additionally, the path P-P may be any shape that forms a generally concave path and may include any curved geometry. The path P-P extends parallel to a horizontal plane H-H that extends along the bottom surface 106 of the head portion 104.

[0084] The head portion 104 also has a wall 108 that extends from a first distal end 110 to a second distal end 112 along the path P-P. The wall 108 has a generally concave shape but does not need to take the form of a single arc of constant radius. The wall 108 may instead be a composite concave shape including a plurality of arcs and linear segments, or other geometries that together form a curved shape. A plurality of finger members 130 extend from the wall 108. Optionally, the head portion ¹04 may be symmetric about the connector 116 as shown, or the head portion 104 may be asymmetric about the connector 116. It is contemplated that the head portion 104 may correspond to the entire dental arch of the user or only a portion of the user's dental arch.

[0085] In still other embodiments, the plurality of finger members 130 may not extend from a single wall 108. Instead, the finger members 130 may be arranged in a series of segments such that a plurality of different walls 108 are formed around the user's dental arch. When in a flat configuration, the head portion 104 may appear to have a zigzag shape to form the desired shape of the head portion 104 when in a folded state.

[0086] In some embodiments, the head portion 104 may be symmetric and extend along a majority of the user's dental arch. In yet other embodiments, the head portion 104 may be asymmetric such that it extends along less than half of the user's dental arch. In still other embodiments, the head portion 104 may be configured to cover approximately half of the user's dental arch. In these embodiments, the head portion 104 may engage one side of the user's oral cavity at a time. The head portion 104 may be moved along the dental arch to brush all of the teeth of the dental arch. Further contemplated, the head portion 104 may engage only a single jaw or may engage both the maxillary and mandibular jaws simultaneously. In the case where the head portion 104 engages both the maxillary and mandibular jaws, the finger members 130 may extend in opposite directions to engage different jaws, or components of the head portion 104 may be doubled to allow for simultaneous brushing of both the maxillary and mandibular jaws.

[0087] The plurality of finger members 130 each have a horizontal portion 132 that extends from the wall 108 along the horizontal plane H-H. The plurality of finger members 130 also have a first bend 134, a distal portion 136, and a second bend 137. The distal portion 136 extends from the horizontal plane H-H at the first bend 134. The second bend 137 is located at the transition between the horizontal portion 132 and the wall 108. In the present embodiment, there are five finger members 130, but in other embodiments, there may be more or fewer than five finger members 130. As can be seen, the finger members 130 are bent relative to the horizontal plane H-H to form an L-shape. The finger members 130 and the wall 108 generally form a U-shaped cross-section. In other embodiments, the distal portions 136 of the finger members 130 may extend from both sides of the horizontal plane H-H to be able to simultaneously brush both the maxillary and mandibular jaws. In yet other embodiments, the horizontal portions 132 of the finger members 130 need not all be disposed along the horizontal plane H-H. In these embodiments, the horizontal portions 132 may be angled relative to each other, parallel to each other but not coplanar, or even have a radius of curvature greater than that of either the first bend 134 or the second bend 137.

[0088] Each finger member 130 is spaced and separated from the other finger members 130, but in some embodiments the finger members 130 may be in surface contact. Preferably, the finger members 130 are not coupled to each other but are individually coupled to the wall 108. An arcuate channel is formed between the finger members 130 and the wall 108. The arcuate channel effectively surrounds the user's teeth, ensuring brushing of three sides of each tooth simultaneously. In combination with movement along the user's dental arch, all surfaces of all teeth can be reached. The arcuate channel may have a U-shaped cross-section but need not be symmetric.

[0089] As can be seen, the head portion 104 has a plurality of bristle clusters 152 that extend from the wall 108 and the plurality of fingers 130. The fingers 130 have bristle clusters 152 on both the horizontal portion 132 and the end portion 136. The bristle clusters 152 are formed of filament bristles and can be formed of any known bristle filament material. Such materials can include polybutylene terephthalate ("PBT"), nylon, polypropylene, or other natural or synthetic materials.

[0090] The head portion 104 is coupled to the neck portion 102 via a connector 114 that is part of the head portion 104 and engages the socket 116 of the neck portion 102. Accordingly, the head portion 104 can be manufactured separately from the neck portion 102, and the head portion 104 can be assembled to the neck portion 102 by snapping the connector 114 of the head portion 104 into the socket 116 of the neck portion 102. In yet some alternative configurations, the connector 114 and the socket 116 can be omitted, and the neck portion 102 can be directly attached to the head portion 104. The connector 114 and the socket 116 can be a permanent connection or can be detachably coupled.

[0091] Turning to ​ , a sheet structure 150 is shown that includes a plurality of bristle clusters 152 and forms part of the head portion 104. The plurality of bristle clusters 152 are arranged in cluster blocks 153. The cluster blocks 153 are groupings of bristle clusters 152 that are spaced and separated from other bristle cluster blocks 153. In some embodiments, a single bristle cluster 152 can form a cluster block 153, while in other embodiments, all of the bristle clusters 152 can be arranged in a single cluster block 153. Each of the plurality of bristle clusters 152 is formed of bristle filaments. These filaments can be any conventional material for forming bristle filaments, such as polybutylene terephthalate ("PBT"), nylon, polypropylene, or other natural or synthetic materials as described above. In the present embodiment, the cluster blocks 153 have a step change in height relative to the surrounding portion of the sheet structure 150. This is optional and can be omitted such that the cluster blocks 153 have the same height as the surrounding portion of the sheet structure 150.

[0092] The sheet structure 150 includes a single cluster block 153 that extends along the length of the sheet structure 150 and smaller cluster blocks 153 on the fingers of the plurality of sheet structures 150. The sheet structure 150 can be formed of at least one sheet of a flexible elastomeric material to which a plurality of bristle clusters 152 are attached, as will be discussed in more detail below. In an alternative configuration, the sheet structure 150 can be formed of only a single cluster block 153. In yet some configurations, a plurality of separate cluster blocks 153 can be used without the sheet structure 150. This configuration will be discussed in more detail below.

[0093] Go to ​ and ​ a view of the tufting tool 300. The tufting tool 300 has a tufting orifice plate 301 that receives filaments to form different clusters. The tufting orifice plate 301 has a plurality of recesses 353, each of the recesses 353 having a plurality of individual tufting orifices 352 located therein. If desired, a recess 353 can have only a single tufting orifice 352. The tufting orifices 352 can be circular, square, rectangular, or any other desired shape as shown. The tufting orifices 352 can have different tufting orifices 352 of different sizes so as to produce clusters of multiple diameters in the resulting device. In the present example, the diameter of the tufting orifices is 1.5 mm, but it can be larger or smaller as needed. The tufting orifices are spaced apart by a column pitch P C and a row pitch P R The column pitch PC and the row pitch PR can be different or can be equal. In some embodiments, the column pitch PC is 1.5 mm and the row pitch PR is 1.5 mm. Optionally, the spacing between the tufting orifices 352 within a recess 353 can vary, or the spacing between different recesses 353 can vary. Optionally, the tufting orifices 352 can be spaced apart in an irregular pattern such as an arcuate pattern, a triangular pattern, or other arrangement. Thus, the tufting orifices 352 do not necessarily have to be arranged in rows and columns.

[0094] ​ illustrates a method for manufacturing a sheet-like structure 150 using the tufting tool 300 and various other devices. In a first step, a plurality of brush filaments 151 are loaded into the top section 302 of the tufting tool 300. Second, the plurality of brush filaments 151 are agitated such that they fall into the tufting orifices 352 in the tufting orifice plate 301. The brush filaments 151 are allowed to fall until they engage a bottom plate 303 that optionally includes protrusions 304 or recesses. Thus, the brush clusters 152 are formed as the brush filaments 151 fill the tufting orifices 352 in the tufting orifice plate 301. The protrusions 304 or recesses allow the formation of clusters 152 having distal ends that are not all at the same height. Optionally, the height of the distal ends of individual clusters 152 can be different, or each cluster 152 can have a different height, but all of the brush filaments 151 within a particular cluster 152 can have substantially the same height. Optionally, the brush filaments 151 can fill the tufting orifices 352 only by gravity.

[0095] Next, the brush capillary filaments 151 can be trimmed to a consistent length. The brush capillary filaments 151 can protrude beyond the top surface 305 of the implant pore plate 301, or can be trimmed as needed to be at or below the top surface 305. As can be seen, the implant pore plate 301 has recesses 353 in the top surface 305. The implant pore plate 301 includes a plurality of recesses 353 as described above. The recesses 353 define the perimeter of the tuft 153. In some other embodiments, the recesses 353 can be omitted, resulting in the tuft 153 lacking a step or other distinct boundary relative to the remainder of the sheet structure 150 as described above.

[0096] Then, the trimmed brush capillary filaments 151 can be prepared by applying heat from a heat source 306 to melt the base portions 154 of the plurality of brush capillary filaments 151 within each individual tuft 152 together. This produces a tuft 152 in which the base portions 154 of the brush capillary filaments 151 form a spherical shape, thereby connecting each brush capillary filament 151 within each individual tuft 152 together. Although some of the base portions 154 in one tuft 152 can be joined to the base portions 154 of another tuft 152, this is not necessary or desirable in this step. The heat source 306 applies heat without direct contact such that the base portions 154 are melted without the spherical shape being altered by direct contact with the heat source 306. The heat source 306 can be a radiant heating device, a convective heating device, or other heat source configured to heat a target object without direct contact with the target object. It is also contemplated that the heat source 306 can be a hot embossing or other heating device that remains spaced from the base portions 154 during this process step. In other words, the heat source 306 can be used to heat in both direct contact and non-direct contact scenarios during different process steps.

[0097] In an alternative process step, instead of applying heat indirectly via the heat source 306, heat is applied via direct contact. For example, the heat source 306 can be a hot embossing tool in contact with the top surface 305 of the implant pore plate 301. The base portions 154 of the brush capillary filaments 151 are melted into a continuous sheet of material that connects all of the base portions 154 of all of the tufts 152 within a given bristle block 153. Thus, all of the tufts 152 are joined together via the base portions 154 of the brush capillary filaments 151. In yet another alternative process step, no heat is applied to the base portions 154 of the tufts 152. In this process step, the brush capillary filaments 151 remain independent of each other.

[0098] In summary, after the step of trimming the brush filaments 151, three alternative process steps are possible. In the first alternative process step, the heat source 306 is used to indirectly heat the base portion 154 to form a ball at the base end of the bristle cluster 152. In the second alternative process step, the heat source 306 is used to directly apply heat to the base portion 154 of the brush filaments 151 of the cluster 152, melting the base portion 154 into a continuous sheet that connects all the base portions 154 within a single bristle mass 153. In the third alternative process step, no heat source is used, and the trimmed brush filaments 151 are kept entirely trimmed for the next process step.

[0099] Moving on to the next process step, the first film layer 155 is placed on the top surface 305 of the implanting orifice plate 301. The thickness of the first film layer 155 can be 0.4 mm, or optionally can be thicker or thinner than 0.4 mm. For example, the first film layer 155 can be 0.2 mm, 0.3 mm, 0.6 mm, 0.8 mm, or 1.0 mm as required. The first film layer 155 is preferably a flexible sheet. The first film layer 155 is preferably an elastic material, such as a thermoplastic elastomer. The first film layer 155 can be a material different from the material used to form the brush filaments 151.

[0100] After placing the first film layer 155, the heat source 306 is applied to the first film layer 155 to bond the base portion 154 of the brush filaments 151 to the first film layer 155. The base portion 154 is melted into the first film layer 155, and the recess 353 is at least partially filled with a mixture of materials from the first film layer 155 and the base portion 154 of the brush filaments 151. This mixture forms a molten cushion layer 156, which is a layer of the molten base portion 154 bonded to the material from the first film layer 155. Depending on the amount of spreading of the base portion 154 during this process step, the molten cushion layer 156 can extend beyond the recess 353.

[0101] In an optional additional process step, a second film layer can be applied to the first film layer 155 and bonded using the heat source 306. This can further extend the molten cushion layer 156 into the second film layer, ensuring improved retention of the cluster 152. If desired, more than two film layers can be used. Optionally, the first film layer and the second film layer can be formed of the same material, or in some other embodiments, the first film layer and the second film layer can be formed of different materials. In the final process step, the sheet structure 150 is removed from the implanting tool 300. The cluster 152 is bonded to the first film layer 155, thereby ensuring retention of the cluster 155. The sheet structure 150 is ready for additional processing steps, as will be discussed in more detail below.

[0102] In certain embodiments, the sheet structure 150 can be formed at least in part from a biocompatible material such as a food-grade polymer. Suitable biocompatible materials include, but are not limited to, acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, polypropylene (PP), polyethylene naphthalate (PEN), polyethylene (PE), silicone, ethylene propylene diene monomer (EPDM), polycarbonate (PC), thermoplastic elastomer (TPE), and other plastic and elastic materials. Of course, the present invention is not so limited in all embodiments, and other materials can also be used to construct the sheet structure 150 and its various components. In certain embodiments, the sheet structure 150 or at least a portion thereof can be formed from an elastic material. Hybrid configurations including components having different materials are envisioned.

[0103] Turning to ​ , some additional details of the process for binding the brush filaments 151 to the membrane layer are shown. In ​ , an example is shown of loading the brush filaments 151 into the implant pores 352 of the implant pore plate 301 of the filament implanting tool 300. The filament implanting tool 300 is agitated up and down manually or via a mechanism such as a vibration table or a vibration device to facilitate loading of the brush filaments 151 into the implant pores 352. ​ Shown are the filaments loaded into the implant pores 352 of the implant pore plate 301, and additional brush filaments 151 that are not implanted into the implant pores 352. As described above, heat is applied to the base portion 154 to cause the base portion 154 of the cluster 152 to form a spherical shape.

[0104] In ​ , a heat source 306 is used to connect the base portion 154 of the brush filaments 151 to the first membrane layer 155. When the heat source 306 is placed in direct contact with the first membrane layer 155 and heat is applied to the base portion 154 and the first membrane layer 155, a molten cushion layer 156 is formed from the materials of the base portion 154 and the first membrane layer 155. The front surface 159 of the first membrane layer 155 is in direct contact with the top surface 305 of the implant pore plate 301, while the opposite rear surface 160 of the first membrane layer 155 is in direct contact with the heat source 306.

