Bristle sheet and method thereof

Abstract

In one embodiment, a bristle sheet is formed by securing a flexible sheet to a fixing device, the flexible sheet having a plurality of clustered holes extending through it. A first plurality of bristles are inserted through a first hole among the plurality of clustered holes. The base portion of the bristles in the first plurality of bristles is melted to form a molten rough surface. The molten rough surface is bonded to one side of the sheet. The flexible sheet may be made of a metallized polymer film or a fluorinated compound.

Description

[0001] Cross-references to related applications This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 608,415 and U.S. Provisional Patent Application Serial No. 63 / 608,403, filed December 11, 2023, the entire contents of which are incorporated herein by reference. Background Technology

[0002] Oral care, specifically the care of an individual's teeth and gums, is crucial for ensuring overall oral health. However, typical oral care routines are time-consuming. For example, most dentists recommend brushing for at least two minutes. Individuals who may have dexterity issues or may not wish to spend the necessary time brushing may suffer from poor oral health. Therefore, there is a need for oral care appliances that can overcome the shortcomings of existing products. Summary of the Invention

[0003] This invention relates to a method for forming a bristle sheet for an oral care appliance. First, a flexible sheet is fixed to a fixing device. The flexible sheet has a first side, a second side, and a plurality of tufted holes extending from the first side to the second side. Next, a first plurality of bristles are inserted through the first hole among the plurality of tufted holes. Subsequently, the bristle base portions of the first plurality of bristles are melted to form a first bristle tuft with a molten rough surface, which is bonded to the second side of the sheet. The flexible sheet is one of a metallized polymer film or a fluorinated compound.

[0004] In another aspect, the present invention can be a method for forming a bristle sheet for an oral care appliance. First, a bundle of bristles is inserted into the bristle container of a fixing device. Second, a flexible sheet is secured to the cover of the fixing device, the flexible sheet being compressed between the cover and the bristle container. Third, a plurality of protrusions of the bristle pusher plate of the fixing device are inserted through a plurality of holes formed in the base plate of the bristle pusher plate, the protrusions allowing first plurality of bristles to pass through first holes formed in the flexible sheet. Fourth, the cover of the fixing device is removed while the flexible sheet remains against the bristle container. Fifth, the base portions of the first plurality of bristles are melted, such that the base portions engage with a second side surface of the flexible sheet. Sixth, the flexible sheet and the first plurality of bristles are removed from the bristle container.

[0005] In another aspect, the present invention can be a bristle sheet for an oral care appliance. The bristle sheet may have a flexible sheet, a first bristle tuft, and a fused roughened surface. The flexible sheet is formed of a metallized polymer film or a fluorinated compound. The first bristle tuft is formed by the free portions of a first plurality of bristles extending through a first hole in the flexible sheet, the first bristle tuft extending from a first side of the flexible sheet. The fused roughened surface is formed by the base portions of the first plurality of bristles, and the fused roughened surface is bonded to a second side of the flexible sheet.

[0006] In another aspect, the present invention can be an oral care appliance having a handle and a head. The handle has a gripping portion, a first neck portion, and a second neck portion. The head is attached to the handle. The head has a first head portion and a second head portion. The first head portion has a base portion having a buccal wall and a plurality of fingers extending from the buccal wall, each of the plurality of fingers having a bend, a plurality of upper buccal wall bristle tufts extending from the inner surface of the buccal wall, and a first plurality of finger bristle tufts extending from the first finger of the plurality of fingers. The first head portion is attached to the first neck portion. The second head portion has a base portion having a buccal wall and a plurality of fingers extending from the buccal wall, each of the plurality of fingers having a bend, a plurality of lower buccal wall bristle tufts extending from the inner surface of the buccal wall, and a first plurality of finger bristle tufts extending from the first finger of the plurality of fingers. The second head portion is attached to the second neck portion. The base portions of the first and second portions are each formed of a rigid plastic material.

