Replaceable toothbrush heads

Abstract

The replaceable brush head has an upper surface, an outer periphery, and a plurality of tufts. The upper surface has bristle tufts. The lower surface has an outwardly extending knockout button. The outer periphery includes at least one protrusion. The replaceable brush head may be disposed within a toothbrush body having a head portion with a recess sized to fit the replaceable brush head having a knockout opening for the knockout button, and at least one groove for coupling with the at least one protrusion. The replaceable brush head can be removed from the toothbrush assembly by applying force to the knockout button in the direction of the tuft plate.

Description

[Technical Field]

[0001] The present invention relates to toothbrushes and replaceable brush heads for toothbrushes. [Background technology]

[0002] Replaceable brush heads are removable brush heads that allow users to replace the brush head of a toothbrush as needed without having to replace the entire toothbrush. They are generally made of plastic and typically connect to the neck of the toothbrush. These replacement brush heads often include a head portion that carries the bristles and a neck portion that extends from the head portion. The neck portion includes an attachment structure, such as a receptacle, that receives a portion of the toothbrush handle and attaches the brush head to the handle. These replaceable brush heads can be difficult to attach and remove and require the replacement of a relatively large amount of plastic material. With ongoing efforts to reduce waste, the amount of plastic material discarded after brush head replacement is often undesirable. Summary of the Invention

[0003] In one aspect, the present invention provides a replaceable brush head for removably attaching to a toothbrush body. The brush head includes a top surface, an outer periphery, and a bottom surface. The top surface defines a plurality of openings, with at least one bristle tuft extending from each of the openings. A plurality of spaced apart projections extend from the outer periphery, the projections configured to secure the replaceable brush head to the toothbrush body. A knockout button extends outward from the surface of the brush head for direct contact by a user in connection with removing the brush head from the toothbrush body.

[0004] In another aspect, the replaceable brush head may be part of a toothbrush assembly having a toothbrush body. The toothbrush body may include a housing having a handle portion, a neck portion, and a head portion. The head portion defines a brush head recess sized to fit over and receive the brush head, the brush head recess having a sidewall with a shape corresponding to the shape of the outer periphery of the brush head. The brush head recess includes a floor portion, and the head portion defines a knockout opening extending completely through the floor portion of the brush head recess, the knockout opening being sized and shaped to receive a knockout button of the brush head, with a portion of the knockout button exposed through the knockout opening for direct contact by a user. The sidewall further defines a plurality of locking portions, the locking portions being sized and positioned to align with at least one protrusion on the brush head.

[0005] The toothbrush body may further include a circuit board housed in the handle portion, the circuit board including a power button and a power source. The neck portion may also house a strain gauge and a vibration motor. The grip portion may at least partially surround the handle portion, the grip portion defining a power button opening aligned with the power button contact point.

[0006] In yet another aspect, the brush head is formed from a tuft plate and a tuft plate cover, each having a stadium-shaped cross-section and a curved outer edge. A distal protrusion can extend from the curved outer edge at the distal end of the tuft plate. A pair of proximal protrusions can each extend from the curved outer edge along a portion of the length of the stadium-shaped cross-section. The multiple tufts can terminate in at least two different planes above the tuft plate. A bottom surface of the receptacle can define an opening toward the distal end of the tuft plate cover. The tuft plate and the tuft plate cover can be joined to each other by ultrasonic welding. The tuft plate and the receptacle can have a first width, and the knockout button can have a second width. The first width can be greater than the second width.

[0007] The neck portion of the upper housing of the toothbrush body may include an indicator light. The head portion may be stadium-shaped, and the peripheral wall may be curved to accommodate a replaceable brush head. The peripheral wall may define three grooves sized and positioned to align with the distal protrusion and a pair of proximal protrusions on the tuft plate. The bottom housing may define two openings in a bottom surface of the bottom housing. Two ferrous metal pieces may be coupled to the bottom housing through the two openings in the bottom surface. The ferrous metal pieces may be configured to magnetically couple the toothbrush body to a charger. A charging plate may be housed in the handle portion in a component cavity below the circuit board and may direct an electromagnetic field to the charging coil. A grip portion may be overmolded over the bottom housing and the handle and neck portions of the bottom housing. The grip portion may define an indicator light opening aligned with the indicator light.

[0008] These and other objects, advantages, and features of the present invention will be more fully understood and appreciated by reference to the description of the present embodiment and drawings.