[0105] ​Shown is a second film layer 157 that is applied to the first film layer 155 and bonded to the first film layer 155 by applying heat from a heat source 306. The heat source 306 is applied directly to the second film layer 157. A front surface 161 of the second film layer 157 is in direct contact with a rear surface 160 of the first film layer 155. A rear surface 162 of the second film layer 157 is opposite the front surface 161 of the second film layer 157. The rear surface 162 is in direct contact with the heat source 306. When the first film layer 155 and the second film layer 157 are joined, the molten cushion layer 156 extends into the second film layer 157.

[0106] Thus, the sheet structure 150 is formed such that the recess 353 is at least partially filled with material from the first film layer 155 and the plurality of brush filaments 151, so that the material within the recess 353 forms a cluster 153. As ​ can be seen, the molten cushion layer 156 extends into the second film layer 157, but does not extend through the entire thickness of the second film layer 157. The molten cushion layer 156 may extend beyond the recess 353 in the plane of the first film layer 155 and the second film layer 157, but only extends to a portion of the thickness of the second film layer 157.

[0107] ​ Shown is the sheet structure 150 after connecting the brush filaments 151 of the plurality of brush tufts 152 to the first film layer 155 and the second film layer 157. It should be noted that only one film layer or more than two film layers may be used to form the sheet structure 150. Additionally, the cluster 153 may not be clearly defined by the recess 353 of the hair implanting tool 300 as shown, but may be entirely defined by the perimeter of the grouping of the corresponding brush tufts 152. During the forming process, the recess 353 may not be completely filled or may not be filled at all. The plurality of brush tufts 152 extend from a front surface 163 of the sheet structure 150. A rear surface 164 of the sheet structure 150 is opposite the front surface 163. ​ Shown is the sheet structure 150 after trimming one or more brush film layers. The sheet structure 150 is trimmed to remove excess material 158 that is not required for subsequent process steps.

[0108] In an alternative configuration, the sheet structure 150 can be formed by molding instead of by laminating. The sheet structure 150 can be formed such that brush tufts 152 can be implanted in the mold. Thus, the brush tufts 152 can be mounted in a mold or other tool, and then layers can be bonded to the base portions 154 of the plurality of brush filaments 151 via molding or the previously described process. The brush tufts 152 can be mounted such that they are arranged in a two-dimensional pattern as shown and described, or they can be mounted in a three-dimensional arrangement such that the resulting sheet structure 150 is non-planar. Thus, the sheet structure 150 formed via such in-mold hair implanting technology can be formed in a final use shape.

[0109] In addition, protrusions or other structures can be formed on the sheet structure 150. It should also be noted that regardless of the manufacturing method, the bristle clusters 152 can be mounted to the sheet structure 150 individually, in blocks or groups of clusters, or in the form of a single group of clusters joined to the remainder of the sheet structure 150. The blocks or groups of clusters 152 can join together the base portions 154 of the brush filaments 151 of all the clusters 152 within the block. Alternatively, even when the clusters 152 are arranged in one or more blocks, the base portions 154 of the brush filaments 151 of each individual cluster 152 can remain separate.

[0110] ​ The head portion 104 during the forming process is shown. ​ and ​ A flat laminate structure 120 and an exploded view of the flat laminate structure 120 are shown, and the exploded view of the flat laminate structure 120 shows the sheet structure 150, two fasteners 165, a base structure 170, a protective structure 190, and a connector 114. ​ and ​ The base structure 170 is shown. ​ The assembled flat laminate structure 120 is shown. ​ Different bending states are shown, which can be used to form the flat laminate structure 120 into the head portion 104.

[0111] The flat laminate structure 120 has a wall portion 122 and a plurality of finger portions 124 extending from the wall portion 122. As can be seen, the finger portions 124 do not need to extend perpendicular to the wall portion 122, nor do they need to extend in a straight line. Instead, the finger portions 124 can have one or more angles along their lengths and can extend at an angle with respect to the wall portion 122. Each finger portion 124 is spaced and separated from the other finger portions 124.

[0112] A plurality of bristle clusters 152 of the sheet structure 150 extend from the front surface 125 of the flat laminate structure 120. Thus, a plurality of bristle clusters 152 of the sheet structure 150 extend from the front surface 125 of the flat laminate structure 120. The front surface 125 of the flat laminate structure 120 is the same as the front surface 163 of the sheet structure 150. The flat laminate structure 120 also has a rear surface 126 opposite to the front surface 125.

[0113] As ​As shown, two fasteners 165 extend through holes 171 in the base structure 170 to couple the connector 114 to the base structure 170. The base structure 170 is formed from a sheet of material such as sheet metal. The base structure 170 can be formed from iron, aluminum, copper, or any metallic element, metal alloy, or metallic material thereof. For example, the base structure 170 can be formed from stainless steel, spring steel, or other alloys. In still other embodiments, the base structure 170 can be formed from a polymeric material that is combined with a metal to form a composite structure. In other embodiments, the base structure 170 can be formed from a polymer or other non-metallic material.

[0114] Preferably, the base structure 170 is formed from a material suitable for allowing plastic deformation, such as a material that can be bent in subsequent assembly steps as will be discussed below. The material of the base structure 170 is selected to achieve the desired properties of the base structure 170. These properties can include vibration transmissibility, elastic modulus, acoustic impedance, mechanical impedance, or dynamic stiffness. Desirably, the base structure 170 is capable of effectively transmitting vibrations while being able to be formed into the desired shape for brushing the user's teeth. The head portion 104 can take the form of a conventional toothbrush shape, an entire or partial oral piece shape, or any other shape suitable for cleaning the user's oral cavity.

[0115] In one embodiment, the base structure 170 is formed from a material having a higher vibration transmissibility than the material of the sheet structure 150 or the protective structure 190. In other embodiments, the base structure 170 is formed from a material having a higher elastic modulus than the material of the sheet structure 150 or the protective structure 190. In other embodiments, the base structure 170 is formed from a material having a higher acoustic impedance than the material of the sheet structure 150 or the protective structure 190. In still other embodiments, the base structure 170 is formed from a material having a higher mechanical impedance and dynamic stiffness than the material of the sheet structure 150 or the protective structure 190.

[0116] The base structure 170 is a substantially flat sheet of material having an embossed portion 172. The embossed portion 172 has a hole 171 formed therein to allow the head of the fastener 165 to be held below the front surface 173 of the base structure. The base structure 170 has a rear surface 174 opposite the front surface 173. Except for the embossed portion 172, the front surface 173 and the rear surface 174 are substantially flat. The embossed portion 172 may be omitted if desired. The fastener 165 need not be a screw or bolt, and instead may be integrally formed with one of the other components of the flat laminate structure 120. For example, the connector 114 may include features that extend through the hole 171 and are thermally riveted to the base structure 170. Alternatively, the fastener 165 may be a separate component that is pressed, riveted, ultrasonically welded, or otherwise attached to the connector 114. Any connection mechanism, including rivets, thermal riveting, press fitting, adhesive bonding, or any other known technique, may be used to attach the connector 114 to the base structure. In still other embodiments, the base structure 170 may be integrally formed with and be integral to the connector 114.

[0117] Holes may be provided in the base structure 170 to achieve excellent bonding with the sheet structure 150 and the protective structure 190. Material from one of the sheet structure 150 and the protective structure 190 may flow through the holes in the base structure 170 to attach the sheet structure 150 to the protective structure 190 by bonding the material from the sheet structure 150 to the material of the protective structure 190.

[0118] The base structure 170 further includes a wall portion 175 and a plurality of finger portions 176. The wall portion 175 extends along the width of the base structure 170 and includes the embossed portion 172 and the hole 171 in the embossed portion 172. The finger portions 176 extend generally perpendicular to the wall portion 175, although they may be angled relative to the wall portion 175 as needed. The finger portions 176 need not extend in a straight line and may have bends or curves along their length.

[0119] The protective structure 190 may be composed of sheet material, or it may be a molded component that is separately molded or overmolded onto other components of the flat laminate structure 120. The protective structure 190 has a front surface 191 and an opposite rear surface 192. The front surface 191 may be generally flat, but need not be completely flat. As shown, the front surface 191 may have a recess that surrounds the base structure 170. The recess need not be formed in the front surface 191 of the protective structure, and in an alternative configuration, the recess may optionally be formed in the rear surface 164 of the sheet structure 150.

[0120] In some embodiments, the protective structure 190 can be formed at least in part from a biocompatible material such as a food-grade polymer. Suitable biocompatible materials include, but are not limited to, acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, polypropylene (PP), polyethylene naphthalate (PEN), polyethylene (PE), silicone, ethylene propylene diene monomer (EPDM), polycarbonate (PC), thermoplastic elastomer (TPE), and other plastic and elastomeric materials. Of course, the present invention is not so limited in all embodiments, and other materials can also be used to construct the protective structure 190 and its various components. In some embodiments, the protective structure 190 or at least a portion thereof can be formed from an elastomeric material. Hybrid configurations including components having different materials are envisioned.

[0121] The protective structure 190 has a perimeter portion 193 that extends beyond the base structure 170. Similarly, the sheet structure 150 has a perimeter portion 166 that extends beyond the base structure 170. In one possible assembly process of the flat laminate structure 120, the sheet structure 150, the base structure 170, and the protective structure 190 are laminated, and then the sheet structure 150 and the protective structure 190 are bonded or joined together to encapsulate the base structure 170. In another possible assembly process, the sheet structure 150 and the base structure 170 are laminated, and then the protective structure 190 is molded onto the sheet structure 150 and the base structure 170 to encapsulate the base structure 170. The protective structure 190 can be connected to the sheet structure 150 by heat welding, ultrasonic welding, adhesive bonding, molding, or any other known method.

[0122] In still other configurations, the protective structure 190 and the sheet structure 150 can be integrally formed and molded onto the base structure 170. Optionally, the materials of the protective structure 190 and the sheet structure 150 can be the same or different, and one of the protective structure 190 or the sheet structure 150 can overlap the edge of the base structure 170 to protect the user from potential sharp edges of the base structure 170.

[0123] Still other processes for producing the flat laminate structure 120 as shown are envisioned. The base structure 170 can be in direct contact with the sheet structure 150 and the protective structure 190 entirely, or the base structure 170 can be joined or otherwise connected to the sheet structure 150 or the protective structure 190 at any point during the assembly process as needed. This can be done by melting one or more components or using an adhesive or some other joining technique. Optionally, the base structure 170 can be exposed through the protective structure 190 in some or more regions. In still other embodiments, the protective structure 190 can be omitted if desired.

[0124] During each assembly process, it is contemplated that the peripheral portion 193 of the protective structure 190 is connected to the peripheral portion 166 of the sheet structure 150. Thus, the sheet structure 150 and the protective structure 190 extend beyond the perimeter of the base structure 170. The rear surface 164 of the sheet structure 150 is in direct surface contact with the front surface 173 of the base structure 170 and is connected to the front surface 191 of the protective structure 190. The rear surface 174 of the base structure 170 is in direct surface contact with the front surface 191 of the protective structure 190. The connector 114 can be coupled to the base structure 170 during, before, or after enclosing the base structure 170. The connector 114 extends from the rear surface 174 of the base structure 170 and the rear surface 192 of the protective structure 190.

[0125] Optionally, the sheet structure 150 and the protective structure 190 can be formed at least in part of an elastic material. As described above, the first film layer 155 and the second film layer 157 can be formed of an elastic material. The protective structure 190 can be formed of the same elastic material as the first film layer 155 and the second film layer 157 of the sheet structure 150. Alternatively, the materials of the protective structure 190 and the first film layer 155 and the second film layer 157 of the sheet structure 150 need not be the same and can be different. For example, the first film layer 155, the second film layer 157, and the protective structure 190 can be elastic materials of different hardnesses, chemical compositions, or can even not be elastic materials. Hard plastics such as ABS, nylon, or other polymers can be used for some or all of the first film layer 155, the second film layer 157, and the protective structure 190 as described above.

[0126] Preferably, the entire front surface 173 of the base structure 170 is connected to the rear surface 164 of the sheet structure 150. The entire rear surface 174 of the base structure 170 is connected to the front surface 191 of the protective structure 190. Thus, the base structure 170 is enclosed by the protective structure 190 and the sheet structure 150. The peripheral portions 166, 193 of the sheet structure 150 and the protective structure 190 extend beyond the base structure 170. As previously described, portions of the base structure 170 can be exposed through the protective structure 190. In particular, if so desired, the protective structure 190 can have holes that expose portions of the rear surface 174 of the base structure 170.

[0127] Optionally, the protective structure 190 can be omitted, and the sheet structure 150 can cover the perimeter of the base structure 170, or even wrap around the base structure 170 to cover a portion of the rear surface 174 of the base structure 170. In yet some other configurations, the protective structure 190 can only cover the perimeter of the base structure 170. It is even contemplated that the sheet structure 150 can cover both the front surface 173 and the rear surface 174 of the base structure 170, while the protective structure 190 can cover the perimeter of the base structure 170.

[0128] In still other embodiments, one or more clusters 152 or cluster blocks may be welded to the sheet structure 150. In this embodiment, the sheet structure 150 may be molded and then the clusters 152 may be welded or bonded to the sheet structure 150, rather than in-mold flocking as described above. Optionally, the sheet structure 150 may be molded separately from the base structure 170, or the sheet structure 150 may be overmolded onto the base structure 170. In other configurations, the bristle clusters 152 or bristle blocks may be placed in a mold with the base structure 170, and the sheet structure 150 may be overmolded onto both the bristle clusters 152 and the base structure 170 simultaneously. In still other configurations, the base structure 170 may be coated. The coating may form both the sheet structure 150 and the protective structure 190. The bristle clusters 152 may be welded or bonded to the coating that forms the sheet structure 150.

