Bristled sheet and method thereof

Abstract

In one implementation, a bristled sheet is formed by securing a flexible sheet to a fixture, the flexible sheet having a plurality of tuft holes extending through the flexible sheet. A first plurality of bristles are inserted through a first hole of the plurality of tuft holes. Base portions of bristles of the first plurality of bristles are melted to form a melt matte. The melt matte is joined to one side of the sheet. The flexible sheet may be made from a metalized polymer film or a fluorine compound.

Description

BRISTLED SHEET AND METHOD THEREOFCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to United States Provisional Patent Application Serial No. 63 / 608,415, filed December 11, 2023, and United States Provisional Patent Application Serial No. 63 / 608,403, filed December 11, 2023, the entireties of each are incorporated herein by reference.BACKGROUND

[0002] Oral care, particularly care of an individual’s teeth and gums, are of utmost importance to ensure overall health. However, typical oral care routines are time consuming. For instance, most dentists recommend brushing teeth for a minimum of two minutes. Those individuals who may have dexterity problems or may not wish to spend the required time brushing may suffer from poor oral health. Thus, a need exists for oral care implements which remedy the deficiencies in existing products.BRIEF SUMMARY

[0003] The present invention is a method of forming a bristled sheet for an oral care implement. First a flexible sheet is secured to a fixture. The flexible sheet has a first side, a second side, and a plurality of tuft holes extending from the first side to the second side. Next, a first plurality of bristles are inserted through a first hole of the plurality of tuft holes. Subsequently, base portions of bristles of the first plurality of bristles are melted to form a first bristle tuft having a melt matte, the melt matte joined to the second side of the sheet. The flexible sheet is one of a metalized polymer film or a fluorine compound.

[0004] In another aspect, the invention may be a method of forming a bristled sheet for an oral care implement. First, a bristle bundle is inserted within a bristle container of a fixture. Second, a flexible sheet is secured to a lid of the fixture, the flexible sheet compressed between the lid and the bristle container of the fixture. Third, a plurality of protuberances of a bristle pusher plate of the fixture are inserted through a plurality of apertures formed in a floor of the bristle pusher plate, the plurality of protuberances causing a first plurality of bristles to pass through a first hole formedin the flexible sheet. Fourth, the lid of the fixture is removed while retaining the flexible sheet against the bristle container. Fifth, base portions of the first plurality of bristles arc melted so that the base portions join with a second side of the flexible sheet. Sixth, the flexible sheet and the first plurality of bristles are removed from the bristle container.

[0005] In a further aspect, the invention may be a bristled sheet for an oral care implement. The bristled sheet may have a flexible sheet, a first bristle tuft, and a melt matte. The flexible sheet is formed of a metalized polymer film or a fluorine compound. The first bristle tuft is formed of 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 melt matte is formed of base portions of the first plurality of bristles, the melt matte bonded to a second side of the flexible sheet.

[0006] In another aspect, the invention may be an oral care implement having a handle and a head. The handle has a grasping portion, a first neck portion, and a second neck portion. The head is coupled 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 facial wall and a plurality of fingers extending from the facial wall, each of the plurality of fingers having a bend, a plurality of upper facial wall bristle tufts extending from an interior surface of the facial wall and a first plurality of finger bristle tufts extending from a first finger of the plurality of fingers, the first head portion coupled to the first neck portion. The second head portion has a base portion having a facial wall and a plurality of fingers extending from the facial wall, each of the plurality of fingers having a bend, a plurality of lower facial wall bristle tufts extending from an interior surface of the facial wall and a first plurality of finger bristle tufts extending from a first finger of the plurality of fingers, the second head portion coupled to the second neck portion. The base portions of the first portion and the second portion are each formed from a hard plastic material.