[0009] Before describing aspects of the invention in detail, it should be understood that the invention is not limited to the operational details or construction details and arrangement of components set forth in the following description or illustrated in the drawings. The invention can be embodied in various other aspects and can be, or be carried out, in alternative ways not expressly disclosed herein. Also, it should be understood that the phraseology and terminology used herein are for purposes of description and should not be regarded as limiting. The use of "including" and "comprising" and variations thereof means the inclusion of the subsequently listed items and equivalents, as well as additional items and equivalents. Furthermore, enumerations may be used in describing various aspects. Unless otherwise expressly stated, the use of enumerations should not be construed as limiting the invention to any particular order or number of components. Also, the use of enumerations should not be construed as excluding from the scope of the invention any additional steps or components that may be combined with or incorporated into the listed steps or components. [Brief explanation of the drawings]

[0010] [Figure 1A-1B] 1A-1B are perspective views of a replaceable brush head according to one embodiment. [Figure 2] FIG. 2 is an exploded view of a replaceable brush head according to one embodiment. [Figures 3A-3D] 3A-3D are top, side, front, and back views of a tuftless replaceable brush head according to one embodiment. [Figure 4] FIG. 4 is a bottom perspective view of a tuft plate according to one embodiment. [Figure 5] FIG. 5 is a plan view of a tuftless replaceable brush head according to one embodiment. [Figure 6] 6 is a cross-sectional view of the replaceable brush head of FIG. 4 taken along line VV. [Figures 7A-7D] 7A-7D are perspective views of a tuftless replaceable brush head according to one embodiment. [Figure 8]FIG. 8 is a bottom view of a replaceable brush head according to one embodiment. [Figures 9A-9D] 9A-9D show top, side, front, and back views of a replaceable brush head according to one embodiment. [Figure 10] FIG. 10 is a plan view of a replaceable brush head according to one embodiment. [Figure 11] FIG. 11 is a cross-sectional view of the replaceable brush head of FIG. 10 taken along line XX. [Figures 12A-12D] 12A-12D are perspective views of a replaceable brush head according to one embodiment. [Figure 13] FIG. 13 is a plan view of a replaceable brush head according to one embodiment. [Figure 14] 14 is a cross-sectional view of the replaceable brush head of FIG. 13 taken along line XIII-XIII. [Figure 15] FIG. 15 is a side view of a replaceable brush head according to one embodiment. [Figure 16] FIG. 16 is a detailed view of Detail B of the replaceable brush head of FIG. [Figure 17] FIG. 17 is a perspective view of a replaceable brush head according to one embodiment. [Figures 18A-18B] 18A-18B are plan views of tuft hole locations and tuft profile locations according to one embodiment. [Figure 19] FIG. 19 is an exploded view of a toothbrush body according to one embodiment. [Figures 20A-20D] 20A-20D are side, top, front, and perspective views of a toothbrush body according to one embodiment. [Figures 21A-21D] 21A-21D are perspective views of a toothbrush assembly according to one embodiment. [Figures 22A-22E] 22A-22E are top, side, bottom, front, and back views of a toothbrush assembly according to one embodiment. [Figure 23] FIG. 23 is a plan view of a toothbrush assembly according to one embodiment. [Figure 24] 24 is a cross-sectional view of the toothbrush assembly of FIG. 23 taken along line XXIII-XXIII. [Figure 25] FIG. 25 is a side view of a toothbrush assembly according to one embodiment. [Figure 26] FIG. 26 is a cross-sectional view of the toothbrush assembly of FIG. 25 taken along line XXV-XXV. DETAILED DESCRIPTION OF THE INVENTION

[0011] A replaceable brush head 100 according to one embodiment is shown in FIGS. 1A-1B. The replaceable brush head 100 is adapted to removably couple to a toothbrush body to form a toothbrush assembly. In one embodiment, the replaceable brush head 100 is made of plastic. The replaceable brush heads 100 shown throughout this disclosure are stadium-shaped (i.e., have generally straight, parallel sides with opposing U-shaped ends) when viewed from above. In other embodiments, the replaceable brush heads 100 can be any other suitable shape, such as rectangular or oval. In one embodiment, the replaceable brush heads 100 described throughout can result in an 80 percent reduction in plastic waste over known replaceable brush heads. As shown in FIG. 2, the replaceable brush head 100 can be composed of two or more components. In the embodiment shown in FIG. 2, the replaceable brush head 100 includes a plurality of tufts 110, a tuft plate 120, and a tuft plate cover 130. Each of the plurality of tufts 110 can include a bundle of individual bristles, such as nylon bristles, or one or more of the tufts can include a monolithic cleaning element, such as an elastomeric cleaning element. The tuft plate 120 can include a top surface 122, an outer edge 124, and a bottom surface (not shown), and in one aspect, the outer edge 124 is curved. The curved outer edge 124 can have a straight portion that helps secure the tuft plate 120 to the tuft plate cover 130.