[0007] In another aspect, the present invention can be a method of forming an oral care appliance. First, a base portion of a first head portion is formed, the base portion having a buccal wall and a plurality of fingers. Second, a plurality of bristle filaments are inserted into tufts in the buccal wall and the plurality of fingers to form a plurality of bristle tufts, each of the buccal wall bristle tufts and the plurality of finger bristle tufts extending along a tuft axis, the tuft axis of the plurality of buccal wall bristle tufts being substantially parallel to the tuft axis of the plurality of finger bristle tufts. Third, the base portion of the first head portion is bent to form a plurality of bends in the plurality of fingers, such that the tuft axis of at least one of the plurality of finger bristle tufts is no longer parallel to the tuft axis of the plurality of buccal wall bristle tufts. Fourth, the first head portion is connected to a first neck portion of a handle.

[0008] Further applications of the invention will become apparent from the specific embodiments provided below. It should be understood that while the detailed description and specific examples indicate preferred embodiments of the invention, they are intended for illustrative purposes only and not for limiting the scope of the invention. Attached Figure Description

[0009] The invention will be more fully understood from the specific embodiments and accompanying drawings, in which: Figure 1 This is a perspective view of a flexible sheet, bristle bundle, and fixing device according to an embodiment of the present invention; Figure 2 yes Figure 1 Lower rear perspective view of the flexible sheet, brush bundles, and fixing device; Figure 3 yes Figure 2Exploded perspective view of the flexible sheet, bristle bundles, and fixing device; Figure 4 It is along the flexible sheet, bristle bundle and fixing device Figure 1 A sectional view taken along line IV-IV; Figure 5 It is along the fixed device Figure 1 The cross-sectional view taken along line IV-IV illustrates the first step in manufacturing the brush sheet; Figure 6 It is the edge of the fixing device, flexible sheet and bristle bundle Figure 1 The cross-sectional view taken along line IV-IV illustrates the second step in manufacturing the brush sheet; Figure 7 It is the edge of the fixing device, flexible sheet and bristle bundle Figure 1 The cross-sectional view taken along line IV-IV illustrates the third step in manufacturing the brush sheet; Figure 8 It is the edge of the fixing device, flexible sheet and bristle bundle Figure 1 The cross-sectional view taken by line IV-IV illustrates the fourth step in manufacturing the brush sheet. Figure 9 It is the edge of the fixing device, flexible sheet and bristle bundle Figure 1 The cross-sectional view taken along line IV-IV illustrates the fifth step in manufacturing the brush sheet; Figure 10 It is along the edge of the brushed sheet after the fifth manufacturing step. Figure 1 A sectional view taken along line IV-IV; Figure 11 It is a perspective view of the implementation plan for oral care appliances; Figure 12 yes Figure 11 Lower perspective view of an oral care appliance; Figure 13 yes Figure 11 Exploded diagram of oral care appliances; Figure 14 It is in a flat state. Figure 11 A perspective view of the base portion of the head part of an oral care appliance; Figure 15 It is in a flat state. Figure 11 A perspective view of the head portion of an oral care appliance; and Figure 16 It is in a bent state. Figure 11 A perspective view of the head portion of an oral care appliance. Detailed Implementation

[0010] The following description of preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its uses.

[0011] The description of exemplary embodiments of the principles of the present invention is intended to be read in conjunction with the accompanying drawings, which should be considered an integral part of the entire written description. Any references to direction or orientation in the description of embodiments of the invention disclosed herein are intended only for convenience of description and are not intended to limit the scope of the invention in any way. Relative terms such as “down,” “up,” “horizontal,” “vertical,” “above,” “below,” “upward,” “downward,” “top,” and “bottom,” and their derivatives (e.g., “horizontally,” “downward,” “upward,” etc.) should be understood to refer to orientations as shown in the drawings described later or discussed. 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 explicitly stated otherwise. Terms such as “attach,” “connect,” “join,” “interconnect,” and similar terms refer to a relationship in which structures are fixed or attached to each other, either directly or indirectly, through an intermediary structure, and to a movable or rigid attachment or relationship between the two, unless otherwise explicitly stated otherwise. Furthermore, reference is made to exemplary embodiments to illustrate the features and beneficial effects of the invention. Therefore, the present invention should not be limited to such exemplary embodiments that illustrate some possible non-limiting combinations of features that may exist alone or in combination with other features; the scope of the invention is defined by the appended claims.