[0007] In a further aspect, the invention may be a method of forming an oral care implement. First, a base portion of a first head portion is formed, the base portion having a facial wall and a plurality of fingers. Second, a plurality of bristle filaments are inserted into tuft holes in the facial wall and the plurality of fingers to form a plurality of bristle tufts, the plurality of bristle tufts having a plurality of facial wall bristle tufts and a plurality of finger bristle tufts, each tuft of the plurality of facial wall bristle tufts and the plurality of finger bristle tufts extending along a tuft axis, the tuft axes of the plurality of facial wall bristle tufts being substantially parallel to the tuft axes ofthe 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 bristle tuft of the plurality of finger bristle tufts is no longer parallel to the tuft axes of the plurality of facial wall bristle tufts. Fourth, the first head portion is coupled to a first neck portion of a handle.

[0008] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment 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

[0009] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0010] FIG. 1 is a perspective view of a flexible sheet, a bristle bundle, and a fixture in accordance with an embodiment of the present invention;

[0011] FIG. 2 is a lower real’ perspective view of the flexible sheet, bristle bundle, and fixture of FIG. 1;

[0012] FIG. 3 is an exploded perspective view of the flexible sheet, bristle bundle, and fixture of FIG. 2;

[0013] FIG. 4 is a cross-sectional view of the flexible sheet, bristle bundle, and fixture taken along line IV-IV of FIG. 1;

[0014] FIG. 5 is a cross-sectional view of the fixture illustrating a first step of manufacturing a bristled sheet taken along line IV-IV of FIG. 1;

[0015] FIG. 6 is a cross-sectional view of the fixture, the flexible sheet, and the bristle bundle illustrating a second step of manufacturing the bristled sheet taken along line IV-IV of FIG. 1;

[0016] FIG. 7 is a cross-sectional view of the fixture, the flexible sheet, and the bristle bundle illustrating a third step of manufacturing the bristled sheet taken along line IV-IV of FIG. 1;

[0017] FIG. 8 is a cross-sectional view of the fixture, the flexible sheet, and the bristle bundle illustrating a fourth step of manufacturing the bristled sheet taken along line IV-IV of FIG. 1;

[0018] FIG. 9 is a cross-sectional view of the fixture, the flexible sheet, and the bristle bundle illustrating a fifth step of manufacturing the bristled sheet taken along line IV-IV of FIG. 1;

[0019] FIG. 10 is a cross-sectional view of the bristled sheet subsequent to the fifth step of manufacturing taken along line IV-IV of FIG. 1;

[0020] FIG. 11 is a perspective view of an embodiment of an oral care implement;

[0021] FIG. 12 is a lower perspective view of the oral care implement of FIG. 11;

[0022] FIG. 13 is an exploded view of the oral care implement of FIG. 11 ;

[0023] FIG. 14 is a perspective view a base portion of a head portion of the oral care implement of FIG. 11 in a flat state;

[0024] FIG. 15 is a perspective view a head portion of the oral care implement of FIG. 11 in a flat state; and

[0025] FIG. 16 is a perspective view a head portion of the oral care implement of FIG. 11 in a bent state.DETAILED DESCRIPTION

[0026] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0027] The description of illustrative embodiments of principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms arc for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limitingcombination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

[0028] Referring to Figs. 1-4, a fixture 100, a flexible sheet 200, and a bristle bundle 250 are illustrated in accordance with an embodiment of the present invention. The fixture 100, in combination with the flexible sheet 200 and the bristle bundle 250, are used to form a bristled sheet which may be used in an oral care implement. The oral care implement may be a manual or a powered device for cleaning a user’s teeth and other oral tissues. If the oral care implement is powered, it may be powered using a motor and vibration generating device, a motor which directly oscillates tooth cleaning elements, or a pneumatic system incorporating the bristled sheet as a portion of a pressure chamber which may be selectively pressurized and depressurized to move the tooth cleaning elements of the bristled sheet.