[0012] 3A-3D show the tuft plate 120 and tuft plate cover 130 in more detail. The tuft plate 120 may be stadium-shaped when viewed from the top. In other words, the tuft plate 120 may have a stadium-shaped cross-section. The tuft plate 120 may define a plurality of openings 126. As shown in FIG. 3A, the plurality of openings 126 may be of at least two shapes 126a, 126b to accommodate bristle tufts of different shapes. In alternative embodiments, the plurality of openings 126 may all be one shape or three or more shapes. In one embodiment, the plurality of openings 126 may be the same shape but different sizes to accommodate bristle tufts of different sizes. The plurality of openings 126 may be located toward a distal end 127 of the top surface 122. As shown in FIG. 3A , the plurality of openings 126 can cover approximately 60 percent of the length of the tuft plate 120, where the length of the tuft plate 120 is defined as the length between the proximal end 125 and the distal end 127 of the tuft plate. In one embodiment, the plurality of openings 126 can cover any other percentage of the top surface 122. In alternative embodiments, the openings 126 can span all or substantially all of the top surface 122. In another embodiment, the openings 126 can be located toward the proximal end 125 of the top surface 122. As shown, at least some of the openings 126 are arranged in a stadium configuration. In other embodiments, the openings 126 can be arranged in any other suitable manner. FIGS. 7A-7D are perspective views of the tuft plate 120 and the tuft plate cover 130.

[0013] Returning to FIG. 2 , the plurality of tufts 110 may be coupled to the tuft plate 120 using a plurality of openings 126. As shown in FIG. 2 , the plurality of tufts 110 may have two different shapes 110a, 110b corresponding to the plurality of openings 126 of different shapes 126a, 126b. In alternative embodiments, the plurality of tufts 110 may have a different shape than the plurality of openings 126. As shown in FIG. 2 , the number of tufts 110 equals the number of openings 126. In alternative embodiments, the number of tufts 110 may not equal the number of openings 126. In one embodiment, the plurality of tufts 110 may be coupled to the tuft plate 120 using staple or anchor-free tufting techniques. In another embodiment, the plurality of tufts 110 may be coupled to the tuft plate 120 in any suitable manner.

[0014] The plurality of tufts 110 can terminate in at least two different planes above the tuft plate 120. FIG. 17 shows the terminal surfaces 112, 114 of the plurality of tufts 110 according to one embodiment. As shown, some of the tufts 110 terminate at terminal surface 112 and some of the tufts 110 terminate at terminal surface 114. Terminal surface 114 is further from terminal surface 112 than terminal surface 112. In an alternative embodiment, the plurality of tufts 110 may terminate in a single plane above the tuft plate 120. FIGS. 18A-18B are plan views of tuft hole locations and tuft profile locations for a replaceable brush head 100 according to one embodiment. In one embodiment, the tuft profile labeled A in FIG. 18B terminates at terminal surface 114, and the tuft profile labeled B terminates at terminal surface 112. In an alternative embodiment, the tuft profile labeled B in FIG. 18B terminates at terminal surface 114 and the tuft profile labeled A terminates at terminal surface 112.

[0015] Figure 13 is a plan view of a replaceable brush head 100 according to one embodiment, and Figure 14 is a cross-sectional view of the replaceable brush head of Figure 13 along line XIII-XIII. In Figure 14, distances D1 and D2 between two shapes of tufts 110 are shown. In one embodiment, distance D1 is 0.4 mm, and distance D2 is 0.4 mm. In the embodiment of Figure 14, tufts 110 terminate in three planes A, B, and C on top surface 122 of tuft plate 120. In one embodiment, plane A is 10 mm with a tolerance of plus or minus 0.4 mm, plane B is 1 mm above plane A with a tolerance of plus or minus 0.2 mm, and plane B is 1 mm below plane A with a tolerance of plus or minus 0.2 mm.

[0016] 3A-3D , at least one protrusion 140 may extend from the outer edge 124. The at least one protrusion 140 may be utilized to secure the replaceable brush head 100 to the toothbrush body 1900, as described below with reference to FIGS. 21A-21D . As shown in FIGS. 3A-3D , the tuft plate 120 may have three protrusions 140 extending from the outer edge 124: one protrusion 140 extending from the distal end 127 and two protrusions 140 extending along the length of opposing sides 131, 133 of the tuft plate 120 adjacent the proximal end 125. In one embodiment, the tuft plate 120 may have a length, including the distal protrusion 140, of 39.9 millimeters (mm), and a width, including the proximal protrusion 140, of 11.9 mm. Throughout this disclosure, all dimensions have a tolerance of ±0.05 mm unless otherwise specified. In one embodiment, three protrusions 140 are spaced apart around the circumference of outer edge 124, although they may be located at any other suitable set of locations along outer edge 124. In alternative embodiments, tuft plate 120 may have one, two, or any other suitable number of protrusions for securing replaceable brush head 100 to toothbrush body 1900. In yet another alternative embodiment, one or more of protrusions 140 may be located on outer edge 154 of receptacle 150 of tuft plate cover 130.

[0017] The tuft plate 120 may include a pair of cylindrical protrusions 123 extending from the upper surface 122. The cylindrical protrusions 123 may be substantially aligned along the length axis L, as shown in FIG. 3A. In one embodiment, the cylindrical protrusions 123 may have any other suitable shape. In one embodiment, the tuft plate 120 may have only one cylindrical protrusion 123. In another embodiment, the tuft plate 120 may include three or more cylindrical protrusions 123. In one embodiment, the cylindrical protrusions 123 may be positioned at different locations on the upper surface 122 of the tuft plate 120. The cylindrical protrusions 123 may be used to position the tuft plate 120 within the bristle member. The cylindrical protrusions 123 may provide alignment to a die that sets the bristle topography.