[0012] See Figures 1 to 4 The illustration shows a fixing device 100, a flexible sheet 200, and a bristle bundle 250 according to an embodiment of the invention. The fixing device 100, together with the flexible sheet 200 and the bristle bundle 250, forms a bristle sheet that can be used in an oral care appliance. The oral care appliance can be a manual or electric device for cleaning a user's teeth and other oral tissues. If the oral care appliance is powered, it can be powered using a motor and a vibration generator, a motor that directly vibrates the tooth-cleaning element, or a pneumatic system incorporating the bristle sheet as part of a pressure chamber that can selectively pressurize and depressurize to move the tooth-cleaning element of the bristle sheet.

[0013] The bristle bundle 250 is a group of dental cleaning elements, such as conventional fine bristles 254, cut to all equal lengths and bound within an outer casing 252. The dental cleaning element can be the bristles 254 and can have a range of diameters and cross-sectional profiles. Preferably, the bristles 254 can have a diameter of 0.003 inches to 0.005 inches, but other diameters are also contemplated. The bristles 254 can also be square, rectangular, rhomboid, polygonal, or any other cross-sectional shape as desired. The bristles 254 can be formed from polybutylene terephthalate (“PBT”), nylon, or other materials commonly used for bristles in oral care applications. The dental cleaning element can be extruded bristles or can be molded or formed by other means.

[0014] The flexible sheet 200 can be formed from a plastic or metallized polymer film or other sheet material. The flexible sheet 200 is preferably flexible enough to allow it to elastically deform under minimal applied force. Preferred materials include fluorinated compounds such as polytetrafluoroethylene (also known as “Teflon” or “PTFE”) and metallized compounds such as metallized polyethylene terephthalate (also known as “Mylar” or “metallized PET”). For example, the flexible sheet 200 can be 0.010” thick PTFE or 0.002” thick metallized PET. The flexible sheet 200 can have greater or lesser thicknesses and can be formed from a wide range of alternative materials. However, polymers such as fluorinated compounds or metallized polymers are preferred over other alternatives. Any thickness can be used, as long as the sheet is sufficiently elastically deformable to allow a user to deform the flexible sheet 200 with finger pressure.

[0015] The flexible sheet 200 is preferably formed of a material with a melting temperature higher than that of the bristles 254. For example, PBT bristles have a melting temperature of about 433°F, while PTFE has a melting temperature of about 620°F. In other embodiments, a metallized film of metallized PET or another metallized polymer material is used to insulate the PET or other polymer material from excessive heat. In these embodiments, the PET or other polymer is protected from the effects of heating during processing by the metallized film layer.

[0016] The flexible sheet 200 has a first side 202 and a second side 204. A plurality of clusters of apertures 206 extend from the first side 202 through the flexible sheet 200 to the second side 204. The clusters of apertures 206 may have circular, rectangular, square, polygonal, elliptical, or other contours. Optionally, the second side 204 may be etched to facilitate the adhesion of the bristle material, as will be discussed in more detail below. A metallization layer may be located on the second side 204, wherein the metallization material is used to form the flexible sheet 200.

[0017] The retaining device 100 is formed by a cover 110, a bristle container 130, and a bristle pusher plate 150. The bristle container 130 is sized to receive the bristle bundle 250 within a cavity 132. The bristle container 130 has a base plate 134 having a plurality of orifices 136 extending through it. Optionally, the orifices 136 may be cylindrical or have another cross-sectional profile, such as rectangular, square, polygonal, or elliptical. The bristle container 130 has a top surface 138 opposite the base plate 134, and the cavity 132 extends from the top surface 138 to the base plate 134 and is defined by a plurality of walls 140. A recess 142 is formed in the bottom surface 144 of the bristle container 130, and the recess 142 is configured to receive the bristle pusher plate 150, as will be discussed further below.