[0029] The bristle bundle 250 is a grouping of tooth cleaning elements, such as conventional filament bristles 254, which are cut to all be an equal length and bound within an outer wrapping 252. The tooth cleaning elements may be bristles 254 and may have a range of diameters and cross-sectional profiles. Preferably, the bristles 254 may have a diameter of 0.003” to 0.005” but other diameters are contemplated. The bristles 254 may also be square, rectangular, diamond, polygonal, or any other cross-sectional shape as desired. The bristles 254 may be formed of polybutylene terephthalate (“PBT”), Nylon, or other materials which are commonly used for bristles used in oral care applications. The tooth cleaning elements may be extruded bristles, or may be molded or formed via other means.

[0030] The flexible sheet 200 may be formed of a plastic or metalized polymer film or other sheet material. The flexible sheet 200 is preferably flexible enough to permit elastic deformation of the flexible sheet 200 with minimal applied force. Preferred materials include fluorine compounds such as polytetrafluoroethylene (also known as “Teflon” or “PTFE”) and metalized compounds such as metalized polyester ethylene terephthalate (also known as “Mylar” or “metalized PET”). For instance, the flexible sheet 200 may be PTFE of 0.010” thickness or metalized PET of 0.002” thickness. The flexible sheet 200 may be of greater or lesser thickness and may be formed of a wide range of alternate materials. However, a polymer such as a fluorine compound or a metalized polymer is preferred over other alternatives. Any thickness may be used so long as the sheet is sufficiently elastically deformable so as to allow a user to deform the flexible sheet 200 with finger pressure.

[0031] The flexible sheet 200 is preferably formed of a material having a melting temperature which is greater than a melting temperature of the bristles 254. For instance, PBT bristles have a melting temperature of approximately 433°F, while PTFE has a melting temperature of approximately 620°F. In other implementations, the metalized film of metalized PET or another metalized polymer material is used to insulate the PET or other polymer material from excess heat. In these implementations, the PET or other polymer is protected from heating during processing by the metalized film layer.

[0032] The flexible sheet 200 has a first side 202 and a second side 204. A plurality of tuft holes 206 extend through the flexible sheet 200 from the first side 202 to the second side 204. The tuft holes 206 may have a circular, rectangular, square, polygonal, elliptical, or other profile. Optionally, the second side 204 may be etched to promote adhesion of the bristle material as will be discussed in greater detail below. The metalized layer may be located on the second side 204 where a metalized material is used to form the flexible sheet 200.

[0033] The fixture 100 is formed of a lid 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 floor 134 with a plurality of apertures 136 extending through the floor 134. Optionally, the apertures 136 may be cylindrical holes, or the apertures 136 may have another cross-sectional profile such as a rectangular, square, polygonal, or elliptical profile. The bristle container 130 has a top surface 138 opposite the floor 134, the cavity 132 extending from the top surface 138 to the floor 134 and defined by a plurality of walls 140. A pocket 142 is formed into a bottom surface 144 of the bristle container 130, the pocket 142 configured to receive the bristle pusher plate 150 as will be discussed further below.

[0034] The lid 110 has a lower surface 112 which receives the flexible sheet 200, an upper surface 114 opposite the lower surface 112, and a plurality of retaining features 118 extending from the lower surface 112. A plurality of apertures 116 extend through the lid 110 from the lower surface 112 to the upper surface 114. The apertures 116 may be cylindrical holes, or may have another cross-sectional profile such as a rectangular, square, polygonal, or elliptical profile.

[0035] The bristle pusher plate 150 has a top surface 152 and a bottom surface 154. A plurality of protuberances 156 extend from the top surface 152. An access opening 157 is also formed through the bristle pusher plate 150 to permit removal of the bristle pusher plate 150 from thebristle container 130. The protuberances 156 may have a cylindrical profile, or may have another cross-sectional profile such as a rectangular, square, polygonal, or elliptical profile.

[0036] The bristle pusher plate 150 is configured to be inserted into the pocket 142 of the bristle container 130. The protuberances 156 are arranged such that they are aligned with the apertures 136 of the bristle container 130. The protuberances 156 are also aligned with the apertures 116 of the lid 110 and the tuft holes 206 of the flexible sheet 200.