[0018] Tuft plate 120 may define an opening 121 in top surface 122. As seen in FIG. 4, opening 121 does not extend through bottom surface 128 of tuft plate 120. Opening 121 may be a plastic injection point during molding of tuft plate 120. Opening 121 may be flush below to prevent any gate debris from protruding into the bristle die.

[0019] 4, the ridges 129 can extend from the bottom surface 128 of the tuft plate 120 along the outer edge 124 of the tuft plate 120. In another embodiment, the ridges 129 can extend around only a portion of the outer edge 124 of the tuft plate 120. A plurality of bonding protrusions 111 can extend from the bottom surface 128 of the tuft plate 120. In versions of the brush head in which the bristles 110 are attached via anchor-free tufting, the bonding protrusions 111 are fused with the tufts 110 to form a mechanical bond between the two materials.

[0020] The tuft plate cover 130 may include a receptacle 150 and a knockout button 160. The knockout button 160 may alternatively be referred to as a removal protrusion. The tuft plate cover 130 may be stadium-shaped when viewed from the top. In other words, the tuft plate cover 130 may have a stadium-shaped cross-section that defines an outer edge 154 of the receptacle. The receptacle 150 may have a top surface 152 (shown in FIG. 2), an outer edge 154, and a bottom surface 158. In one aspect, the outer edge 154 is curved. As shown in FIG. 2, the receptacle 150 may define a receiving groove 159 along the periphery of the top surface 152. The receiving groove 159 is sized to receive a portion of the raised portion 129 of the tuft plate 120 when the tuft plate 120 and the tuft plate cover 130 are coupled together, and the tuft plate outer edge 124 and the receiving portion outer edge 154 combine to form the outer periphery 200 of the brush head 100. The receiving portion 150 can define a first opening 156 at the proximal end 141. As shown in FIG. 2 , the first opening 156 is stadium-shaped. In alternative embodiments, the first opening 156 can be any other suitable shape. In another embodiment, the receiving portion 150 can not include the first opening 156.

[0021] In one embodiment, the tuft plate 120 and tuft plate cover 130 can be joined together by ultrasonic welding to form the completed brush head 100. FIG. 15 shows a side view of a replaceable brush head 100 according to one embodiment. FIG. 16 shows Detail B from FIG. 15. The ultrasonic weld seam 132 is shown in FIG. 16. In one embodiment, the ultrasonic weld seam 132 may be 0.05 mm, with a maximum weld offset of plus or minus 0.05 mm. In one embodiment, the ultrasonic weld strength may be 50 Newtons or greater. In alternative embodiments, the tuft plate 120 and tuft plate cover 130 can be joined together by any other suitable method. For example, the tuft plate 120 and tuft plate cover 130 can be joined by fitting or by using an adhesive. In one embodiment, the distance or height of the joined outer peripheral edge 200 of the brush head 100 between the top surface 122 of the tuft plate 120 and the bottom surface 158 of the receiver 150 is 4.08 mm, and the distance from the top surface 122 of the tuft plate 120 to the terminal edge 163 of the knockout button 160 is 7.4 mm.

[0022] 3A-3D , the knockout button 160 may extend from the bottom surface 158 of the receptacle 150. As shown in FIGS. 3A-3D , the knockout button 160 can extend from the receptacle 150 at the proximal end 141 of the receptacle 150. In alternative embodiments, the knockout button 160 may extend from a different portion of the bottom surface 158 or from another surface of the brush head 100. For example, the knockout button 160 may extend from the bottom surface 158 at the distal end 143 of the receptacle 150. As shown, the knockout button 160 extends from the bottom surface 158 at a first opening 156, which forms an opening for the knockout button 160. As shown, the knockout button 160 is stadium-shaped when viewed from the bottom. In alternative embodiments, the knockout button 160 may have any other suitable shape. In one embodiment, knock-out button 160 has the same shape as receptacle 150. In an alternative embodiment, knock-out button 160 can have a different shape than receptacle 150. FIG. 6 shows a cross-section of tuft plate 120 and tuft plate cover 130 of FIG. 5 taken along line VV. As shown in FIG. 6, knock-out button 160 aligns with first opening 156 and defines a cavity 162 extending therefrom. Cavity 162 helps reduce the amount of plastic required to manufacture a replaceable brush head. In another alternative embodiment, knock-out button 160 extends from tuft plate 120 to form a removal protrusion 160 that can be used to remove brush head 100 by pulling the removal protrusion or with the aid of a removal tool.