[0018] The cover 110 has a lower surface 112 for receiving a flexible sheet 200, an upper surface 114 opposite to the lower surface 112, and a plurality of retaining features 118 extending from the lower surface 112. A plurality of orifices 116 extend from the lower surface 112 through the cover 110 to the upper surface 114. The orifices 116 may be cylindrical or have another cross-sectional profile, such as rectangular, square, polygonal, or elliptical.

[0019] The bristle pusher 150 has a top surface 152 and a bottom surface 154. A plurality of protrusions 156 extend from the top surface 152. An access opening 157 is also formed through the bristle pusher 150 to allow removal of the bristle pusher 150 from the bristle container 130. The protrusions 156 may have a cylindrical profile or may have another cross-sectional profile, such as a rectangular, square, polygonal, or elliptical profile.

[0020] The bristle pusher 150 is configured to insert into the recess 142 of the bristle container 130. The protrusion 156 is arranged such that it is aligned with the orifice 136 of the bristle container 130. The protrusion 156 is also aligned with the orifice 116 of the cover 110 and the cluster holes 206 of the flexible sheet 200.

[0021] When the bristle pusher 150 is inserted into the recess 142, the protrusion 156 extends through the orifice 136. The protrusion 156 has a diameter d1, while the orifice 136 has a diameter d2. The orifice 116 also has a diameter d3. The cluster hole 206 has a diameter d4. When the orifices 136, 116, and cluster hole 206 are not circular, the maximum size is equal to the corresponding diameters d2, d3, and d4. The diameter d1 of the protrusion 156 is smaller than the diameters d2, d3, and d4 of the orifices 136, 116, and cluster hole 206. The diameters d2, d3, and d4 can be equal, or the diameters d2 and d3 can be larger than the diameter d4. Specifically, the diameter d1 is smaller than the diameter d4 of the cluster hole 206 to facilitate the insertion of the bristles 254 through the cluster hole 206.

[0022] As in Figure 4 As can be clearly seen, the bristle pusher 150 is inserted into the recess 142 such that the bristles 254 are inserted through the cluster holes 206 and the openings 116 of the cover 110. The flexible sheet 200 is held between the cover 110 and the top surface 138 of the bristle container 130, and the retaining feature 118 ensures that the flexible sheet 200 is aligned with the cover 110 and the cover 110 is aligned with the bristle container 130. The first side 202 faces away from the cover 110, while the second side 204 is in direct surface contact with the lower surface 112 of the cover 110. The protrusion 156 or the outer edge 158 can be used to align the bristle pusher 150 with the openings 136 and the cluster holes 206 of the flexible sheet 200.

[0023] Go to Figures 5 to 10 This illustrates a method for manufacturing brush sheet material. In Figure 5 The document provides a fixing device 100, which includes a cover 110, a bristle container 130, and a bristle pusher 150. The cavity 132 of the bristle container 130 is... Figure 5 The first step shown is empty. Proceed to... Figure 6 In the illustrated second step, the flexible sheet 200 is secured to the cover 110 of the securing device 100. The bristle bundle 250 is also inserted into the cavity 132, with the bristles 254 retained within the package 252. The bristle bundle 250 abuts against the base plate 134 of the bristle container 130. In this second step, the bristle pusher plate 150 separates from the bristle container 130, so that no bristles 254 are displaced by the protrusion 156.

[0024] The third step in manufacturing the brush sheet is illustrated in Figure 7 In this configuration, the flexible sheet 200 is fixed between the cover 110 and the top surface 138 of the bristle container 130. The top surface 138 contacts the first side surface 202 of the flexible sheet 200, and the lower surface 112 of the cover 110 contacts the second side surface 204 of the flexible sheet 200. The bristle pusher plate 150 remains separated from the bristle container 130, so that no bristles 254 are displaced by the protrusion 156.