[0129] In still other alternative configurations, the cluster block 153 may be formed with the bristle clusters 152. The cluster block 153 may be formed of a rigid plastic material such as ABS, nylon, or other non-elastic plastics. Then, the bristle clusters 152 may be attached to the cluster block 153 to form a complete cluster block 153. Then, the cluster block 153 may be joined, welded, or otherwise connected to the base structure 170. Thus, the sheet structure 150 may be omitted. Optionally, the protective structure 190 may be formed around the cluster block 153 to encapsulate the base structure 170, or the protective structure 190 may expose a portion of the front surface 191.

[0130] As ​ best shown, the flat laminate structure 120 is shown in an unbent state, whereby the flat laminate structure 120 generally extends along a plane. As can be seen, a plurality of bristles 152 are arranged in a plurality of bristle blocks 153 extending from the front surface 125 of the flat laminate structure 120. ​ The flat laminate structure 120 is shown in a first partially bent state, where the flat laminate structure 120 no longer extends along a plane. Instead, the flat laminate structure 120 has been bent to begin forming the flat laminate structure 120 into the head portion 104. ​ The flat laminate structure 120 is shown in a second partially bent state, where the finger portion 124 of the flat laminate structure 120 is partially bent. ​ The flat laminate structure 120 is shown in a fully bent state. After transitioning from the unbent state to the fully bent state, the flat laminate structure 120 transforms into the head portion 104 ready to be assembled with the neck portion 102.

[0131] In ​In the first part of the shown bent state, the wall portion 122 of the flat laminate structure 120 has been bent along the path P-P. The path P-P can be arcuate, a series of arcuate shapes, a combination of arcuate and linear shapes, or any other shape as required. The path P-P can be designed to conform to the user's dental arch or its approximation. The wall portion 122 of the flat laminate structure 120 can be bent as a whole or can be bent by making a series of smaller bends. In either case, the wall portion 122 plastically deforms to achieve the desired shape. As can be seen, the finger portion 124 extends perpendicular to the path P-P and remains unbent in the first part of the bent state.

[0132] In ​ In the second part of the shown bent shape, the finger portion 124 of the flat laminate structure 120 bends at a first bend 127 adjacent to the distal end 128 of the finger portion 124. Thus, the finger portion 176 of the base structure 170 extends to the distal end 128 of the finger portion 124 of the flat laminate structure. The finger portions 124 of the flat laminate structure 120 do not have to bend at the same angle, and the bending angles of the respective finger portions 124 can be different.

[0133] ​ The flat laminate structure 120 in a fully bent state is shown. Thus, the flat laminate structure 120 has now formed the head portion 104. The finger portion 124 of the flat laminate structure 120 bends at a second bend 129 adjacent to the wall portion 122. As described above, the finger portion 124 forms an L shape, wherein the horizontal portion 132 of the finger 130 extends along the horizontal plane H-H from the wall 108. An arcuate channel is formed by the wall 108 and the finger 130, which receives the teeth of the user's dental arch. By forming the flat laminate structure 120 in a series of states from the unbent state to the first part of the bent state to the second part of the bent state and then to the fully bent state, the flat laminate structure 120 is converted into the head portion 104, which takes the form of a three-dimensional oral appliance. The oral appliance is configured to engage the user's dental arch. More specifically, the oral appliance is capable of brushing the buccal, labial, and occlusal surfaces of the user's teeth.

[0134] In some embodiments, the finger portion 124 can bend before the wall portion 122 bends. In other embodiments, the finger portion 124 can bend after the wall portion 122 bends. In still other embodiments, the finger portion 124 can bend simultaneously with the wall portion 122. In some embodiments, the connector 114 can be coupled to the base structure 170 before the finger portion 124 and the wall portion 122 bend.

[0135] Turning to ​, a series of alternative configurations of the head portion 104 are shown. Thus, each of these arrangements, in addition to the previously described examples, is an example of how the head portion 104 can be formed. Each of these embodiments is shown, with the bristles omitted. In ​ In the embodiment of, the base structure 170 is only encapsulated by the protective structure 190 at the perimeter 177 of the base structure 170. A plurality of holes 171 may be formed in the base structure 170 to allow the material of the protective structure 190 to pass therethrough and improve the attachment of the protective structure 190 to the base structure 170. Optionally, the bristles may be directly bonded to the base structure 170, or the sheet structure 150 may be bonded to some or all of the exposed base structure 170 on one or both sides of the base structure 170.

[0136] ​ Another embodiment is shown in which the sheet structure 150 is deformed around the base structure 170 and the protective structure 190 remains substantially flat before bending. Thus, the sheet structure 150 has a raised portion that encapsulates the base structure 170 therein. The combined thickness of the perimeter portions 166, 193 of the sheet structure 150 and the protective structure 190 is less than the thickness of the sheet structure 150, the protective structure 190, and the base structure 170. In an alternative configuration, the sheet structure 150 and the protective structure may be reversed such that the sheet structure 150 is flat and the protective structure 190 has a raised portion. Optionally, the sheet structure 150 and the protective structure 190 may be formed of the same material or different materials.

[0137] ​ One embodiment is shown in which the sheet structure 150 has a recess 169 for receiving the base structure 170. The protective structure 190 may be flat and bonded to the sheet structure 150. The recess 169 may be formed in the sheet structure 150 before encapsulating the base structure 170, or the recess 169 may be formed as a result of overmolding or another process. Optionally, the recess 169 may be formed in the protective structure 190 instead of the sheet structure 150. In this configuration, the sheet structure 150 may be substantially flat.

[0138] ​ A completely encapsulated base structure 170 is shown. Thus, the sheet structure 150 and the protective structure 190 are integrally formed as a single unitary component. This can be accomplished by overmolding the base structure 170. Similarly, ​ A base structure 170 in which a plurality of holes 171 are formed is shown to improve the retention of the sheet structure 150 and the protective structure 190.

[0139] ​An embodiment is shown in which only one side of the base structure 170 is exposed. Optionally, the bristles may be directly attached to the base structure 170, or the protective structure 190 may be integrally formed with the sheet structure 150, and the protective structure 190 may only cover the perimeter 177 of the base structure 170.

[0140] ​ A protective structure 190 surrounding the base structure 170 is shown. The sheet structure 150 may be formed of a different material and is only formed on one surface of the base structure 170. ​ A configuration is shown in which the sheet structure 150 extends through the holes 171 in the base structure 170 and covers both sides of the base structure 170. The protective portion 190 surrounds the perimeter 177 of the base structure 170. The sheet structure 150 may also be formed of a different material from the protective portion 190.

[0141] ​ Various embodiments are shown which illustrate variations regarding the attachment of the bristle clusters 152. ​ It is shown that the bristle clusters 152 can be individually connected to the rest of the sheet structure 150. Thus, the base portions 154 of the bristle filaments 151 are only connected to the base portions 154 of the bristle filaments 151 within the same bristle cluster 152. In contrast, ​ It is shown that the base portions 154 of the bristle filaments 151 are connected across a plurality of bristle clusters 152 forming a single cluster mass. ​ An embodiment is shown in which the base portions 154 of the bristle filaments 151 are connected together such that all the base portions 154 of the bristle filaments 151 of all the bristle clusters 152 form a single cluster mass. Optionally, in each embodiment, the bristle clusters 152 may be combined as described above, or they may be combined using an adhesive or other method.

[0142] ​ An embodiment is shown in which the base portions 154 of the bristle filaments 151 may be formed using anchor free tufting or other techniques to form a bristle mass in which the base portions 154 form an integral structure. This structure is then combined, welded, or otherwise connected to the remaining portion of the sheet structure 150. The sheet structure 150 may have a cavity or recess for receiving the bristle mass. Alternatively, as ​ shown, the structure may be located on top of one or more layers of the sheet structure 150. As in ​In some of the configurations shown, the bristle block can be embedded within the sheet structure 150 such that the material of the sheet structure 150 covers the base portion 154 and extends between adjacent bristle clusters 152. Optionally, the sheet structure 150 can have a non-flat surface. This can be the result of enclosing the base portion 154 or can be for forming additional cleaning structures such as protrusions from the material of the layer used to form the sheet structure 150.

[0143] Turning ​ , an alternative embodiment of the head 400 of the oral care appliance 1000 is shown. The head 400 can replace any of the head configurations discussed above. The head 400 is configured to operate with the handle 200 described above. The head 400 has a head portion 404 coupled to a neck portion 402. The neck portion 402 can engage the stem or other engagement features of the handle 200. The head portion 404 is coupled to the neck portion 402 and has a generally arcuate shape suitable for insertion into a user's oral cavity. The head portion 404 is configured to simultaneously engage a plurality of the user's teeth. The head 400 extends along a longitudinal axis A-A.

[0144] The head portion 404 has a front surface 406 and an opposite rear surface 408. A plurality of bristle clusters 452 extend from the front surface 406 of the head portion 404. The bristle clusters 452 are formed of filamentary bristles and can be formed of any known bristle filament material. Such materials can include polybutylene terephthalate (“PBT”), nylon, polypropylene, or other natural or synthetic materials.

[0145] The head portion 404 has a multi-component construction having a sheet structure 450, a base structure 470, and a protective structure 490. The sheet structure 450 is formed of a flexible sheet 456 and a plurality of bristle clusters 452. The flexible sheet 456 can be an elastic material or can be a polymeric material. Preferably, the flexible sheet 456 has a thickness of less than 2.6 mm, but can be thinner or thicker as needed. In other embodiments, the flexible sheet 456 can be formed of: a rigid plastic material such as ABS, nylon, polytetrafluoroethylene (“PTFE”), polyethylene terephthalate (“PET”), or other similar non-elastic polymers. In all embodiments, the flexible sheet 456 is thin enough to allow bending using finger pressure.

[0146] The sheet-like structure 450 has a front surface 458, a rear surface 460 opposite the front surface 458, and a perimeter 462 extending between the front surface 458 and the rear surface 460. A plurality of bristle clusters 452 extend from the front surface 458, and no bristle clusters 452 extend from the rear surface 460. Optionally, one or more agglomerates may be formed by the molten portions of the bristles of the bristle clusters 452 that have been mixed with the material of the flexible sheet 456. The agglomerates may be formed on the front surface 458 or the rear surface 460, depending on the method of attaching the bristles of the bristle clusters 452 to the flexible sheet 456.

[0147] The base structure 470 may be formed of metal or a metallic material such as steel, iron, aluminum, or another metallic material. Preferably, the base structure 470 is formed of a sheet metal material. The base structure 470 has a front surface 472 and a rear surface 474 opposite the front surface 472. The base structure 470 also extends from a proximal end 474 to a distal end 476. The base structure 470 is preferably embedded within the protective structure 490, except for a portion of the front surface 472 where the sheet-like structure 450 is coupled to the front surface 472 of the base structure 470. At least the proximal end 476 of the base structure 470 is coupled to the protective structure 490, allowing vibrations to be transmitted from the handle 200 through the base structure 470 to the bristle clusters 452. As shown, both the proximal end 476 and the distal end 478 are coupled to the protective structure 490, but in other embodiments, the distal end 478 may remain exposed or may be covered by another component.

[0148] The protective structure 490 includes a cavity 492 that receives the base structure 470 and the sheet-like structure 450. The protective structure 490 is preferably formed of a rigid plastic material such as ABS, polystyrene, nylon, or another inelastic polymer. However, in other embodiments, the protective structure 490 may be an elastic material. The protective structure 490 is preferably molded onto the base structure 470 and the sheet-like structure 450, but may also be molded or otherwise formed, and the base structure 470 and the sheet-like structure 450 may be assembled into the protective structure 490 after the protective structure 490 is formed.

[0149] The sheet structure 450 is preferably thermally welded, heat welded or adhesively bonded to the front surface 472 of the base structure 470, but can be attached in any known manner. The sheet structure 450 and the base structure 470 are then connected to the protective structure 490, and the cavity 492 corresponds to the shape of the sheet structure 450 and the base structure 470. As described above, this can be done by insert molding, or the cavity 492 can be formed and then the sheet structure 450 and the base structure 470 can be installed. Preferably, the base structure 470 extends into the neck portion 402 adjacent to the rod cavity 410 to better transfer vibrations from the vibration generating means in the handle 200 to the bristle clusters 452. In some embodiments, when the head 400 is coupled to the handle 200, the vibration generating means can be in direct physical contact with the base structure 470 to further improve vibration transfer.

[0150] The protective structure 490 covers the base structure 470 and is in direct contact with the sheet structure 450. The protective structure 490 covers the entire rear surface 474 of the base structure 470 and a part of the front surface 472 of the base structure 470. The protective structure 490 extends upward to the perimeter 460 of the sheet structure 450, thus encapsulating the base structure 470. This advantageously prevents contact between the user's oral tissues and the base structure 470, but in some other embodiments, some parts of the base structure 470 may be exposed. For example, in certain embodiments, a portion of the rear surface 474 may be exposed through the protective structure 490. The entire rear surface 460 of the sheet structure 450 is in direct contact with the front surface 472 of the base structure 470. Preferably, the protective structure 490 is integrally formed with the neck portion 402, thus forming an integrally formed component including both the protective structure 490 and the neck portion 402.

[0151] In a preferred method of manufacturing the head 400, a plurality of brush filaments are connected to a flexible sheet 456 to form the sheet structure 450. The sheet structure 450 has a front surface 458, a rear surface 460 and a perimeter 462. When a plurality of brush filaments are connected to the flexible sheet 456, they form a plurality of bristle clusters 452. The plurality of bristle clusters 452 extend from the front surface 458 of the sheet structure 450. Subsequently, the sheet structure 450 is positioned in direct contact with the front surface 472 of the base structure 470 such that the rear surface 460 of the sheet structure is in direct contact with the front surface 472 of the base structure 470. Subsequently, the rear surface 474 of the base structure 470 is covered by the protective structure 490, which is in direct contact with the perimeter 462 of the sheet structure 450 and covers a part of the front surface 472 of the base structure 470.

[0152] Go to ​, showing another embodiment of the head 400. Except as noted, ​ the head 400 shown in ​ is the same as the head 400 shown in

[0153] The head 400 has a sheet structure 450, a base structure 470, and a protective structure 490. The sheet structure 450 has a plurality of bristle clusters 452 extending from a front surface 458. A rear surface 460 is opposite the front surface 458, and a perimeter 462 extends from the front surface 458 to the rear surface 460 of the sheet structure 450.