[0023] 9A-9D show plan, side, front, and rear views of a replaceable brush head 100 according to one embodiment. As shown in the figures. As shown in FIGS. 9C-9D, the tuft plate 120 and receiver 150 have a first width W1, and the knockout button 160 has a second width W2. The first width W1 is wider than the second width W2. In alternative embodiments, the first width W1 may be the same as the second width W2. In other embodiments, the first width W1 may be smaller than the second width W2. As shown in FIGS. 9C-9D, the knockout button 160 tapers to width W2 via a tapered portion 164. In alternative embodiments, the knockout button 160 may have width W2 throughout without the tapered portion 164. FIG. 10 is a plan view of a replaceable brush head 100 according to one embodiment, and FIG. 11 is a cross-sectional view of the replaceable brush head 100 of FIG. 10 along line XX.

[0024] 8 shows a bottom view of the replaceable brush head 100 according to one embodiment. The bottom surface 158 of the receptacle 150 may define an injection molding gate 151. The gate 151 can serve as a plastic injection point for manufacturing the replaceable brush head 100. The gate 151 may be flush below to prevent any gate remnants from protruding beyond the main surface (bottom surface 158).

[0025] The replaceable brush head 100 may be part of a toothbrush assembly 2100. More specifically, the replaceable brush head 100 may be molded to mate with and be removable from the toothbrush assembly 2100. FIGS. 21A-21D illustrate a toothbrush assembly 2100 according to one embodiment. The toothbrush assembly 2100 generally includes a toothbrush body 1900. FIG. 19 illustrates an exploded view of the toothbrush body 1900 according to one embodiment. The toothbrush body 1900 may include an upper housing 1910, a bottom housing 1930, a circuit board 1940, a strain gauge 1950, a vibration motor 1960, and a grip portion 1970. The upper housing may include a handle portion 1912, a neck portion 1914, and a head portion 1920. As shown, the handle portion 1912 is thicker than the neck portion 1914. The handle portion may include a power button contact point 1913. The neck portion 1914 may optionally include an indicator light 1915. In one aspect, the indicator light 1915 may be used to indicate the charging status of the toothbrush assembly 2100 to the user.

[0026] The head portion 1920 defines a brush head recess 1922 that forms a receptacle 1922 that is sized to fit over and receive the outer periphery 200 of the brush head 100. In the illustrated embodiment, the receptacle 1922 is sized to fit over and receive the outer edge 124 of the tuft plate 120. The head portion 1920 may also define a knockout opening 1924 defined in a floor 1923 of the brush head recess 1922. The knockout opening 1924 may alternatively be referred to as a notch 1924. The knockout opening 1924 extends completely through the floor 1923 and mates with the outer surface 163 of the knockout button 160, and may be sized and shaped to closely fit and receive the knockout button 160. As shown, the knockout opening 1924 is located at the proximal end of the head portion 1920. In alternative embodiments, the knockout opening 1924 can be located at the distal end of the head portion 1920. In another embodiment, the knockout opening 1924 can be located anywhere on the head portion 1920 such that it aligns with the knockout button 160. The recess 1922 includes a peripheral wall 1926 having an upper rim 1929. In one embodiment, the peripheral wall 1926 can be the same height as the outer periphery 200 of the brush head 100 (i.e., the height of the tuft plate 120 and receiver joined together). The interior surface of the peripheral wall 1926 can include at least one channel or stop 1927 sized and positioned to align with at least one protrusion 140 on the tuft plate 120. In one embodiment, the head portion 1920 is stadium-shaped. In one embodiment, the peripheral wall 1926 is curved in shape to align with the curvature of the outer periphery 200 of the replaceable brush head 100. In one aspect, the head portion 1920 may be made from a hard plastic to create a proper seal between the head portion 1920 and the removable brush head 100. In an alternative aspect, only the peripheral wall 1926 of the head portion 1920 may be made from a hard plastic. In yet another embodiment, at least one of the head 100 and the head portion 1920 may be formed from a resilient material, such as a thermoplastic elastomer.

[0027] The bottom housing 1930 may include a handle portion 1932 and a neck portion 1934. The bottom housing 1930 may define a component cavity 1936. The bottom housing 1930 may be coupled to the top housing 1910 by any suitable coupling method. A circuit board 1940 may be housed in the handle portion of the component cavity 1936. The circuit board 1940 may include a power button 1942 and a power source 1944. In one aspect, the power source 1944 is a battery. In one aspect, the power source 1944 is a supercapacitor. When the top housing 1910 is coupled to the bottom housing 1930, the power button contact point 1913 may contact the power button 1942. A strain gauge 1950 may be housed in the neck portion 1934 of the component cavity 1936 proximal to the handle portion 1932. The strain gauge 1950 may alternatively be a pressure sensor. In one aspect, the strain gauge 1950 may be used to determine if a user is brushing their teeth too hard. The vibration motor 1960 may be housed in the neck portion 1934 of the part cavity 1936 distal from the handle portion 1932. By locating the vibration motor within the neck portion 1934, the replaceable brush head 100 may be vibrated while minimizing the vibration felt by the user's grip.