[0025] The fourth step in manufacturing the brush sheet is illustrated in Figure 8 In the bristle pusher 150, the bristle pusher 150 is inserted into the recess 142. A protrusion 156 is inserted through an orifice 136 until the top surface 152 of the bristle pusher 150 contacts the bottom plate 134 of the bristle container 130. The protrusion 156 allows the base portion 256 of the bristles 254 to be inserted through the cluster hole 206 and pass through the orifice 116 of the cover 110. Alternatively, the bristles 254 may not be fully inserted through the cover 110, but may only extend a portion of the distance from the lower surface 112 to the upper surface 114.

[0026] Go to Figure 9This illustrates the fifth step in manufacturing the brush sheet. In this fifth step, the cover 110 is removed, leaving the bristles 254 extending through the cluster holes 206 of the flexible sheet 200. The first surface 202 of the flexible sheet 200 remains in contact with the top surface 138 of the brush container 130.

[0027] A heat source 270 is applied to the base portion 256 of the bristles 254, causing the base portion 256 to melt into a molten texture 260, the molten texture 260 comprising the base portion 254 of the bristles 254 extending through each cluster hole 206. Optionally, pressure can be applied by the heat source 270 or another tool. Thus, the molten texture 260 is formed by the base portions 256 of a plurality of cluster holes 206. Optionally, the molten texture 260 can be flattened to help bond the molten texture 260 to the flexible sheet 200.

[0028] In other embodiments, individual fused textured surfaces 260 may be formed, each corresponding to a single cluster hole in the cluster holes 206. In other embodiments, multiple fused textured surfaces 260 may be formed, each corresponding to a base portion 254 extending through multiple cluster holes 206 but less than all cluster holes 206. The fused textured surfaces 260 are bonded or joined to the second side surface 204, and the connection between the fused textured surfaces 260 and the second side surface of the flexible sheet 200 helps to retain the bristles 254.

[0029] 300 examples of brushed sheet material are shown below Figure 10 In this process, the bristle sheet 300 is extracted from the bristle container 130. Multiple bristle tufts 258 are formed from bristles 254 inserted through tuft holes 206, wherein the base portion 256 is subsequently melted to form a molten rough surface 260. The remaining bristles 254 are retained within the bristle bundle 250, which is held within the cavity 132 of the bristle container 130. Each bristle 254 in the multiple bristle tufts 258 has a free portion 259 extending from a first side 202 of the flexible sheet 200. The bristle sheet 300 can be attached to the head of an oral care appliance and can be used as part of the cavity of a chamber, thereby allowing selective inflation and deflation to move the bristles 254 of the multiple bristle tufts 258.

[0030] Go to Figures 11 to 13 An embodiment of an oral care appliance 1000 is illustrated, wherein a tooth cleaning element is omitted. The oral care appliance 1000 may be formed in the shape of a dental brace and may be adapted to clean a user's teeth. Specifically, the oral care appliance 1000 may have first and second head portions 1100, which are configured to correspond to a portion of the user's dental arch. Preferably, the head portions 1100 are symmetrical and correspond to approximately half of the user's dental arch to allow brushing one side of the user's mouth and then brushing the other side of the user's mouth.

[0031] The oral care appliance includes a handle 1010 and a head 1060. The handle has a gripping portion 1012, a first neck portion 1014, and a second neck portion 1016. A longitudinal axis AA extends along the gripping portion 1012. The first neck portion 1014 and the second neck portion 1016 diverge from the longitudinal axis AA, and each of the first neck portion 1014 and the second neck portion 1016 terminates at a connector 1015. The connectors 1015 of the first neck portion 1014 and the second neck portion 1016 engage with corresponding connectors 1065 of the first and second head portions 1100. The head portions 1100 are spaced apart from each other and isolated, connected only via the handle 1010.