[0037] When the bristle pusher plate 150 is inserted into the pocket 142, the protuberances 156 extend through the apertures 136. The protuberances 156 have a diameter di, while the apertures 136 have a diameter d . The apertures 116 also have a diameter da. The tuft holes 206 have a diameter d4. When the apertures 136, 116 and the tuft holes 206 are not circular, the largest dimension equates to the respective diameters di, da, d4. The diameter di of the protuberances 156 is less than the diameters do, da, d4 of the apertures 136, 116 and the tuft holes 206. The diameters di, da, d may be equal or the diameters da, da may be greater than the diameter cU. In particular, the diameter di is sized to be less than the diameter d4 of the tuft holes 206 to aid in inserting the bristles 254 through the tuft holes 206.

[0038] As best seen in Fig. 4, the insertion of the bristle pusher plate 150 into the pocket 142 causes bristles 254 to be inserted through the tuft holes 206 and the apertures 116 of the lid 110. The flexible sheet 200 is captured between the lid 110 and the top surface 138 of the bristle container 130, the retaining features 118 ensuring alignment of the flexible sheet 200 with the lid 110 and the lid 110 with the bristle container 130. The first side 202 faces away from the lid 110 while the second side 204 is in direct surface contact with the lower surface 112 of the lid 110. The protuberances 156 or an outer edge 158 can be used to align the bristle pusher plate 150 with the apertures 136 and the tuft holes 206 of the flexible sheet 200.

[0039] Turning to Figs. 5-10, a method of manufacturing a bristled sheet is illustrated. In Fig. 5, the fixture 100 is provided, the fixture 100 including the lid 110, the bristle container 130, and the bristle pusher plate 150. The cavity 132 of the bristle container 130 is empty in the first step illustrated by Fig. 5. Turning to a second step illustrated in Fig. 6, the flexible sheet 200 is secured to the lid 110 of the fixture 100. The bristle bundle 250 is also inserted into the cavity 132, the bristles 254 remaining within the wrapping 252. The bristle bundle 250 rests against the floor 134 of the bristle container 130. In the second step, the bristle pusher plate 150 is separate from the bristle container 130 so that no bristles 254 are displaced by the protuberances 156.

[0040] A third step of manufacturing the bristled sheet is illustrated in Fig. 7, the flexible sheet 200 is secured between the lid 110 and the top surface 138 of the bristle container 130. The top surface 138 is in contact with the first side 202 of the flexible sheet 200 and the lower surface 112 of the lid 110 is in contact with the second side 204 of the flexible sheet 200. The bristle pusher plate 150 remains separate from the bristle container 130 so that no bristles 254 are displaced by the protuberances 156.

[0041] A fourth step of manufacturing the bristled sheet is illustrated in Fig. 8, where the bristle pusher plate 150 is inserted into the pocket 142. The protuberances 156 are inserted through the apertures 136 until the top surface 152 of the bristle pusher plate 150 is in contact with the floor 134 of the bristle container 130. The protuberances 156 cause base portions 256 of the bristles 254 to be inserted through the tuft holes 206 and through the apertures 116 of the lid 110. Optionally, the bristles 254 may not be inserted all the way through the lid 110, but may instead extend only a portion of the distance from the lower surface 112 to the upper surface 114.

[0042] Turning to Fig. 9, a fifth step of manufacturing the bristled sheet is illustrated. In the fifth step, the lid 110 is removed, leaving the bristles 254 extending through the tuft 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 bristle container 130.

[0043] A heat source 270 is applied to the base portions 256 of the bristles 254, causing the base portions 256 to melt into a melt matte 260, the melt matte 260 comprising base portions 254 of the bristles 254 extending through each of the tuft holes 206. Optionally, pressure may be applied by the heat source 270 or another tool. Thus, the melt matte 260 is formed of the base portions 256 of a plurality of the tuft holes 206. Optionally, the melt matte 260 may be pressed flat to aid in bonding the melt matte 260 to the flexible sheet 200.