[0154] The base structure 470 has a front surface 472, a rear surface 474 opposite the front surface 472, a proximal end 476, and a distal end 478. The rear surface 460 of the sheet structure 450 is in direct surface contact with the front surface 472 of the base structure 470. The base structure 470 is preferably formed of a sheet metal material such as steel or another material as described above. The base structure 470 is located within a cavity 492 of the protective structure 490, and the protective structure 490 covers the entire rear surface 474 of the base structure 470. The proximal end 476 of the base structure 470 extends into the neck portion 402.

[0155] ​

[0156] Exemplary Claim 1: An oral care appliance, comprising: a handle; and a head removably coupled to the handle, the head comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure; a sheet structure in contact with the base structure, the sheet structure including a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet structure; and a protective structure including a front surface and a rear surface, the front surface of the protective structure being connected to at least a portion of the rear surface of the sheet structure to encapsulate the base structure between the sheet structure and the protective structure.

[0157] Exemplary Claim 2: The oral care appliance according to Exemplary Claim 1, wherein the sheet structure comprises an elastic material.

[0158] Exemplary Claim 3: The oral care appliance according to Exemplary Claim 1 or Exemplary Claim 2, wherein the protective structure comprises an elastic material.

[0159] Exemplary Claim 4: The oral care appliance according to any one of Exemplary Claims 1 to 3, wherein the sheet-like structure and the protective structure each include a peripheral portion, and the sheet-like structure and the protective structure are connected along their respective peripheral portions.

[0160] Exemplary Claim 5: The oral care appliance according to any one of Exemplary Claims 1 to 4, wherein the sheet-like structure is heat welded to the protective structure.

[0161] Exemplary Claim 6: The oral care appliance according to any one of Exemplary Claims 1 to 4, wherein the sheet-like structure is ultrasonically welded to the protective structure.

[0162] Exemplary Claim 7: The oral care appliance according to any one of Exemplary Claims 1 to 4, wherein the sheet-like structure is adhesively bonded to the protective structure.

[0163] Exemplary Claim 8: The oral care appliance according to any one of Exemplary Claims 1 to 4, wherein the protective structure is molded onto both the sheet-like structure and the protective structure.

[0164] Exemplary Claim 9: The oral care appliance according to any one of Exemplary Claims 1 to 8, wherein the base structure includes a front surface and a rear surface, the entire front surface of the base structure is connected to the rear surface of the sheet-like structure, and the entire rear surface of the base structure is connected to the front surface of the protective structure.

[0165] Exemplary Claim 10: The oral care appliance according to any one of Exemplary Claims 1 to 9, wherein the plurality of bristle clusters of the sheet-like structure are formed by a plurality of filamentary bristles.

[0166] Exemplary Claim 11: The oral care appliance according to any one of Exemplary Claims 1 to 10, wherein the base structure is metallic.

[0167] Exemplary Claim 12: The oral care appliance according to any one of Exemplary Claims 1 to 11, wherein the base structure is formed of a metal sheet.

[0168] Exemplary Claim 13: The oral care appliance according to any one of Exemplary Claims 1 to 12, wherein the head portion extends along an arcuate path.

[0169] Exemplary Claim 14: An oral care appliance according to any one of exemplary claims 1 to 13, wherein the head portion includes a concave wall and a plurality of finger members extending from the wall.

[0170] Exemplary Claim 15: An oral care appliance according to exemplary claim 14, wherein each of the plurality of finger members includes a horizontal portion extending from the wall in a horizontal plane.

[0171] Exemplary Claim 16: An oral care appliance according to exemplary claim 15, wherein each of the plurality of finger members includes a curved portion and an end portion, and the end portion of the finger member is offset from the horizontal plane at the curved portion.

[0172] Exemplary Claim 17: An oral care appliance according to exemplary claim 14, wherein the plurality of finger members and the wall form an arcuate channel.

[0173] Exemplary Claim 18: An oral care appliance according to any one of exemplary claims 14 to 17, wherein each of the plurality of finger members forms an L shape.

[0174] Exemplary Claim 19: An oral care appliance according to any one of exemplary claims 14 to 18, wherein the plurality of finger members are spaced apart and separated from each other.

[0175] Exemplary Claim 20: An oral care appliance according to any one of exemplary claims 14 to 19, wherein a first finger member of the plurality of finger members includes a first bristle cluster and a second bristle cluster of the plurality of bristle clusters, the first bristle cluster being located on the horizontal portion of the first finger member, and the second bristle cluster being located on the end portion of the first finger member, the end portion being angled relative to the horizontal portion.

[0176] Exemplary Claim 21: An oral care appliance according to any one of exemplary claims 14 to 20, wherein the base structure extends to the end portion of each of the plurality of finger members.

[0177] Exemplary Claim 22: A head of an oral care appliance, comprising: a neck portion; and a head portion coupled to the neck portion, the head portion including: a base structure; a sheet structure in contact with the base structure, the sheet structure including a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet structure; and a protective structure in contact with a portion of the rear surface of the sheet structure and the rear surface of the base structure.

[0178] Exemplary Claim 23: The head according to exemplary claim 22, wherein the sheet structure comprises an elastic material.

[0179] Exemplary Claim 24: The head according to exemplary claim 22 or exemplary claim 23, wherein the protective structure comprises an elastic material.

[0180] Exemplary Claim 25: The head according to any one of exemplary claims 22 to 24, wherein the sheet structure and the protective structure each include a peripheral portion, and the sheet structure and the protective structure are connected along their respective peripheral portions.

[0181] Exemplary Claim 26: The head according to any one of exemplary claims 22 to 25, wherein the sheet structure is thermally welded to the protective structure.

[0182] Exemplary Claim 27: The head according to any one of exemplary claims 22 to 25, wherein the sheet structure is ultrasonically welded to the protective structure.

[0183] Exemplary Claim 28: The head according to any one of exemplary claims 22 to 25, wherein the sheet structure is adhesively bonded to the protective structure.

[0184] Exemplary Claim 29: The head according to any one of exemplary claims 22 to 25, wherein the protective structure is molded onto both the sheet structure and the protective structure.

[0185] Exemplary Claim 30: The head according to any one of exemplary claims 22 to 29, wherein the base structure includes a front surface and a rear surface, the entire front surface of the base structure is in contact with the rear surface of the sheet structure, and the entire rear surface of the base structure is in contact with the front surface of the protective structure.

[0186] Exemplary Claim 31: The head according to any one of exemplary claims 22 to 30, wherein the plurality of tufts of bristles of the sheet structure are formed by a plurality of filamentary bristles.

[0187] Exemplary Claim 32: The head according to any one of exemplary claims 22 to 31, wherein the base structure is metallic.

[0188] Exemplary Claim 33: The head according to any one of exemplary claims 22 to 32, wherein the base structure is formed of a metal sheet.

[0189] Exemplary claim 34: A head according to any one of exemplary claims 22 to 33, wherein the head portion extends along an arcuate path.

[0190] Exemplary claim 35: A head according to any one of exemplary claims 22 to 34, wherein the head portion includes a concave wall and a plurality of fingers extending from the wall.

[0191] Exemplary claim 36: A head according to exemplary claim 35, wherein each of the plurality of fingers includes a horizontal portion extending from the wall in a horizontal plane.

[0192] Exemplary claim 37: A head according to exemplary claim 36, wherein each of the plurality of fingers includes a bent portion and an end portion, and the end portion of the finger is offset from the horizontal plane at the bent portion.

[0193] Exemplary claim 38: A head according to exemplary claim 35, wherein the plurality of fingers and the wall form an arcuate channel.

[0194] Exemplary claim 39: A head according to any one of exemplary claims 35 to 38, wherein each of the plurality of fingers forms an L shape.

[0195] Exemplary claim 40: A head according to any one of exemplary claims 35 to 39, wherein the plurality of fingers are spaced apart and separated from each other.

[0196] Exemplary claim 41: A head according to any one of exemplary claims 35 to 40, wherein a first finger of the plurality of fingers includes a first bristle cluster and a second bristle cluster of the plurality of bristle clusters, the first bristle cluster being located on the horizontal portion of the first finger, and the second bristle cluster being located on the end portion of the first finger, the end portion being angled with respect to the horizontal portion.

[0197] Exemplary claim 42: A head according to any one of exemplary claims 35 to 41, wherein the base structure extends to the end portion of each of the plurality of fingers.

[0198] Exemplary claim 43: A method of manufacturing an oral care appliance, comprising: a) providing a sheet structure including a plurality of bristle clusters extending from a front surface of the sheet structure; and b) encapsulating a base structure between the sheet structure and a protective structure to form a head portion.

[0199] Exemplary claim 44: The method according to exemplary claim 43, wherein in step b), the rear surface of the sheet-like structure is brought into contact with the front surface of the base structure.

[0200] Exemplary claim 45: The method according to exemplary claim 43 or exemplary claim 44, wherein in step b), the front surface of the protective structure is brought into contact with the rear surface of the base structure and the rear surface of the sheet-like structure.

[0201] Exemplary claim 46: The method according to any one of exemplary claims 43 to 45, further comprising a bending step, wherein the wall of the head portion is bent into a concave shape.

[0202] Exemplary claim 47: The method according to exemplary claim 46, wherein in the bending step, a plurality of finger-like members of the head portion are bent such that they extend away from the inner surface of the wall.

[0203] Exemplary claim 48: The method according to exemplary claim 47, wherein in the bending step, each of the plurality of finger-like members is bent such that each of the plurality of finger-like members has an L shape.

[0204] Exemplary claim 49: The method according to any one of exemplary claims 43 to 48, wherein before step b), the assembly step comprises fixing a connector to the base structure.

[0205] Exemplary claim 50: The method according to exemplary claim 49, wherein after step b), the connector is coupled to the neck portion of the oral care appliance.

[0206] Exemplary claim 51: An oral care appliance, comprising: a handle; and a head removably coupled to the handle, the head comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising a sheet-like structure, the sheet-like structure comprising: a first film layer having a front surface and a rear surface, the front surface forming the front surface of the sheet-like structure; a second film layer having a front surface and a rear surface, the rear surface forming the rear surface of the sheet-like structure; and a plurality of tufts of bristles extending from the front surface of the first film layer; wherein the first film layer and the second film layer are formed of the same material.

[0207] Exemplary claim 52: The oral care appliance according to exemplary claim 51, wherein the sheet-like structure comprises an elastic material.

[0208] Exemplary claim 53: The oral care appliance according to exemplary claim 51 or exemplary claim 52, wherein the plurality of bristle clusters are formed by a plurality of bristle filaments.

[0209] Exemplary claim 54: The oral care appliance according to exemplary claim 53, wherein each of the plurality of bristle filaments has a cleaning portion and a base portion, and the base portion, a portion of the first film layer, and a portion of the second film layer form a molten cushion layer.

[0210] Exemplary claim 55: The oral care appliance according to any one of exemplary claims 51 to 54, further comprising a protective structure, wherein the sheet structure and the protective structure each include a perimeter portion, and the sheet structure and the protective structure are connected along their respective perimeter portions.

[0211] Exemplary claim 56: The oral care appliance according to exemplary claim 55, wherein the sheet structure is thermally welded to the protective structure.

[0212] Exemplary claim 57: The oral care appliance according to exemplary claim 55, wherein the sheet structure is ultrasonically welded to the protective structure.

[0213] Exemplary claim 58: The oral care appliance according to exemplary claim 55, wherein the sheet structure is adhesively bonded to the protective structure.

[0214] Exemplary claim 59: The oral care appliance according to any one of exemplary claims 51 to 58, wherein the first film layer and the second film layer are formed of a first material, and the plurality of bristle clusters are formed of filaments of a second material, and the first material is different from the second material.

[0215] Exemplary claim 60: The oral care appliance according to any one of exemplary claims 51 to 59, wherein the sheet structure includes a molten cushion layer formed of materials from the first film layer, the second film layer, and the plurality of bristle clusters.

[0216] Exemplary claim 61: The oral care appliance according to any one of exemplary claims 51 to 60, wherein the thickness of each of the first film layer and the second film layer is 0.8 mm or less.

[0217] Exemplary claim 62: The oral care appliance according to exemplary claim 61, wherein the thickness of each of the first film layer and the second film layer is 0.4 mm or less.

[0218] Exemplary claim 63: An oral care implement according to any one of exemplary claims 51 to 62, wherein the sheet structure comprises a molten cushion layer formed from the materials of the first film layer, the second film layer, and the plurality of bristle clusters.

[0219] Exemplary claim 64: A head of an oral care implement, comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure having a front surface; and a sheet structure coupled to the base structure, the sheet structure comprising: a first film layer, a front surface of the first film layer forming a front surface of the sheet structure; a second film layer connected to the first film layer, a rear surface of the second film layer forming a rear surface of the sheet structure; a plurality of bristle clusters extending from the front surface of the first film layer; wherein the first film layer and the second film layer are formed of an elastic material; and wherein the rear surface of the sheet structure contacts the front surface of the base structure.

[0220] Exemplary claim 65: The head according to exemplary claim 64, wherein the first film layer and the second film layer are formed of the same material.

[0221] Exemplary claim 66: The head according to exemplary claim 64 or exemplary claim 65, wherein the plurality of bristle clusters are formed of a plurality of bristle filaments.

[0222] Exemplary claim 67: The head according to exemplary claim 66, wherein each of the plurality of bristle filaments has a cleaning portion and a base portion, and the base portion, a portion of the first film layer, and a portion of the second film layer form a molten cushion layer.

[0223] Exemplary claim 68: The head according to any one of exemplary claims 64 to 67, further comprising a protective structure, wherein the sheet structure and the protective structure each comprise a perimeter portion, and the sheet structure and the protective structure are connected along their respective perimeter portions.

[0224] Exemplary claim 69: The head according to exemplary claim 68, wherein the sheet structure is thermally welded to the protective structure.

[0225] Exemplary claim 70: The head according to exemplary claim 68, wherein the sheet structure is ultrasonically welded to the protective structure.

[0226] Exemplary claim 71: The head according to exemplary claim 68, wherein the sheet structure is adhesively bonded to the protective structure.