[0028] The bottom housing 1930 may define two openings (not shown) in a bottom surface (not shown) of the bottom housing 1930. A charging plate 1938 may be housed in the handle portion 1932 in a component cavity 1936 below the circuit board 1940. In one embodiment, the charging plate 1938 may be made of a ferrous material. Two ferrous metal pieces 1939 may be coupled to the bottom housing 1930 through the two openings in the bottom surface. In one embodiment, the two ferrous metal pieces 1939 are permanent magnets. The two ferrous metal pieces 1939 may be configured to couple to a charger to charge the power source 1944. The charging plate 1938 may direct an electromagnetic field received through the ferrous metal pieces 1939 to a charging coil (not shown).

[0029] The grip portion 1970 can at least partially surround the handle portion 1912 and neck portion 1914 of the top housing 1910 and bottom housing 1930. In one aspect, the grip portion 1970 is overmolded onto the handle portion 1912 and neck portion 1914 of the top housing 1910 and bottom housing 1930. In one embodiment, the top housing 1910 and bottom housing 1930 can be formed of a more rigid plastic such as polypropylene, and the grip portion 1970 can be formed of a resilient material such as a thermoplastic elastomer. In another embodiment, these portions can be formed of the same polymeric material. The grip portion 1970 can define a power button opening 1972 that aligns with the power button contact point 1913. The grip portion 1970 can optionally define an indicator light opening 1974 that aligns with the indicator light 1915 on the top housing 1910. 20A-20D show an assembled toothbrush body 1900 according to one embodiment. In one embodiment, all exterior surfaces of the toothbrush body 1900 meet the YICK-SANG YS300001 texture standard. As shown in FIG. 20A, the head portion 1920 has a thickness T1. In one embodiment, the thickness T1 may be 6.36 mm. The toothbrush body 1900 may have a length L2 and a width W4, as shown in FIG. 20B. In one embodiment, the length L2 may be 219 mm and the width W4 may be 14 mm.

[0030] 21A-21D are perspective views of a toothbrush assembly 2100 at various stages of coupling and decoupling of a removable / replaceable brush head 100 and a toothbrush body 1900, according to one embodiment. The removable brush head 100 can be coupled to the toothbrush body 1900 by applying force to the tuft plate 120 until the removable brush head 100 and toothbrush body 1900 are coupled together. As shown in FIG. 21C, in one embodiment, the distal end of the removable brush head 100 can be first inserted into the toothbrush body 1900 so that the distal protrusions 140 align with the distal channels (not shown), and then force can be applied to the proximal end of the removable brush head 100 so that the knockout button 160 extends into or through the knockout opening 1924 and the remaining protrusions 140 align with and interfit with the remaining channels or locks 1927. The bond between the protrusions 140 and the channels secures the replaceable brush head 100 to the toothbrush body 1900. Forming the protrusions 140 completely on the tuft plate 120 ensures that the replaceable brush head 100 is fully retained within the toothbrush body 1900, even if the tuft plate 120 and tuft plate cover 130 are decoupled. In this embodiment, the tuft plate cover 130 is sandwiched between the toothbrush body 1900 and the tuft plate 1920, reducing the risk of parts coming loose after the replaceable brush head 100 is attached. In one embodiment, the top surface 122 of the tuft plate is flush with the terminal edge of the peripheral wall 1926 when the replaceable brush head 100 is attached to the toothbrush body 1900. FIGS. 22A-22E show top, side, bottom, front, and back views of a toothbrush assembly 2100 according to one embodiment. Figure 23 is a plan view of toothbrush assembly 2100 according to one embodiment, Figure 24 is a cross-sectional view of toothbrush assembly 2100 of Figure 23 taken along line XXIII-XXIII, Figure 25 is a side view of toothbrush assembly 2100 according to one embodiment, and Figure 26 is a cross-sectional view of toothbrush assembly 2100 alone of Figure 25 taken along line XXV-XXV.

[0031] The design of the replaceable brush head 100 also provides for easy and efficient removal from the toothbrush body 1900. A user can apply force directly to the knock-out button 160 in the direction of the tuft plate 120 by pressing (and in alternative embodiments, pulling) the knock-out button to release the brush head 100. This force can release the replaceable brush head 100 from the toothbrush body 1900, allowing it to be removed. This allows for convenient and easy replacement of the replaceable brush head 100. In this manner, the knock-out button 160 functions as a "knock-out" button for easy and straightforward removal by the user, who has the ability to directly contact the underside 163 of the knock-out button 160 to overcome the holding force exerted by the mating protrusions 140 and the locking portions 1927 and remove the brush head 100. In yet another embodiment, the knock-out button 160 can be replaced or supplemented with additional removal structure, such as a spring, disposed between the brush head 100 and the toothbrush body 1900.