[0032] Each head portion 1100 has a base portion 1102 having a buccal wall 1104 and a plurality of fingers 1106. The fingers 1106 and the buccal wall 1104 have a plurality of bends 1108. The bends 1108 of the buccal wall 1104 allow the buccal wall 1104 to conform to the curvature of the user's dental arch, generally following the arch profile PP. The bends 1108 in the buccal wall 1104 are arranged perpendicular to the arch profile PP. The buccal wall 1104 and the fingers 1106 also have a plurality of clusters 1110, each cluster 1110 having a plurality of cluster apertures 1112. The cluster apertures 1112 may extend through the clusters 1110, or may be blind apertures extending only into the clusters 1110 without being exposed on opposite sides. One of the clusters 1110 includes a connector 1065.

[0033] A portion of the bend 1108 in the finger 1106 can be substantially aligned with the arched profile PP, thereby separating the buccal wall 1104 from the finger 1106. An additional bend 1108 in the finger 1106 allows the finger 1106 to bend rearward to face the buccal wall 1104. This allows for simultaneous cleaning of the buccal, lingual, and occlusal surfaces of the user's teeth. Therefore, the buccal wall 1104 has an inner surface 1114, and each finger 1106 has an inner surface 1116, with the inner surfaces 1114 and 1116 facing the user's teeth during use. In some embodiments, if some clusters 1110 do not require cleaning elements to achieve cleaning of the user's teeth, they may not have cluster holes 1112. For example, not all clusters 1110 of the finger 1106 adjacent to the connector 1065 have cluster holes 1112.

[0034] The base portion 1102 and the handle 1010 of the head portion 1100 are preferably formed of a rigid plastic material, such as nylon, polystyrene, ABS, or another rigid plastic. These materials have advantages in terms of ease of forming, low cost, rigidity, and durability compared to wood, metal, rubber, or other elastomer materials.

[0035] Figure 14 An example is shown: the base portion 1102 of the head portion 1100 of the head 1060 of an oral care appliance 1000. The head portion 1100 is in a first state, which is a flat state. The base portion 1102 in the first state is free of clusters and is substantially flat. Unless otherwise stated, the base portion 1102 may be in a flat state. The base portion 1102 may be formed by molding, machining, or any other known method. Figure 15 An example of the head portion 1100 in a second state is shown, wherein multiple bristles 254 extend from the inner surfaces 1114, 1116 of the cheek wall 1104 and the fingers 1106. Thus, the head portion 1100 remains flat in the second state, but bristles 254 have been added to the base portion 1102. The bristles 254 are arranged in bristle tufts 1256, each bristle tuft 1256 extending from one tuft aperture 1112.

[0036] Figure 16 An example is shown of the head portion 1100 in a third state, which is a bent state. In the third state, the head portion 1100 is bent at a bend 1108. The head portion 1100 is formed such that the fingers 1106 are bent, wherein the bristle tufts 1256 of different tufts 1110 are arranged at different angles such that the bristle tufts 1256 of different tufts 1110 do not extend along a parallel axis. The cheek wall 1104 is bent at the bend 1108 to allow the cheek wall 1104 to generally follow an arcuate path PP. Bending can be accomplished by applying heat to the bend 1108, or the bend 1108 can be plastically deformed without the use of heat. In other embodiments, the base portion 1108 can be molded in a bent state, then elastically deformed to a flat state to allow tufting, and later allowed to return to a bent state by removing the applied force.

[0037] This method of forming the head portion 1100 allows the bristle tuft 1256 to be installed while the base portion 1102 is in a flat state, and then the base portion 1102 is bent to form the complete head portion 1100. The head portion 1100 can later be connected to the connector 1115 of the neck portions 1014, 1016 of the handle 1010 to complete the oral care appliance 1000.

[0038] The term "range" is used throughout as a concise expression to describe each value within the range. Any value within the range can be chosen as an endpoint of the range. Furthermore, all references cited herein are incorporated in their entirety. In the event of any conflict between definitions in this disclosure and definitions in cited references, this disclosure shall prevail.