[0227] Exemplary claim 72: The head according to any one of exemplary claims 64 to 71, wherein the first film layer and the second film layer are formed of a first material, and the plurality of bristle clusters are formed of filaments of a second material, the first material being different from the second material.

[0228] Exemplary claim 73: The head according to any one of exemplary claims 64 to 72, wherein the sheet structure includes a fused cushion formed of materials from the first film layer, the second film layer, and the plurality of bristle clusters.

[0229] Exemplary claim 74: The head according to any one of exemplary claims 64 to 73, wherein each of the first film layer and the second film layer has a thickness of 0.8 mm or less.

[0230] Exemplary claim 75: The head according to exemplary claim 74, wherein each of the first film layer and the second film layer has a thickness of 0.4 mm or less.

[0231] Exemplary claim 76: The head according to any one of exemplary claims 64 to 75, wherein the sheet structure includes a fused cushion formed of materials from the first film layer, the second film layer, and the plurality of bristle clusters.

[0232] Exemplary claim 77: A method of manufacturing a sheet structure for an oral care implement, comprising: a) inserting a plurality of brush filaments into a plurality of hair implanting holes of a hair implanting tool to form a plurality of bristle clusters; b) fusing a first film layer to a base portion of the plurality of bristle clusters; and c) fusing a second film layer to the first film layer.

[0233] Exemplary claim 78: The method according to exemplary claim 77, wherein, after step a) and before step b), a step of melting a base portion of each of the plurality of brush filaments.

[0234] Exemplary claim 79: The method according to exemplary claim 78, wherein the melting step includes forming a mushroom shape on each of the pickup positions of the plurality of bristle clusters.

[0235] Exemplary claim 80: The method according to any one of exemplary claims 77 to 79, wherein the plurality of bristle clusters extend from a front surface of the first film layer.

[0236] Exemplary claim 81: The method according to any one of exemplary claims 77 to 80, wherein the first film layer and the second film layer are formed of an elastic material.

[0237] Exemplary claim 82: The method according to any one of exemplary claims 77 to 81, wherein the first film layer and the second film layer are formed of the same material.

[0238] Exemplary claim 83: The method according to exemplary claim 82, wherein the plurality of brush capillary filaments are formed of a material different from that of the first film layer and the second film layer.

[0239] Exemplary claim 84: The method according to any one of exemplary claims 77 to 83, wherein the thickness of the first film layer is about 0.4 mm, and the thickness of the second film layer is about 0.4 mm.

[0240] Exemplary claim 85: The method according to any one of exemplary claims 77 to 84, wherein the first film layer and the second film layer are free of perforations.

[0241] Exemplary claim 86: The method according to any one of exemplary claims 77 to 85, wherein a molten cushion layer is formed during the fusing step, and the molten cushion layer includes a base portion of the plurality of brush capillary filaments, a portion of the first film layer, and a portion of the second film layer.

[0242] Exemplary claim 87: An oral care appliance, comprising: a handle including a vibration generating device; and a head detachably coupled to the handle, the head including: a neck portion; and a head portion coupled to the neck portion, the head portion including: a base structure formed of a metallic material; and a sheet-like structure in contact with the base structure, the sheet-like structure including a front surface, a rear surface, and a plurality of brush tufts extending from the front surface of the sheet-like structure.

[0243] Exemplary claim 88: The oral care appliance according to exemplary claim 87, wherein the base structure extends from the neck portion to a first distal end and a second distal end of the head portion.

[0244] Exemplary claim 89: The oral care appliance according to exemplary claim 87 or exemplary claim 88, wherein the head portion extends along an arcuate path.

[0245] Exemplary claim 90: The oral care appliance according to any one of exemplary claims 87 to 89, wherein the head portion includes a concave wall and a plurality of finger-like members extending from the concave wall.

[0246] Exemplary claim 91: The oral care appliance according to exemplary claim 90, wherein each of the plurality of finger-like members includes a horizontal portion extending along a horizontal plane from the concave wall.

[0247] Exemplary claim 92: The oral care appliance according to exemplary claim 91, wherein each of the plurality of finger members includes a bent portion and an end portion, and the end portion of the finger member is offset from the horizontal plane at the bent portion.

[0248] Exemplary claim 93: The oral care appliance according to exemplary claim 90, wherein the plurality of finger members and the concave wall form an arcuate channel.

[0249] Exemplary claim 94: The oral care appliance according to any one of exemplary claims 90 to 93, wherein each of the plurality of finger members forms an L shape.

[0250] Exemplary claim 95: The oral care appliance according to any one of exemplary claims 90 to 94, wherein the plurality of finger members are spaced apart and separated from each other.

[0251] Exemplary claim 96: The oral care appliance according to any one of exemplary claims 90 to 95, wherein a first finger member of the plurality of finger members includes a first bristle cluster and a second bristle cluster of the plurality of bristle clusters, the first bristle cluster is located on a horizontal portion of the first finger member, the second bristle cluster is located on an end portion of the first finger member, and the end portion is angled relative to the horizontal portion.

[0252] Exemplary claim 97: The oral care appliance according to any one of exemplary claims 90 to 96, wherein the base structure extends to an end portion of each of the plurality of finger members.

[0253] Exemplary claim 98: The oral care appliance according to any one of exemplary claims 87 to 97, wherein the sheet structure comprises an elastic material.

[0254] Exemplary claim 99: The oral care appliance according to any one of exemplary claims 87 to 98, further comprising a protective structure, wherein the protective structure comprises an elastic material.

[0255] Exemplary claim 100: The oral care appliance according to exemplary claim 99, wherein the sheet structure and the protective structure each include a perimeter portion, and the sheet structure and the protective structure are connected along their respective perimeter portions.

[0256] Exemplary claim 101: The oral care appliance according to exemplary claim 99, wherein the sheet structure is heat welded to the protective structure.

[0257] Exemplary claim 102: The oral care appliance according to exemplary claim 99, wherein the sheet structure is ultrasonically welded to the protective structure.

[0258] Exemplary claim 103: The oral care appliance according to exemplary claim 99, wherein the sheet structure is adhesively bonded to the protective structure.

[0259] Exemplary claim 104: The oral care appliance according to exemplary claim 99, wherein the protective structure is molded onto both the sheet structure and the protective structure.

[0260] Exemplary claim 105: The oral care appliance according to any one of exemplary claims 87 to 104, wherein the base structure includes a front surface and a rear surface, and the entire front surface of the base structure is connected to the rear surface of the sheet structure.

[0261] Exemplary claim 106: The oral care appliance according to any one of exemplary claims 87 to 105, wherein the plurality of bristle clusters of the sheet structure are formed by a plurality of filament bristles.

[0262] Exemplary claim 107: A head of an oral care appliance, comprising: a neck portion; and a head portion coupled to the neck portion, the head portion including: a base structure formed of a first material; a sheet structure in contact with the base structure, the sheet structure including a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet structure, the sheet structure being formed of a second material; wherein a first vibration transmission rate of the first material is greater than a second vibration transmission rate of the second material.

[0263] Exemplary claim 108: The head according to exemplary claim 107, wherein the first material is a metallic material.

[0264] Exemplary claim 109: The head according to exemplary claim 107 or 108, wherein the base structure is formed of a metal sheet.

[0265] Exemplary claim 110: The head according to any one of exemplary claims 107 to 109, wherein the sheet structure comprises an elastic material.

[0266] Exemplary claim 111: The head according to any one of exemplary claims 107 to 110, wherein the base structure extends from the neck portion to a first distal end and a second distal end of the head portion.

[0267] Exemplary claim 112: The head according to any one of exemplary claims 107 to 111, wherein the head portion extends along an arcuate path.

[0268] Exemplary claim 113: The head according to any one of exemplary claims 107 to 112, wherein the head portion includes a concave wall and a plurality of fingers extending from the concave wall.

[0269] Exemplary claim 114: The head according to exemplary claim 113, wherein each of the plurality of fingers includes a horizontal portion extending from the concave wall along a horizontal plane.

[0270] Exemplary claim 115: The head according to exemplary claim 114, wherein each of the plurality of fingers includes a bent portion and a distal portion, and the distal portion of the finger is offset from the horizontal plane at the bent portion.

[0271] Exemplary claim 116: The head according to exemplary claim 113, wherein the plurality of fingers and the concave wall form an arcuate channel.

[0272] Exemplary claim 117: The head according to any one of exemplary claims 113 to 116, wherein each of the plurality of fingers forms an L shape.

[0273] Exemplary claim 118: The head according to any one of exemplary claims 113 to 117, wherein the plurality of fingers are spaced apart and separated from each other.

[0274] Exemplary claim 119: The head according to any one of exemplary claims 113 to 118, wherein a first finger of the plurality of fingers includes a first bristle cluster and a second bristle cluster of the plurality of bristle clusters, the first bristle cluster being located on the horizontal portion of the first finger, and the second bristle cluster being located on the distal portion of the first finger, the distal portion being angled relative to the horizontal portion.

[0275] Exemplary claim 120: The head according to any one of exemplary claims 113 to 119, wherein the base structure extends to the distal portion of each of the plurality of fingers.

[0276] Exemplary claim 121: The head according to any one of exemplary claims 107 to 120, further comprising a protective structure, wherein the protective structure comprises an elastic material.

[0277] Exemplary claim 122: The head according to exemplary claim 121, wherein the sheet structure and the protective structure each include a peripheral portion, and the sheet structure and the protective structure are connected along their respective peripheral portions.

[0278] Exemplary claim 123: The head according to exemplary claim 121, wherein the sheet structure is heat welded to the protective structure.

[0279] Exemplary claim 124: The head according to exemplary claim 121, wherein the sheet structure is ultrasonically welded to the protective structure.

[0280] Exemplary claim 125: The head according to exemplary claim 121, wherein the sheet structure is adhesively bonded to the protective structure.

[0281] Exemplary claim 126: The head according to exemplary claim 121, wherein the protective structure is molded onto both the sheet structure and the protective structure.

[0282] Exemplary claim 127: The head according to any one of exemplary claims 107 to 126, wherein the base structure includes a front surface and a rear surface, and the entire front surface of the base structure is connected to the rear surface of the sheet structure.

[0283] Exemplary claim 128: The head according to any one of exemplary claims 107 to 127, wherein the plurality of bristle clusters of the sheet structure are formed by a plurality of filament bristles.

[0284] Exemplary claim 129: A method of exciting bristle filaments, comprising: a) providing an oral care appliance, the oral care appliance including a handle and a head, the head including a neck portion and a head portion, the head portion being coupled to the neck portion, and the neck portion being coupled to the handle; b) generating vibrations with a vibration generating device; and c) transmitting the vibrations from the handle to the bristle filaments via the neck portion, a metal base structure of the head portion coupled to the neck portion, and a sheet structure of the head portion in contact with the base structure; wherein the bristle filaments extend from the sheet structure.

[0285] Exemplary claim 130: The method according to exemplary claim 129, wherein the base structure is formed of a first material, and the sheet structure includes a second material, and a first vibration transfer rate of the first material is greater than a second vibration transfer rate of the second material.

[0286] Exemplary claim 131: The method according to exemplary claim 129 or 130, wherein the base structure is formed of a metallic material.

[0287] Exemplary claim 132: The method according to any one of exemplary claims 129 to 131, wherein the base structure extends from the neck portion to a first distal end and a second distal end of the head portion.

[0288] Exemplary claim 133: The method according to any one of exemplary claims 129 to 132, wherein the head portion extends along an arcuate path.

[0289] Exemplary claim 134: The method according to any one of exemplary claims 129 to 133, wherein the head portion includes a concave wall and a plurality of fingers extending from the concave wall.

[0290] Exemplary claim 135: The method according to exemplary claim 134, wherein each of the plurality of fingers includes a horizontal portion extending from the concave wall in a horizontal plane.

[0291] Exemplary claim 136: The method according to exemplary claim 135, wherein each of the plurality of fingers includes a bent portion and an end portion, and the end portion of the finger is offset from the horizontal plane at the bent portion.

[0292] Exemplary claim 137: The method according to exemplary claim 134, wherein the plurality of fingers and the concave wall form an arcuate channel.

[0293] Exemplary claim 138: The method according to any one of exemplary claims 134 to 137, wherein each of the plurality of fingers forms an L shape.

[0294] Exemplary claim 139: The method according to any one of exemplary claims 134 to 138, wherein the plurality of fingers are spaced apart and separated from each other.

[0295] Exemplary claim 140: The method according to any one of exemplary claims 134 to 139, wherein a first finger of the plurality of fingers includes a first bristle cluster and a second bristle cluster of a plurality of bristle clusters, the first bristle cluster is located on the horizontal portion of the first finger, and the second bristle cluster is located on the end portion of the first finger, and the end portion is angled with respect to the horizontal portion.

[0296] Exemplary claim 141: The method according to any one of exemplary claims 134 to 140, wherein the base structure extends to an end portion of each of the plurality of finger-like members.

[0297] Exemplary claim 142: The method according to any one of exemplary claims 129 to 141, wherein the base structure includes a front surface and a rear surface, and the entire front surface of the base structure is connected to the rear surface of the sheet structure.

[0298] Exemplary claim 143: A method of forming an oral piece, comprising: a) forming a flat laminated structure having a plurality of tufts of bristles extending from a front surface of the flat laminated structure; and b) bending the flat laminated structure into a three-dimensional oral piece.

[0299] Exemplary claim 144: The method according to exemplary claim 143, wherein the flat laminated structure includes a sheet structure and a base structure, and the sheet structure includes a plurality of tufts of bristles.

[0300] Exemplary claim 145: The method according to exemplary claim 144, wherein the flat laminated structure further includes a protective structure, and the sheet structure and the protective structure enclose the base structure.

[0301] Exemplary claim 146: The method according to any one of exemplary claims 143 to 145, wherein the flat laminated structure is plastically deformed during step b).

[0302] Exemplary claim 147: The method according to any one of exemplary claims 143 to 146, wherein step b) further includes step b-1), and step b-1) includes bending a wall portion of the flat laminated structure into a concave shape.

[0303] Exemplary claim 148: The method according to any one of exemplary claims 143 to 147, wherein step b) further includes step b-2), and step b-2) includes bending a plurality of finger-like member portions of the flat laminated structure.