[0032] The above description is a description of the present embodiments of the present invention. Various substitutions and modifications can be made to the present invention without departing from the spirit and broader aspects of the invention as defined in the claims. These are to be interpreted in accordance with the principles of patent law, including the doctrine of equivalents. The present disclosure is presented for illustrative purposes and should not be construed as an exhaustive description of all embodiments of the invention or as limiting the scope of the claims to the specific elements shown or described in connection with these embodiments. For example, and without limitation, any individual element of the described invention may be replaced by an alternative element that provides substantially similar functionality or provides appropriate operation. This includes, for example, currently known alternatives, such as those currently known to those skilled in the art, and alternatives that may be developed in the future, such as those that may be recognized by those skilled in the art as alternatives upon development. Furthermore, the disclosed embodiments include multiple features that are described in a coordinated manner and that may cooperatively provide a set of benefits. The invention is not limited to only embodiments that include all of these features or provide all of the described benefits, unless expressly recited in the issued claims. Features from various embodiments may be used in combination with features from other embodiments. Directional terms such as "vertical," "horizontal," "upper," "lower," "front," "rear," "upper," "lower," "inner," "inside," "outer," "outside," "forward," and "rearward" are used to help describe the invention based on the lateral orientation shown in the figures. The use of directional terms should not be construed to limit the invention to any particular orientation. For example, any reference to a claim element in the singular using the articles "a," "an," "the," or "said" should not be construed as limiting the element to the singular.

Claims

1. A replaceable brush head for removably attaching to a toothbrush body, comprising: The replaceable brush head comprises: It has a top surface, a periphery, and a bottom surface. the upper surface defining a plurality of openings and having a plurality of bristle tufts, each of the bristle tufts extending from one of the plurality of openings; at least one protrusion extending from the outer periphery, the at least one protrusion configured to secure the replaceable brush head to the toothbrush body; a knock-out button extending outwardly from the bottom surface for contact in connection with removing the replaceable brush head from the toothbrush body; A replaceable brush head.

2. The replaceable brush head of claim 1 , wherein the plurality of bristle tufts terminate in at least two different planes above a tuft plate.

3. 2. The replaceable brush head of claim 1, wherein the replaceable brush head is formed from a tuft plate and a tuft plate cover, the tuft plate comprising the top surface of the replaceable brush head, the tuft plate cover comprising the bottom surface of the replaceable brush head, at least a portion of the tuft plate and the tuft plate cover combined to form the outer periphery of the replaceable brush head, and the tuft plate and the tuft plate cover joined to each other.

4. 2. The replaceable brush head of claim 1, wherein the knock-out button extends outward from a portion of the bottom surface, the knock-out button having an outer edge spaced inward from the outer periphery of the replaceable brush head.

5. The replaceable brush head of claim 1 , wherein the plurality of openings are located adjacent a distal end of the replaceable brush head and the knockout button is located adjacent a proximal end of the replaceable brush head.

6. 2. The replaceable brush head of claim 1, wherein the outer peripheral edge of the replaceable brush head includes opposing lateral brush head sides, and the at least one protrusion includes a plurality of protrusions spaced apart from one another, at least one of the plurality of protrusions being positioned on the outer peripheral edge of the replaceable brush head at the distal end, and two additional protrusions being positioned on the outer peripheral edge of the replaceable brush head along the opposing lateral brush head sides.

7. The replaceable brush head of claim 1 , wherein the at least two additional protrusions are located on the lateral brush head sides of the replaceable brush head and adjacent a proximal end of the replaceable brush head.

8. The replaceable brush head of claim 1 , wherein the tuft plate defines a tuft plate outer edge, and the protrusion extends from the tuft plate outer edge.

9. The replaceable brush head of claim 1 , wherein the at least two additional protrusions are vertically aligned with the knock-out button.

10. 2. The replaceable brush head of claim 1, wherein the tuft plate and the tuft plate cover each have a stadium-shaped cross-section that defines a brush head cross-sectional area, and the knockout button has a stadium-shaped cross-section that defines a knockout button cross-sectional area, the knockout button cross-sectional area being smaller than the brush head cross-sectional area.

11. 1. A toothbrush assembly comprising: a replaceable brush head including a top surface, an outer periphery, and a bottom surface opposite the top surface, the top surface defining a plurality of openings with at least one bristle tuft extending from each opening, the bottom surface having a knockout button extending outwardly therefrom, and the outer periphery having a plurality of protrusions spaced from one another around the outer periphery; A toothbrush body, a housing having a handle portion, a neck portion, and a head portion, the handle portion having a power button contact point; a housing, the head portion defining a brushhead recess sized to fit the replaceable brushhead, the brushhead recess including a sidewall having a shape corresponding to the shape of the outer periphery of the replaceable brushhead, the brushhead recess having a floor, the head portion defining a knockout opening extending completely through the floor of the brushhead recess, the knockout opening sized and shaped to receive the knockout button of the replaceable brushhead with a portion of the knockout button exposed through the knockout opening for direct contact by a user, the sidewall further defining a plurality of locking portions, at least one locking portion sized and positioned to align with at least one of the protrusions on the replaceable brushhead; a circuit board housed in the handle portion, the circuit board having a power button and a power source, the power button being connected to the power button contact point; a strain gauge housed in the neck portion; a vibration motor housed in one of the handle and the neck; a toothbrush body including a grip portion at least partially surrounding the handle portion, the grip portion defining a power button opening aligned with the power button contact point; A toothbrush assembly comprising:

12. 12. The toothbrush assembly of claim 11, wherein both the outer periphery of the replaceable brush head and the brush head recess are stadium-shaped.