[0044] In other implementations, individual melt mattes 260 may be formed, each melt matte 260 corresponding to a single one of the tuft holes 206. In yet other implementations, a plurality of melt mattes 260 may be formed, with each melt matte 260 corresponding to the base portions 254 extending through a plurality of tuft holes 206 but fewer than all the of the tuft holes 206. The melt matte 260 is bonded or joined to the second side 204, the coupling of the melt matte 260 to the second side of the flexible sheet 200 aiding in bristle retention of the bristles 254.

[0045] A bristled sheet 300 is illustrated in Fig. 10, the bristled sheet 300 being withdrawn from the bristle container 130. A plurality of bristle tufts 258 are formed by the bristles 254 which havebeen inserted through the tuft holes 206, with the base portions 256 subsequently melted to form the melt matte 260. The remaining bristles 254 remain within the bristle bundle 250, the bristle bundle 250 remaining within the cavity 132 of the bristle container 130. Each of the bristles 254 of the plurality of bristle tufts 258 have a free portion 259, the free portions 259 extending from the first side 202 of the flexible sheet 200. The bristled sheets 300 can be coupled to a head of an oral care implement and can be used as a portion of a cavity of a chamber, allowing selective inflation and deflation to move the bristles 254 of the plurality of bristle tufts 258.

[0046] Turning to Figs. 11-13, an embodiment of an oral care implement 1000 is illustrated with the tooth cleaning elements omitted. The oral care implement 1000 may be formed in a mouthguard shape and may be adapted for cleaning a user’s teeth. In particular, the oral care implement 1000 may have first and second head portions 1100, the head portions 1100 configured to correspond to a portion of a user’s dental arch. Preferably, the head portions 1100 are symmetrical and correspond to approximately half a user’ s dental arch to permit brushing of one side of a user’s mouth and subsequently brushing an opposite side of the user’s mouth.

[0047] The oral care implement comprises a handle 1010 and a head 1060. The handle has a grasping portion 1012, a first neck portion 1014, and a second neck portion 1016. A longitudinal axis A-A extends along the grasping portion 1012. The first and second neck portions 1014, 1016 diverge from the longitudinal axis A-A, and each of the first and second neck portions 1014, 1016 terminating in a connector 1015. The connectors 1015 of the first and second neck portions 1014, 1016 engage corresponding connectors 1065 of the first and second head portions 1100. The head portions 1100 are spaced and isolated from one another, only connected via the handle 1010.

[0048] The head portions 1100 each have a base portion 1102, the base portion 1102 having a facial wall 1104 and a plurality of fingers 1106. The fingers 1106 and the facial wall 1104 have a plurality of bends 1108. The bends 1108 of the facial wall 1104 allow the facial wall 1104 to conform to the curvature of the user’s dental arch, generally following an arcuate profile P-P. The bends 1108 in the facial wall 1104 are arranged perpendicular to the arcuate profile P-P. The facial wall 1104 and the fingers 1106 also have a plurality of tuft blocks 1110, the tuft blocks 1110 each having a plurality of tuft holes 1112. The tuft holes 1112 may extend through the tuft blocks 1110, or may be blind holes that only extend into the tuft blocks 1110 without being exposed on the opposite side. One of the tuft blocks 1110 incorporates the connector 1065.

[0049] A portion of the bends 1 108 in the fingers 1106 may be substantially aligned with the arcuate profile P-P, separating the facial wall 1104 from the fingers 1106. Additional bends 1108 in the fingers 1106 may allow the fingers 1106 to bend back to face the facial wall 1104. This allows simultaneous cleaning of facial, lingual, and bite surfaces of the user’s teeth. Thus, the facial wall 1104 has an interior surface 1114, and each of the fingers 1106 has an interior surface 1116, the interior surfaces 1114, 1116 facing the user’ s teeth during use. In some implementations, some of the tuft blocks 1110 may not have tuft holes 1112 if they do not require cleaning elements to achieve cleaning of the user’s teeth. For example, the tuft blocks 1110 of the fingers 1106 adjacent the connectors 1065 do not all have tuft holes 1112.