[0039] Although the invention has been described with reference to specific examples (including the currently preferred mode for carrying out the invention), those skilled in the art will understand that numerous variations and substitutions exist for the systems and techniques described above. It should be understood that other embodiments can be utilized and structural and functional modifications can be made without departing from the scope of the invention. Therefore, the spirit and scope of the invention should be broadly interpreted as set forth in the appended claims.

Claims

1. A method for forming a bristle sheet for an oral care appliance, the method comprising: a) Fixing a flexible sheet to a fixing device, the flexible sheet including a first side, a second side, and a plurality of clusters of holes extending from the first side to the second side; b) Insert the first plurality of bristles through the first hole in the plurality of cluster holes; c) Melt the base portion of the bristles in the first plurality of bristles to form a first bristle cluster including a molten rough surface, the molten rough surface being bonded to the second side surface of the sheet; The flexible sheet comprises either a metallized polymer film or a fluorinated compound.

2. The method of claim 1, wherein step a) further comprises step a-1), which comprises positioning the bristle bundle within the bristle container of the fixing device.

3. The method of claim 1 or claim 2, wherein step a) further comprises step a-2), which comprises positioning the flexible sheet within the cover of the fixing device and securing the cover to the bristle container of the fixing device.

4. The method of claim 3, wherein the cover includes a plurality of openings aligned with the plurality of cluster holes.

5. The method of claim 4, wherein, In step b), the base portion of the bristles of the first plurality of bristles extends into the plurality of openings of the cover.

6. The method of any one of claims 1 to 5, the method further comprising step c-1), step c-1) comprising removing the cover of the fixing device.

7. The method of any one of claims 1 to 6, wherein step b) further comprises step b-1), which comprises securing a bristle pusher to the bristle container such that the first plurality of bristles are inserted through the first hole in the plurality of cluster holes.

8. The method of claim 7, wherein the bristle pusher includes a top surface and a plurality of protrusions, each of the plurality of protrusions being aligned with a corresponding cluster hole in the plurality of cluster holes.

9. The method of claim 8, wherein the first protrusion of the plurality of protrusions has a protrusion diameter, and the first hole of the plurality of cluster holes has a hole diameter, the protrusion diameter being smaller than the hole diameter.

10. The method of any one of claims 7 to 9, wherein the bristle container includes a base plate, a plurality of orifices extending through the base plate, and a plurality of protrusions of the bristle pusher extending through the plurality of orifices.

11. The method of any one of claims 1 to 10, wherein in step c), the molten rough surface is formed by the base portion of each of the plurality of bristles.

12. The method according to any one of claims 1 to 11, wherein, Prior to step a), the flexible sheet is etched on the second side surface, and the molten rough surface formed in step c) adheres to the second side surface of the flexible sheet.

13. The method according to any one of claims 1 to 12, wherein, In step a), the flexible sheet includes a metallization layer and a polymer layer, the metallization layer forming the second side surface of the flexible sheet, and the polymer layer forming the first side surface of the flexible sheet.

14. The method according to any one of claims 1 to 12, wherein, In step a), the flexible sheet comprises polytetrafluoroethylene and has a thickness of 0.254 mm or less.

15. A method for forming a bristle sheet for an oral care appliance, the method comprising: a) Insert the bristle bundle into the bristle container of the fixing device; b) Secure the flexible sheet to the cover of the fixing device and compress the flexible sheet between the cover of the fixing device and the bristle container; c) Inserting a plurality of protrusions of the bristle push plate of the fixing device through a plurality of holes formed in the bottom plate of the bristle push plate, the plurality of protrusions causing a first plurality of bristles to pass through a first hole formed in the flexible sheet. d) Remove the cover of the fixing device while keeping the flexible sheet against the bristle container; e) Melt the base portion of the first plurality of bristles, such that the base portion is joined to the second side of the flexible sheet; as well as f) Remove the flexible sheet and the first plurality of bristles from the bristle container.