[0304] Exemplary claim 149: The method according to any one of exemplary claims 143 to 148, further including step c), and step c) includes coupling a connector to the flat laminated structure.

[0305] Exemplary claim 150: The method according to exemplary claim 149, wherein the connector is configured to engage a socket of a neck portion.

[0306] Exemplary claim 151: The method according to exemplary claim 149 or exemplary claim 150, wherein step c) is performed before step b).

[0307] Exemplary claim 152: The method according to any one of exemplary claims 143 to 151, wherein the flat laminated structure comprises a sheet structure and a base structure, and the base structure is metallic.

[0308] Exemplary claim 153: The method according to exemplary claim 152, wherein the sheet structure comprises an elastic material and the plurality of tufts of bristles.

[0309] Exemplary claim 154: A head of an oral care appliance, comprising: a head portion, the head portion comprising: a base structure formed of a first material; and a plurality of clusters in contact with a front surface of the base structure, each of the plurality of clusters comprising a front surface, a rear surface, and a plurality of tufts of bristles extending from the front surface, the plurality of clusters being formed of a second material; wherein a first vibration transmission rate of the first material is greater than a second vibration transmission rate of the second material.

[0310] Exemplary claim 155: The head according to exemplary claim 154, wherein the first material is a metallic material.

[0311] Exemplary claim 156: The head according to exemplary claim 154 or 155, wherein the base structure is formed of a metal sheet.

[0312] Exemplary claim 157: The head according to any one of exemplary claims 154 to 156, wherein the plurality of clusters comprises a non-elastic material.

[0313] Exemplary claim 158: The head according to any one of exemplary claims 154 to 157, wherein the base structure extends from a neck portion to a first distal end and a second distal end of the head portion.

[0314] Exemplary claim 159: The head according to any one of exemplary claims 154 to 158, wherein the head portion extends along an arcuate path.

[0315] Exemplary claim 160: The head according to any one of exemplary claims 154 to 159, wherein the head portion comprises a concave wall and a plurality of fingers extending from the concave wall.

[0316] Exemplary claim 161: The head according to exemplary claim 160, wherein each of the plurality of fingers comprises a horizontal portion extending along a horizontal plane from the concave wall.

[0317] Exemplary claim 162: The head according to exemplary claim 161, wherein each of the plurality of finger members includes a bent portion and an end portion, and the end portion of the finger member is offset from the horizontal plane at the bent portion.

[0318] Exemplary claim 163: The head according to exemplary claim 160, wherein the plurality of finger members and the concave wall form an arcuate channel.

[0319] Exemplary claim 164: The head according to any one of exemplary claims 160 to 163, wherein each of the plurality of finger members forms an L shape.

[0320] Exemplary claim 165: The head according to any one of exemplary claims 160 to 164, wherein the plurality of finger members are spaced apart and separated from each other.

[0321] Exemplary claim 166: The head according to any one of exemplary claims 160 to 165, wherein a first finger member of the plurality of finger members includes a first brush tuft and a second brush tuft of the plurality of brush tufts, the first brush tuft is located on a horizontal portion of the first finger member, and the second brush tuft is located on an end portion of the first finger member, and the end portion is angled relative to the horizontal portion.

[0322] Exemplary claim 167: The head according to any one of exemplary claims 160 to 166, wherein the base structure extends to an end portion of each of the plurality of finger members.

[0323] Exemplary claim 168: The head according to any one of exemplary claims 154 to 167, further comprising a protective structure, wherein the protective structure comprises an elastic material.

[0324] Exemplary claim 169: The head according to exemplary claim 168, wherein the plurality of cluster blocks are thermally welded to the protective structure.

[0325] Exemplary claim 170: The head according to exemplary claim 168, wherein the plurality of cluster blocks are ultrasonically welded to the protective structure.

[0326] Exemplary claim 171: The head according to exemplary claim 168, wherein the plurality of cluster blocks are adhesively bonded to the protective structure.

[0327] Exemplary claim 172: The head according to exemplary claim 168, wherein the protective structure is molded onto both the plurality of cluster blocks and the protective structure.

[0328] Exemplary claim 173: The head according to any one of exemplary claims 154 to 172, wherein the plurality of bristle clusters of the plurality of cluster blocks are formed by a plurality of filament bristles.

[0329] Exemplary claim 174: An oral care appliance, comprising: a handle; and a head coupled to the handle, the head including: a neck portion; and a head portion coupled to the neck portion, the head portion including: a base structure extending from a proximal end to a distal end, the proximal end being coupled to the neck portion; a sheet-like structure in contact with the base structure, the sheet-like structure including a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet-like structure; and a protective structure covering the base structure and in contact with the sheet-like structure.

[0330] Exemplary claim 175: The oral care appliance according to exemplary claim 174, wherein the sheet-like structure comprises an elastic material.

[0331] Exemplary claim 176: The oral care appliance according to exemplary claim 174 or exemplary claim 175, wherein the protective structure comprises a hard plastic material.

[0332] Exemplary claim 177: The oral care appliance according to any one of exemplary claims 174 to 176, wherein the sheet-like structure is thermally welded to the protective structure.

[0333] Exemplary claim 178: The oral care appliance according to any one of exemplary claims 174 to 176, wherein the sheet-like structure is ultrasonically welded to the protective structure.

[0334] Exemplary claim 179: The oral care appliance according to any one of exemplary claims 174 to 176, wherein the sheet-like structure is adhesively bonded to the protective structure.

[0335] Exemplary claim 180: The oral care appliance according to any one of exemplary claims 174 to 176, wherein the protective structure is molded onto both the sheet-like structure and the protective structure.

[0336] Exemplary claim 181: An oral care device according to any one of exemplary claims 174 to 180, wherein the base structure includes a front surface and a rear surface, the entire rear surface of the sheet structure is connected to the front surface of the base structure, and the entire rear surface of the base structure is in contact with the protective structure.

[0337] Exemplary Claim 182: The oral care implement of any one of Exemplary Claims 174 to 181, wherein the plurality of bristle tufts of the sheet-like structure are formed from a plurality of filament bristles.

[0338] Exemplary Claim 183: The oral care implement of any one of exemplary claims 174 to 182, wherein the base structure is metallic.

[0339] Exemplary Claim 184: The oral care implement of any one of Exemplary Claims 174 to 183 wherein the base structure is formed from sheet metal.

[0340] Exemplary Claim 185: The oral care implement of any one of exemplary claims 174 to 184, wherein the base structure extends into a neck portion of the head.

[0341] Exemplary claim 186: The oral care implement of any one of exemplary claims 174 to 185, wherein the sheet-like structure includes a perimeter extending between the front surface and the rear surface, the perimeter being in contact with the guard structure.

[0342] Exemplary claim 187: The oral care implement of any one of exemplary claims 174 to 186, wherein the guard structure overlies a portion of the front surface of the sheet-like structure.

[0343] Exemplary claim 188: A head portion of an oral care device, comprising: a neck portion; and a head portion connected to the neck portion, the head portion comprising: a base structure having a front surface and an opposite rear surface, the base structure being formed of a metal material; a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface and a plurality of bristle clusters extending from the front surface of the sheet structure; and a protective structure covering the rear surface of the base structure.

[0344] Example claim 189: The head according to example claim 188, wherein the sheet structure comprises an elastic material.

[0345] Exemplary claim 190: The head according to exemplary claim 188 or exemplary claim 189, wherein the protective structure comprises a hard plastic material.

[0346] Exemplary claim 191: The head according to any one of exemplary claims 188 to 190, wherein the sheet structure is thermally welded to the protective structure.

[0347] Exemplary claim 192: The head according to any one of exemplary claims 188 to 191, wherein the sheet structure is ultrasonically welded to the protective structure.

[0348] Exemplary claim 193: The head according to any one of exemplary claims 188 to 191, wherein the sheet structure is adhesively bonded to the protective structure.

[0349] Exemplary claim 194: The head according to any one of exemplary claims 188 to 191, wherein the protective structure is molded onto both the sheet structure and the protective structure.

[0350] Exemplary claim 195: The head according to any one of exemplary claims 188 to 194, wherein the entire rear surface of the sheet structure is connected to the front surface of the base structure, and the entire rear surface of the base structure contacts the protective structure.

[0351] Exemplary claim 196: The oral care implement according to any one of exemplary claims 188 to 195, wherein the plurality of tufts of bristles of the sheet structure are formed by a plurality of filamentary bristles.

[0352] Exemplary claim 197: The oral care implement according to any one of exemplary claims 188 to 196, wherein the base structure is metallic.

[0353] Exemplary claim 198: The oral care implement according to any one of exemplary claims 188 to 197, wherein the base structure is formed of a metal sheet.

[0354] Exemplary claim 199: The oral care implement according to any one of exemplary claims 188 to 198, wherein the base structure extends into the neck portion of the head.

[0355] Exemplary claim 200: The oral care implement according to any one of exemplary claims 188 to 199, wherein the sheet structure includes a perimeter extending between the front surface and the rear surface, and the perimeter contacts the protective structure.

[0356] Exemplary claim 201: An oral care implement according to any one of exemplary claims 188 to 200, wherein the protective structure overlaps a part of the front surface of the sheet structure.

[0357] Exemplary claim 202: A method of manufacturing a head of an oral care implement, comprising: a) connecting a plurality of brush filaments to a flexible sheet to form a sheet structure, the sheet structure including a front surface, a rear surface, and a plurality of brush tufts extending from the front surface of the sheet structure; b) positioning the sheet structure in direct contact with the front surface of a base structure; and c) covering the rear surface of the base structure with a protective structure that is in direct contact with the perimeter of the sheet structure and covers a part of the front surface of the base structure.

[0358] Exemplary claim 203: The method according to exemplary claim 202, wherein, in step c), the protective structure covers a part of the front surface of the sheet structure.

[0359] Exemplary claim 204: The method according to exemplary claim 202 or exemplary claim 203, wherein the sheet structure comprises an elastic material.

[0360] Exemplary claim 205: The method according to any one of exemplary claims 202 to 204, wherein the protective structure comprises a hard plastic material.

[0361] Exemplary claim 206: The method according to any one of exemplary claims 202 to 205, wherein the base structure comprises a metallic material.

[0362] Exemplary claim 207: The method according to any one of exemplary claims 202 to 206, wherein, in step b), the sheet structure is thermally welded to the protective structure.

[0363] Exemplary claim 208: The method according to any one of exemplary claims 202 to 206, wherein, in step b), the sheet structure is ultrasonically welded to the protective structure.

[0364] Exemplary claim 209: The method according to any one of exemplary claims 202 to 206, wherein, in step b), the sheet structure is adhesively bonded to the protective structure.

[0365] Exemplary claim 210: The head according to any one of exemplary claims 202 to 209, wherein, in step c), the protective structure is molded onto both the sheet structure and the protective structure.

[0366] As used throughout, ranges are used as shorthand for any and every value within the range. Any value within the range can be selected as the endpoint of the range. Additionally, all references cited herein are hereby incorporated by reference in their entirety. In the event of a conflict between a definition in the present disclosure and a definition in a cited reference, the present disclosure controls.

[0367] Although the invention has been described with respect to specific examples including the presently preferred modes of carrying out the invention, those skilled in the art will recognize that there are many variations and permutations of the above systems and techniques. It is understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the invention. Accordingly, the spirit and scope of the invention should be interpreted broadly as set forth in the appended claims.

Claims

1. An oral care appliance, comprising: a handle; and a head removably coupled to the handle, the head comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising: a base structure; a sheet structure in contact with the base structure, the sheet structure comprising a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet structure; and a protective structure comprising a front surface and a rear surface, the front surface of the protective structure being connected to at least a portion of the rear surface of the sheet structure to encapsulate the base structure between the sheet structure and the protective structure.

2. The oral care appliance according to claim 1, wherein the sheet structure comprises an elastic material.

3. The oral care appliance according to claim 1 or claim 2, wherein the protective structure comprises an elastic material.

4. The oral care appliance according to any one of claims 1 to 3, wherein the sheet structure and the protective structure each comprise a perimeter portion, and the sheet structure and the protective structure are connected along their respective perimeter portions.

5. The oral care appliance according to any one of claims 1 to 4, wherein the sheet structure is thermally welded to the protective structure.

6. The oral care appliance according to any one of claims 1 to 4, wherein the sheet structure is ultrasonically welded to the protective structure.

7. The oral care appliance according to any one of claims 1 to 4, wherein the sheet structure is adhesively bonded to the protective structure.

8. The oral care appliance according to any one of claims 1 to 4, wherein the protective structure is molded onto both the sheet structure and the protective structure.

9. The oral care appliance according to any one of claims 1 to 8, wherein the base structure comprises a front surface and a rear surface, the entire front surface of the base structure is connected to the rear surface of the sheet structure, and the entire rear surface of the base structure is connected to the front surface of the protective structure.

10. The oral care appliance according to any one of claims 1 to 9, wherein the plurality of bristle clusters of the sheet structure are formed by a plurality of filamentary bristles.

11. The oral care appliance according to any one of claims 1 to 10, wherein the base structure is metallic.

12. The oral care appliance according to any one of claims 1 to 11, wherein the base structure is formed of a metal sheet.

13. The oral care appliance according to any one of claims 1 to 12, wherein the head portion extends along an arcuate path.

14. The oral care appliance according to any one of claims 1 to 13, wherein the head portion comprises a concave wall and a plurality of finger-like members extending from the wall.

15. The oral care appliance according to claim 14, wherein each of the plurality of finger-like members comprises a horizontal portion extending from the wall along a horizontal plane.

16. The oral care implement according to claim 15, wherein each of the plurality of finger-shaped members includes a bent portion and a distal portion, and the distal portion of the finger-shaped member is offset from the horizontal plane at the bent portion.

17. The oral care implement according to claim 14, wherein the plurality of finger-shaped members and the wall form an arcuate channel.

18. The oral care implement according to any one of claims 14 to 17, wherein each of the plurality of finger-shaped members forms an L shape.

19. The oral care implement according to any one of claims 14 to 18, wherein the plurality of finger-shaped members are spaced apart and separated from each other.