13. the neck portion of the housing includes an indicator light; 12. The toothbrush assembly of claim 11, wherein the grip portion defines an indicator light opening aligned with the indicator light.

14. 12. The toothbrush assembly of claim 11, wherein when a force in the direction of the tuft plate is applied to the knockout button, the replaceable brush head separates from the head portion and the knockout opening exposes the knockout button of the replaceable brush head for direct user contact.

15. 12. The toothbrush assembly of claim 11, wherein the grip portion is overmolded onto the handle portion and the neck housing.

16. the replaceable brush head has a first width and the knock-out button has a second width; 12. The toothbrush assembly of claim 11, wherein the first width is greater than the second width.

17. 12. The toothbrush assembly of claim 11, wherein the plurality of bristle tufts terminate in at least two different planes above the replaceable brush head.

18. 12. The toothbrush assembly of claim 11, wherein the plurality of openings spans approximately 60 percent of the length of the replaceable brush head defined between the proximal end and the distal end, the plurality of openings are positioned adjacent to the distal end, and the knockout button is positioned adjacent to the proximal end.

19. 12. The toothbrush assembly of claim 11, wherein the protrusions include a first protrusion on the outer edge of a tuft plate at the distal end of the replaceable brush head and two protrusions on the outer edge of the tuft plate adjacent the proximal end.

20. 1. A toothbrush assembly comprising: A replaceable brush head, A tuft plate having a stadium-shaped cross section and a curved outer edge, an upper surface defining a plurality of openings, the plurality of openings being located toward a distal end of the upper surface and spaced apart from a proximal end of the upper surface; a distal projection extending from the curved outer edge at a distal end of the tuft plate; a pair of proximal projections each extending from the curved outer edge along a portion of the length of the stadium-shaped cross-section; a tuft plate having a ridge extending from a bottom surface of the tuft plate along an outer edge of the tuft plate; a plurality of tufts connected to the tuft plate through the plurality of openings in the tuft plate; A tufted plate cover, a receiver having a stadium-shaped cross-section and a curved outer edge, the receiver defining a receiving groove along the outer edge of a top surface of the receiver, the receiver defining a first opening at a stadium-shaped proximal end, the receiving groove mating with the raised portion of the tuft plate; a tuft plate cover having a knockout button extending from a portion of the bottom surface of the receptacle to a proximal end of the receptacle, the knockout button defining a cavity, the cavity being aligned with the first opening; a brush head including: A toothbrush body, an upper housing including a handle portion, a neck portion, and a head portion, the handle portion including a power button contact point, the neck portion including an indicator light, and the handle portion having a thickness greater than a thickness of the neck portion; the head portion has a stadium shape, the head portion including an upper surface defining a brush head recess sized to fit over the tuft plate and the receiver, the brush head recess having a floor and a sidewall extending upwardly from the floor, the head portion defining a knockout opening in the floor of the brush head recess, the knockout opening sized to fit over the knockout button; an upper housing, the sidewall of the head portion being curved to receive the replaceable brush head, the sidewall defining three stops, the three stops being sized and positioned to align with the distal projection and a pair of proximal projections on the tuft plate; a bottom housing including a handle portion and a neck portion, the bottom housing defining a component cavity and connectable to the upper housing, the bottom housing defining two openings in a bottom surface of the bottom housing; a circuit board housed in the handle portion of the component cavity, the circuit board including a power button and a power source, the power button being connected to the power button contact points when the top housing is mated to the bottom housing; a strain gauge housed in the neck portion of the part cavity proximal to the handle portion; a vibration motor housed in the neck portion of the part cavity distal to the handle; two ferrous metal pieces coupled to the bottom housing through the two openings in the bottom surface, the two ferrous metal pieces configured to magnetically couple the toothbrush body to a charger; a charge plate received in the handle portion of the component cavity below the circuit board, the charge plate directing an electromagnetic field to a charging coil; a toothbrush body including a grip portion overmolded onto the handle portion and the neck portion of the upper housing, the grip portion defining a power button opening aligned with the power button contact point and an indicator light opening aligned with the indicator light; Equipped with the tuft plate and the tuft plate cover of the replaceable brush head are joined together; the tuft plate and the receiver have a first width, and the knockout button has a second width; The toothbrush assembly, wherein the first width is greater than the second width.

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