16. The method of claim 15, wherein, In step c), the plurality of protrusions also allow a second plurality of bristles to pass through a second hole formed in the flexible sheet.

17. The method of claim 16, wherein the molten rough surface comprises the base portion of the second plurality of bristles and the base portion of the first plurality of bristles.

18. The method according to any one of claims 15 to 17, wherein, In step e), the free portions of the first plurality of bristles form a first bristle tuft.

19. A bristle sheet for an oral care appliance, said bristle sheet comprising: A flexible sheet, said flexible sheet being formed of a metallized polymer film or a fluorine compound; The first bristle tuft is formed by the free portion of a first plurality of bristles extending through a first hole in the flexible sheet, the first bristle tuft extending from a first side of the flexible sheet. A fused rough surface, formed from the base portion of the first plurality of bristles, is bonded to the second side of the flexible sheet.

20. The brush sheet of claim 19, wherein the second side of the flexible sheet is etched.

21. An oral care appliance, the oral care appliance comprising: The handle includes a gripping portion, a first neck portion, and a second neck portion; as well as A head, which is connected to the handle, the head comprising: A first head portion, the first head portion including a base portion, the base portion including a cheek wall and a plurality of fingers extending from the cheek wall, each of the plurality of fingers including a bend, a plurality of upper cheek wall bristle tufts extending from the inner surface of the cheek wall, and a first plurality of finger bristle tufts extending from a first finger of the plurality of fingers, the first head portion being connected to a first neck portion; and The second head portion includes a base portion, the base portion including a cheek wall and a plurality of fingers extending from the cheek wall, each of the plurality of fingers including a bend, a plurality of lower cheek wall bristle tufts extending from the inner surface of the cheek wall and a first plurality of finger bristle tufts extending from a first finger of the plurality of fingers, the second head portion being connected to the second neck portion; The base portions of the first and second portions are each formed of a rigid plastic material.

22. The oral care appliance of claim 21, wherein the first plurality of finger-shaped bristle tufts of the first head portion extend at an angle to the plurality of upper buccal bristle tufts of the first head portion.

23. The oral care appliance of claim 21 or claim 22, wherein the cheek wall of the first head portion includes a curved portion.

24. The oral care appliance of any one of claims 21 to 23, wherein the first head portion and the second head portion are detachably connected to the handle portion.

25. The oral care appliance of any one of claims 21 to 24, wherein the first neck portion and the second neck portion are divergent.

26. A method of forming an oral care appliance, the method comprising: a) A base portion forming a first head portion, the base portion having cheek facets and a plurality of fingers; b) Inserting multiple bristle filaments into the tufts in the cheek wall and the plurality of fingers to form a plurality of bristle tufts, the plurality of bristle tufts including a plurality of cheek wall bristle tufts and a plurality of finger bristle tufts, each of the plurality of cheek wall bristle tufts and the plurality of finger bristle tufts extending along a tuft axis, the tuft axis of the plurality of cheek wall bristle tufts being substantially parallel to the tuft axis of the plurality of finger bristle tufts; c) Bending the base portion of the first head portion to form a plurality of bends in the plurality of fingers, such that the cluster axis of at least one of the plurality of finger bristle clusters is no longer parallel to the cluster axis of the plurality of cheek wall bristle clusters. as well as d) Connect the first head portion to the first neck portion of the handle.

27. The method of claim 26, wherein the base portion of the first head portion is formed of a rigid plastic material.

28. The method of claim 26 or claim 27, wherein, In step a-1), a base portion of a second head portion is formed, the base portion of the second head portion having cheek facets and a plurality of fingers.

29. The method of claim 28, wherein, In step b-1), a second plurality of bristle filaments are inserted into the cheek wall of the base portion of the second head portion and into the cluster holes of the plurality of fingers.

30. The method of claim 29, wherein, In step d-1), the second head portion is attached to the second neck portion of the handle.

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