20. The oral care implement according to any one of claims 14 to 19, wherein a first finger-shaped member of the plurality of finger-shaped members includes a first tuft of bristles and a second tuft of bristles of the plurality of tufts of bristles, the first tuft of bristles being located on a horizontal portion of the first finger-shaped member, and the second tuft of bristles being located on a distal portion of the first finger-shaped member, the distal portion being angled relative to the horizontal portion.

21. The oral care implement according to any one of claims 14 to 20, wherein the base structure extends to a distal portion of each of the plurality of finger-shaped members.

22. A head of an oral care implement, comprising: a neck portion; and a head portion coupled to the neck portion, the head portion including: a base structure; a sheet-like structure in contact with the base structure, the sheet-like structure including a front surface, a rear surface, and a plurality of tufts of bristles extending from the front surface of the sheet-like structure; and a protective structure that contacts a portion of the rear surface of the sheet-like structure and the rear surface of the base structure.

23. The head according to claim 22, wherein the sheet-like structure comprises an elastic material.

24. The head according to claim 22 or claim 23, wherein the protective structure comprises an elastic material.

25. The head according to any one of claims 22 to 24, wherein the sheet-like structure and the protective structure each include a perimeter portion, and the sheet-like structure and the protective structure are connected along their respective perimeter portions.

26. The head according to any one of claims 22 to 25, wherein the sheet-like structure is heat welded to the protective structure.

27. The head according to any one of claims 22 to 25, wherein the sheet-like structure is ultrasonically welded to the protective structure.

28. The head according to any one of claims 22 to 25, wherein the sheet-like structure is adhesively bonded to the protective structure.

29. The head according to any one of claims 22 to 25, wherein the protective structure is molded onto both the sheet-like structure and the protective structure.

30. The head according to any one of claims 22 to 29, wherein the base structure includes a front surface and a rear surface, the entire front surface of the base structure is in contact with the rear surface of the sheet-like structure, and the entire rear surface of the base structure is in contact with the front surface of the protective structure.

31. The head according to any one of claims 22 to 30, wherein the plurality of bristle clusters of the sheet-like structure are formed by a plurality of filament bristles.

32. The head according to any one of claims 22 to 31, wherein the base structure is metallic.

33. The head according to any one of claims 22 to 32, wherein the base structure is formed by a metal sheet.

34. The head according to any one of claims 22 to 33, wherein the head portion extends along an arcuate path.

35. The head according to any one of claims 22 to 34, wherein the head portion includes a concave wall and a plurality of finger-like members extending from the wall.

36. The head according to claim 35, wherein each of the plurality of finger-like members includes a horizontal portion extending from the wall along a horizontal plane.

37. The head according to claim 36, wherein each of the plurality of finger-like members includes a bent portion and a distal portion, and the distal portion of the finger-like member is offset from the horizontal plane at the bent portion.

38. The head according to claim 35, wherein the plurality of finger-like members and the wall form an arcuate channel.

39. The head according to any one of claims 35 to 38, wherein each of the plurality of finger-like members forms an L shape.

40. The head according to any one of claims 35 to 39, wherein the plurality of finger-like members are spaced apart and separated from each other.

41. The head according to any one of claims 35 to 40, wherein a first finger-like member of the plurality of finger-like members includes a first bristle cluster and a second bristle cluster of the plurality of bristle clusters, the first bristle cluster being located on the horizontal portion of the first finger-like member, and the second bristle cluster being located on the distal portion of the first finger-like member, the distal portion being angled relative to the horizontal portion.

42. The head according to any one of claims 35 to 41, wherein the base structure extends to the distal portion of each of the plurality of finger-like members.

43. A method of manufacturing an oral care appliance, comprising: a) providing a sheet-like structure including a plurality of bristle clusters extending from a front surface of the sheet-like structure; and b) encapsulating a base structure between the sheet-like structure and a protective structure to form a head portion.

44. The method according to claim 43, wherein, In step b), a rear surface of the sheet-like structure is brought into contact with a front surface of the base structure.

45. The method according to claim 43 or claim 44, wherein, In step b), a front surface of the protective structure is brought into contact with a rear surface of the base structure and a rear surface of the sheet-like structure.

46. The method according to any one of claims 43 to 45, further comprising a bending step, wherein a wall of the head portion is bent into a concave shape.

47. The method according to claim 46, wherein, In the bending step, a plurality of finger-like members of the head portion are bent such that they extend away from an inner surface of the wall.

48. The method according to claim 47, wherein, In the bending step, each of the plurality of finger-like members is bent such that each of the plurality of finger-like members has an L shape.

49. The method according to any one of claims 43 to 48, wherein Before step b), an assembly step includes fixing a connector to the base structure.

50. The method according to claim 49, wherein, After step b), the connector is coupled to the neck portion of the oral care appliance.

51. An oral care appliance, comprising: a handle; and a head removably coupled to the handle, the head comprising: a neck portion; and a head portion coupled to the neck portion, the head portion comprising a sheet structure, the sheet structure comprising: a first film layer having a front surface and a rear surface, the front surface forming the front surface of the sheet structure; a second film layer having a front surface and a rear surface, the rear surface forming the rear surface of the sheet structure; and a plurality of bristle clusters extending from the front surface of the first film layer; wherein the first film layer and the second film layer are formed of the same material.

52. The oral care appliance according to claim 51, wherein the sheet structure comprises an elastic material.

53. The oral care appliance according to claim 51 or claim 52, wherein the plurality of bristle clusters are formed of a plurality of bristle filaments.

54. The oral care appliance according to claim 53, wherein each of the plurality of bristle filaments has a cleaning portion and a base portion, and the base portion, a portion of the first film layer, and a portion of the second film layer form a molten pad.

55. The oral care appliance according to any one of claims 51 to 54, further comprising a protective structure, wherein the sheet structure and the protective structure each comprise a perimeter portion, and the sheet structure and the protective structure are connected along their respective perimeter portions.

56. The oral care appliance according to claim 55, wherein the sheet structure is thermally welded to the protective structure.

57. The oral care appliance according to claim 55, wherein the sheet structure is ultrasonically welded to the protective structure.

58. The oral care appliance according to claim 55, wherein the sheet structure is adhesively bonded to the protective structure.

59. The oral care appliance according to any one of claims 51 to 58, wherein the first film layer and the second film layer are formed of a first material, and the plurality of bristle clusters are formed of filaments of a second material, and the first material is different from the second material.

60. The oral care appliance according to any one of claims 51 to 59, wherein the sheet structure comprises a molten pad formed of materials from the first film layer, the second film layer, and the plurality of bristle clusters.

61. The oral care appliance according to any one of claims 51 to 60, wherein each of the first film layer and the second film layer has a thickness of 0.8 mm or less.

62. The oral care appliance according to claim 61, wherein each of the first film layer and the second film layer has a thickness of 0.4 mm or less.

63. The oral care appliance according to any one of claims 51 to 62, wherein the sheet structure comprises a molten pad formed of materials from the first film layer, the second film layer, and the plurality of bristle clusters.

64. A head of an oral care appliance, comprising: a neck portion; and A head portion coupled to the neck portion, the head portion comprising: A base structure having a front surface; and A sheet structure coupled to the base structure, the sheet structure comprising: A first film layer, the front surface of the first film layer forming the front surface of the sheet structure; A second film layer connected to the first film layer, the rear surface of the second film layer forming the rear surface of the sheet structure; A plurality of tufts of bristles extending from the front surface of the first film layer; Wherein the first film layer and the second film layer are formed of an elastic material; and Wherein the rear surface of the sheet structure contacts the front surface of the base structure.

65. The head according to claim 64, wherein the first film layer and the second film layer are formed of the same material.

66. The head according to claim 64 or claim 65, wherein the plurality of tufts of bristles are formed of a plurality of bristle filaments.

67. The head according to claim 66, wherein each of the plurality of bristle filaments has a cleaning portion and a base portion, and the base portion, a portion of the first film layer, and a portion of the second film layer form a molten cushion layer.

68. The head according to any one of claims 64 to 67, further comprising a protective structure, the sheet structure and the protective structure each comprising a perimeter portion, and the sheet structure and the protective structure are connected along their respective perimeter portions.

69. The head according to claim 68, wherein the sheet structure is thermally welded to the protective structure.

70. The head according to claim 68, wherein the sheet structure is ultrasonically welded to the protective structure.

71. The head according to claim 68, wherein the sheet structure is adhesively bonded to the protective structure.

72. The head according to any one of claims 64 to 71, wherein the first film layer and the second film layer are formed of a first material, and the plurality of tufts of bristles are formed of filaments of a second material, the first material being different from the second material.

73. The head according to any one of claims 64 to 72, wherein the sheet structure comprises a molten cushion layer formed of materials from the first film layer, the second film layer, and the plurality of tufts of bristles.

74. The head according to any one of claims 64 to 73, wherein the thickness of each of the first film layer and the second film layer is 0.8 mm or less.

75. The head according to claim 74, wherein the thickness of each of the first film layer and the second film layer is 0.4 mm or less.

76. The head according to any one of claims 64 to 75, wherein the sheet structure comprises a molten cushion layer formed of materials from the first film layer, the second film layer, and the plurality of tufts of bristles.

77. A method of manufacturing a sheet structure for an oral care appliance, comprising: a) Inserting a plurality of bristle filaments into a plurality of hair implanting holes of a hair implanting tool to form a plurality of tufts of bristles; b) Fusing a first film layer to the base portion of the plurality of tufts of bristles; And c) Fusing a second film layer to the first film layer.

78. The method according to claim 77, wherein, After step a) and before step b), a step of melting the base portion of each of the plurality of brush capillary filaments.

79. The method according to claim 78, wherein the melting step comprises forming a mushroom shape on each of the pick-up positions of the plurality of brush tufts.

80. The method according to any one of claims 77 to 79, wherein the plurality of brush tufts extend from the front surface of the first film layer.

81. The method according to any one of claims 77 to 80, wherein the first film layer and the second film layer are formed of an elastic material.

82. The method according to any one of claims 77 to 81, wherein the first film layer and the second film layer are formed of the same material.

83. The method according to claim 82, wherein the plurality of brush capillary filaments are formed of a material different from that of the first film layer and the second film layer.

84. The method according to any one of claims 77 to 83, wherein the thickness of the first film layer is about 0.4 mm, and the thickness of the second film layer is about 0.4 mm.

85. The method according to any one of claims 77 to 84, wherein the first film layer and the second film layer are free of perforations.

86. The method according to any one of claims 77 to 85, wherein a molten cushion layer is formed during the fusion step, the molten cushion layer comprising the base portions of the plurality of brush capillary filaments, a portion of the first film layer, and a portion of the second film layer.

87. An oral care appliance, comprising: a handle portion including vibration generating means; and a head portion detachably coupled to the handle portion, the head portion including: a neck portion; and a head portion coupled to the neck portion, the head portion including: a base structure formed of a metallic material; a sheet structure in contact with the base structure, the sheet structure including a front surface, a rear surface, and a plurality of brush tufts extending from the front surface of the sheet structure.

88. The oral care appliance according to claim 87, wherein the base structure extends from the neck portion to a first distal end and a second distal end of the head portion.

89. The oral care appliance according to claim 87 or 88, wherein the head portion extends along an arcuate path.

90. The oral care appliance according to any one of claims 87 to 89, wherein the head portion includes a concave wall and a plurality of finger-like members extending from the concave wall.

91. The oral care appliance according to claim 90, wherein each of the plurality of finger-like members includes a horizontal portion extending along a horizontal plane from the concave wall.

92. The oral care appliance according to claim 91, wherein each of the plurality of finger-like members includes a curved portion and a distal portion, the distal portion of the finger-like member being offset from the horizontal plane at the curved portion.

93. The oral care appliance according to claim 90, wherein the plurality of finger-like members and the concave wall form an arcuate channel.

94. The oral care implement according to any one of claims 90 to 93, wherein each of the plurality of finger-shaped members forms an L shape.

95. The oral care implement according to any one of claims 90 to 94, wherein the plurality of finger-shaped members are spaced apart and separated from each other.

96. The oral care implement according to any one of claims 90 to 95, wherein a first finger-shaped member of the plurality of finger-shaped members includes a first bristle cluster and a second bristle cluster of the plurality of bristle clusters, the first bristle cluster being located on a horizontal portion of the first finger-shaped member, and the second bristle cluster being located on an end portion of the first finger-shaped member, the end portion being angled relative to the horizontal portion.

97. The oral care implement according to any one of claims 90 to 96, wherein the base structure extends to an end portion of each of the plurality of finger-shaped members.

98. The oral care implement according to any one of claims 87 to 97, wherein the sheet structure comprises an elastic material.

99. The oral care implement according to any one of claims 87 to 98, further comprising a protective structure, wherein the protective structure comprises an elastic material.

100. The oral care implement according to claim 99, wherein the sheet structure and the protective structure each include a perimeter portion, and the sheet structure and the protective structure are connected along their respective perimeter portions.

101. The oral care implement according to claim 99, wherein the sheet structure is thermally welded to the protective structure.

102. The oral care implement according to claim 99, wherein the sheet structure is ultrasonically welded to the protective structure.

103. The oral care implement according to claim 99, wherein the sheet structure is adhesively bonded to the protective structure.

104. The oral care implement according to claim 99, wherein the protective structure is molded onto both the sheet structure and the protective structure.

105. The oral care implement according to any one of claims 87 to 104, wherein the base structure includes a front surface and a rear surface, and the entire front surface of the base structure is connected to the rear surface of the sheet structure.

106. The oral care implement according to any one of claims 87 to 105, wherein the plurality of bristle clusters of the sheet structure are formed of a plurality of filamentary bristles.

107. A head of an oral care implement, comprising: a neck portion; and a head portion coupled to the neck portion, the head portion including: a base structure formed of a first material; a sheet structure in contact with the base structure, the sheet structure including a front surface, a rear surface, and a plurality of bristle clusters extending from the front surface of the sheet structure, the sheet structure being formed of a second material; wherein a first vibration transmissivity of the first material is greater than a second vibration transmissivity of the second material.

108. The head according to claim 107, wherein the first material is a metallic material.

109. The head according to claim 107 or 108, wherein the base structure is formed of a metal sheet.

110. The head according to any one of claims 107 to 109, wherein the sheet-like structure comprises an elastic material.

111. The head according to any one of claims 107 to 110, wherein the base structure extends from the neck portion to the first distal end and the second distal end of the head portion.

112. The head according to any one of claims 107 to 111, wherein the head portion extends along an arcuate path.

113. The head according to any one of claims 107 to 112, wherein the head portion includes a concave wall and a plurality of finger-like members extending from the concave wall.

114. The head according to claim 113, wherein each of the plurality of finger-like members includes a horizontal portion extending along a horizontal plane from the concave wall.

115. The head according to claim 114, wherein each of the plurality of finger-like members includes a bent portion and an end portion, and the end portion of the finger-like member is offset from the horizontal plane at the bent portion.

116. The head according to claim 113, wherein the plurality of finger-like members and the concave wall form an arcuate channel.

117. The head according to any one of claims 113 to 116, wherein each of the plurality of finger-like members forms an L shape.

118. The head according to any one of claims 113 to 117, wherein the plurality of finger-like members are spaced apart and separated from each other.

119. The head according to any one of claims 113 to 118, wherein the first finger-like member of the plurality of finger-like members includes a first brush tuft and a second brush tuft of the plurality of brush tufts, the first brush tuft is located on the horizontal portion of the first finger-like member, and the second brush tuft is located on the end portion of the first finger-like member, and the end portion is angled with respect to the horizontal portion.

120. The head according to any one of claims 113 to 119, wherein the base structure extends to the end portion of each of the plurality of finger-like members.

121. The head according to any one of claims 107 to 120, further comprising a protective structure, wherein the protective structure comprises an elastic material.

122. The head according to claim 121, wherein the sheet-like structure and the protective structure each include a perimeter portion, and the sheet-like structure and the protective structure are connected along their respective perimeter portions.

123. The head according to claim 121, wherein the sheet-like structure is thermally welded to the protective structure.

124. The head according to claim 121, wherein the sheet-like structure is ultrasonically welded to the protective structure.

125. The head according to claim 121, wherein the sheet-like structure is adhesively bonded to the protective structure.

126. The head according to claim 121, wherein the protective structure is molded onto both the sheet-like structure and the protective structure.

127. The head according to any one of claims 107 to 126, wherein the base structure includes a front surface and a rear surface, and the entire front surface of the base structure is connected to the rear surface of the sheet-like structure.

128. The head according to any one of claims 107 to 127, wherein the plurality of bristle clusters of the sheet-like structure are formed by a plurality of filament bristles.

129. A method of exciting bristle filaments, comprising: a) providing an oral care appliance, the oral care appliance including a handle and a head, the head including a neck portion and a head portion, the head portion being coupled to the neck portion, and the neck portion being coupled to the handle; b) generating vibrations with a vibration generating device; and c) transmitting the vibrations from the handle to the bristle filaments via the neck portion, a metal base structure of the head portion coupled to the neck portion, and a sheet-like structure of the head portion in contact with the base structure; wherein the bristle filaments extend from the sheet-like structure.

130. The method according to claim 129, wherein the base structure is formed of a first material, and the sheet-like structure includes a second material, and a first vibration transmission rate of the first material is greater than a second vibration transmission rate of the second material.

131. The method according to claim 129 or 130, wherein the base structure is formed of a metallic material.

132. The method according to any one of claims 129 to 131, wherein the base structure extends from the neck portion to a first distal end and a second distal end of the head portion.

133. The method according to any one of claims 129 to 132, wherein the head portion extends along an arcuate path.

134. The method according to any one of claims 129 to 133, wherein the head portion includes a concave wall and a plurality of finger-like members extending from the concave wall.

135. The method according to claim 134, wherein each of the plurality of finger-like members includes a horizontal portion extending along a horizontal plane from the concave wall.

136. The method according to claim 135, wherein each of the plurality of finger-like members includes a bent portion and a distal portion, and the distal portion of the finger-like member is offset from the horizontal plane at the bent portion.

137. The method according to claim 134, wherein the plurality of finger-like members and the concave wall form an arcuate channel.

138. The method according to any one of claims 134 to 137, wherein each of the plurality of finger-like members forms an L shape.

139. The method according to any one of claims 134 to 138, wherein the plurality of finger-like members are spaced apart from and separated from each other.

140. The method according to any one of claims 134 to 139, wherein a first finger-like member of the plurality of finger-like members includes a first bristle cluster and a second bristle cluster of the plurality of bristle clusters, the first bristle cluster being located on the horizontal portion of the first finger-like member, and the second bristle cluster being located on the distal portion of the first finger-like member, the distal portion being angled relative to the horizontal portion.

141. The method according to any one of claims 134 to 140, wherein the base structure extends to an end portion of each of the plurality of finger-like members.

142. The method according to any one of claims 129 to 141, wherein the base structure includes a front surface and a rear surface, and the entire front surface of the base structure is connected to the rear surface of the sheet-like structure.

143. A method of forming an oral appliance, comprising: a) forming a flat laminated structure having a plurality of tufts of bristles extending from a front surface of the flat laminated structure; and b) bending the flat laminated structure into a three-dimensional oral appliance.

144. The method according to claim 143, wherein the flat laminated structure includes a sheet-like structure and a base structure, and the sheet-like structure includes a plurality of tufts of bristles.

145. The method according to claim 144, wherein the flat laminated structure further includes a protective structure, and the sheet-like structure and the protective structure enclose the base structure.

146. The method according to any one of claims 143 to 145, wherein the flat laminated structure is plastically deformed during step b).

147. The method according to any one of claims 143 to 146, wherein step b) further includes step b-1), and step b-1) includes bending a wall portion of the flat laminated structure into a concave shape.

148. The method according to any one of claims 143 to 147, wherein step b) further includes step b-2), and step b-2) includes bending a plurality of finger-like member portions of the flat laminated structure.

149. The method according to any one of claims 143 to 148, further including step c), and step c) includes coupling a connector to the flat laminated structure.

150. The method according to claim 149, wherein the connector is configured to engage a socket of a neck portion.

151. The method according to claim 149 or claim 150, wherein step c) is performed before step b).

152. The method according to any one of claims 143 to 151, wherein the flat laminated structure includes a sheet-like structure and a base structure, and the base structure is metallic.

153. The method according to claim 152, wherein the sheet-like structure includes an elastic material and the plurality of tufts of bristles.

154. A head of an oral care appliance, comprising: a head portion, the head portion including: a base structure formed of a first material; and a plurality of clusters in contact with a front surface of the base structure, each of the plurality of clusters including a front surface, a rear surface and a plurality of tufts of bristles extending from the front surface, the plurality of clusters being formed of a second material; wherein a first vibration transmission rate of the first material is greater than a second vibration transmission rate of the second material.

155. The head according to claim 154, wherein the first material is a metallic material.

156. The head according to claim 154 or 155, wherein the base structure is formed of a metal sheet.

157. The head according to any one of claims 154 to 156, wherein the plurality of tufts comprises an inelastic material.

158. The head according to any one of claims 154 to 157, wherein the base structure extends from the neck portion to a first distal end and a second distal end of the head portion.

159. The head according to any one of claims 154 to 158, wherein the head portion extends along an arcuate path.

160. The head according to any one of claims 154 to 159, wherein the head portion includes a concave wall and a plurality of fingers extending from the concave wall.

161. The head according to claim 160, wherein each of the plurality of fingers includes a horizontal portion extending from the concave wall in a horizontal plane.

162. The head according to claim 161, wherein each of the plurality of fingers includes a bent portion and a distal portion, the distal portion of the finger being offset from the horizontal plane at the bent portion.

163. The head according to claim 160, wherein the plurality of fingers and the concave wall form an arcuate channel.

164. The head according to any one of claims 160 to 163, wherein each of the plurality of fingers forms an L shape.

165. The head according to any one of claims 160 to 164, wherein the plurality of fingers are spaced apart and separated from each other.

166. The head according to any one of claims 160 to 165, wherein a first finger of the plurality of fingers includes a first tuft and a second tuft of the plurality of tufts of bristles, the first tuft being located on the horizontal portion of the first finger and the second tuft being located on the distal portion of the first finger, the distal portion being angled relative to the horizontal portion.

167. The head according to any one of claims 160 to 166, wherein the base structure extends to the distal portion of each of the plurality of fingers.

168. The head according to any one of claims 154 to 167, further comprising a protective structure, wherein the protective structure comprises an elastic material.

169. The head according to claim 168, wherein the plurality of tufts are thermally welded to the protective structure.

170. The head according to claim 168, wherein the plurality of tufts are ultrasonically welded to the protective structure.

171. The head according to claim 168, wherein the plurality of tufts are adhesively bonded to the protective structure.

172. The head according to claim 168, wherein the protective structure is molded onto both the plurality of tufts and the protective structure.

173. The head according to any one of claims 154 to 172, wherein the plurality of tufts of bristles of the plurality of tufts are formed by a plurality of filamentary bristles.

174. An oral care appliance, comprising: a handle; and a head coupled to the handle, the head including: a neck portion; and a head portion coupled to the neck portion, the head portion including: A base structure extending from a proximal end to a distal end, the proximal end being coupled to the neck portion; A sheet structure in contact with the base structure, the sheet structure including a front surface, a rear surface, and a plurality of tufts of bristles extending from the front surface of the sheet structure; and A protective structure that covers the base structure and is in contact with the sheet structure.

175. The oral care implement according to claim 174, wherein the sheet structure comprises an elastic material.

176. The oral care implement according to claim 174 or claim 175, wherein the protective structure comprises a rigid plastic material.

177. The oral care implement according to any one of claims 174 to 176, wherein the sheet structure is heat welded to the protective structure.

178. The oral care implement according to any one of claims 174 to 176, wherein the sheet structure is ultrasonically welded to the protective structure.

179. The oral care implement according to any one of claims 174 to 176, wherein the sheet structure is adhesively bonded to the protective structure.

180. The oral care implement according to any one of claims 174 to 176, wherein the protective structure is molded onto both the sheet structure and the base structure.

181. The oral care implement according to any one of claims 174 to 180, wherein the base structure includes a front surface and a rear surface, the entire rear surface of the sheet structure is connected to the front surface of the base structure, and the entire rear surface of the base structure is in contact with the protective structure.

182. The oral care implement according to any one of claims 174 to 181, wherein the plurality of tufts of bristles of the sheet structure are formed by a plurality of filamentary bristles.

183. The oral care implement according to any one of claims 174 to 182, wherein the base structure is metallic.

184. The oral care implement according to any one of claims 174 to 183, wherein the base structure is formed of a metal sheet.

185. The oral care implement according to any one of claims 174 to 184, wherein the base structure extends into the neck portion of the head.

186. The oral care implement according to any one of claims 174 to 185, wherein the sheet structure includes a perimeter extending between the front surface and the rear surface, the perimeter being in contact with the protective structure.

187. The oral care implement according to any one of claims 174 to 186, wherein the protective structure overlays a portion of the front surface of the sheet structure.

188. A head of an oral care implement, comprising: A neck portion; And A head portion coupled to the neck portion, the head portion including: A base structure having a front surface and an opposite rear surface, the base structure being formed of a metallic material; A sheet structure in contact with the base structure, the sheet structure including a front surface, a rear surface, and a plurality of tufts of bristles extending from the front surface of the sheet structure; and A protective structure that covers the rear surface of the base structure.

189. The head according to claim 188, wherein the sheet structure comprises an elastic material.

190. The head according to claim 188 or claim 189, wherein the protective structure comprises a hard plastic material.

191. The head according to any one of claims 188 to 190, wherein the sheet structure is thermally welded to the protective structure.

192. The head according to any one of claims 188 to 191, wherein the sheet structure is ultrasonically welded to the protective structure.

193. The head according to any one of claims 188 to 191, wherein the sheet structure is adhesively bonded to the protective structure.

194. The head according to any one of claims 188 to 191, wherein the protective structure is molded onto both the sheet structure and the base structure.

195. The head according to any one of claims 188 to 194, wherein the entire rear surface of the sheet structure is connected to the front surface of the base structure, and the entire rear surface of the base structure is in contact with the protective structure.

196. The oral care appliance according to any one of claims 188 to 195, wherein the plurality of tufts of bristles of the sheet structure are formed by a plurality of filamentary bristles.

197. The oral care appliance according to any one of claims 188 to 196, wherein the base structure is metallic.

198. The oral care appliance according to any one of claims 188 to 197, wherein the base structure is formed from a metal sheet.

199. The oral care appliance according to any one of claims 188 to 198, wherein the base structure extends into the neck portion of the head.

200. The oral care appliance according to any one of claims 188 to 199, wherein the sheet structure includes a perimeter extending between the front surface and the rear surface, and the perimeter is in contact with the protective structure.

201. The oral care appliance according to any one of claims 188 to 200, wherein the protective structure overlays a portion of the front surface of the sheet structure.

202. A method of manufacturing a head of an oral care appliance, comprising: a) connecting a plurality of brush filaments to a flexible sheet to form a sheet structure, the sheet structure including a front surface, a rear surface, and a plurality of tufts of bristles extending from the front surface of the sheet structure; b) positioning the sheet structure in direct contact with the front surface of a base structure; and c) covering the rear surface of the base structure with a protective structure that is in direct contact with the perimeter of the sheet structure and covers a portion of the front surface of the base structure.

203. The method according to claim 202, wherein, In step c), the protective structure covers a portion of the front surface of the sheet structure.

204. The method according to claim 202 or claim 203, wherein the sheet structure comprises an elastic material.

205. The method according to any one of claims 202 to 204, wherein the protective structure comprises a rigid plastic material.

206. The method according to any one of claims 202 to 205, wherein the base structure comprises a metallic material.

207. The method according to any one of claims 202 to 206, wherein, In step b), the sheet structure is thermally welded to the protective structure. The method according to any one of claims 202 to 206, wherein In step b), the sheet structure is ultrasonically welded to the protective structure. The method according to any one of claims 202 to 206, wherein, In step b), the sheet structure is adhesively bonded to the protective structure.

210. The head according to any one of claims 202 to 209, wherein In step c), the protective structure is molded onto both the sheet structure and the protective structure.

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