[0050] The base portion 1102 of the head portion 1100 and the handle 1010 are preferably formed of a hard plastic material such as nylon, polystyrene, ABS, or another hard plastic. These materials offer advantages in ease of formation, low cost, rigidity, and durability as compared with wood, metal, rubber, or other elastomeric materials.

[0051] Fig. 14 illustrates a base portion 1102 of the head portion 1100 of the head 1060 of the oral care implement 1000. The head portion 1100 is in a first state, the first state being a flat state. The base portion 1102, in the first state, is free of tufts and is substantially planar. 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. Fig. 15 illustrates the head portion 1100 in a second state, with a plurality of bristles 254 extending from the interior surfaces 1114, 1116 of the facial wall 1104 and the fingers 1106. Thus, the head portion 1100 remains in a flat state 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 of the tuft holes 1112.

[0052] Fig. 16 illustrates the head portion 1100 in a third state, which is a bent state. In the third state, the head portion 1100 is bent at the bends 1108. The head portion 1100 is formed such that the fingers 1106 are curved, with bristle tufts 1256 of different tuft blocks 1110 arranged at different angles, such that the bristle tufts 1256 of different tuft blocks 1110 do not extend along parallel axes. The facial wall 1104 is bent at the bends 1108 to allow the facial wall 1104 to generally follow the arcuate path P-P. The bending may be done by applying heat to the bends 1108 or the bends 1108 may be plastically deformed using no heat. In yet other implementations, the base portion 1108 may be molded in the bent state, then elastically deformed into the flat state to allow tufting, and later allowed to return to the bent state by removing applied forces.

[0053] This method of formation of the head portions 1100 allows installation of the bristle tufts 1256 while the base portion 1102 is in a flat state, then subsequently bending the base portion 1102 to form a completed head portion 1100. The head portions 1100 can later be coupled to the connectors 1115 of the neck portions 1014, 1016 of the handle 1010 to complete the oral care implement 1000.

[0054] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by reference in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

[0055] While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention. Thus, the spirit and scope of the invention should be construed broadly as set forth in the appended claims.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A method of forming a bristled sheet for an oral care implement comprising: a) securing a flexible sheet to a fixture, the flexible sheet comprising a first side, a second side, and a plurality of tuft holes extending from the first side to the second side; b) inserting a first plurality of bristles through a first hole of the plurality of tuft holes; c) melting base portions of bristles of the first plurality of bristles to form a first bristle tuft comprising a melt matte, the melt matte joined to the second side of the sheet; wherein the flexible sheet comprises one of a metalized polymer film or a fluorine compound.

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

3. The method of claim 1 or claim 2 wherein step a) further comprises step a-2), step a-2) comprising positioning the flexible sheet within a lid of the fixture and securing the lid to a bristle container of the fixture.

4. The method of claim 3 wherein the lid comprises a plurality of apertures aligned with the plurality of tuft holes.

5. The method of claim 4 wherein, in step b), the base portions of the bristles of the first plurality of bristles extend into the plurality of apertures of the lid.

6. The method of any one of claims 1 to 5 further comprising step c-1), step c-1) comprising removing a lid of the fixture.

7. The method of any one of claims 1 to 6 wherein step b) further comprises step b-1), step b-1) comprising securing a bristle pusher plate to the bristle container, causing the first plurality of bristles to be inserted through the first hole of the plurality of tuft holes.

8. The method of claim 7 wherein the bristle pusher plate comprises a top surface and a plurality of protuberances, each of the plurality of protuberances aligned with a corresponding one of the plurality of tuft holes.

9. The method of claim 8 wherein a first one of the plurality of protuberances has a protuberance diameter and the first hole of the plurality of tuft holes has a hole diameter, the protuberance diameter less than the hole diameter.

10. The method of any one of claims 7 to 9 wherein the bristle container comprises a floor, a plurality of apertures extending through the floor and the plurality of protuberances of the bristle pusher plate extending through the plurality of apertures.

11. The method of any one of claims 1 to 10 wherein in step c), the melt matte is formed of base portions of bristles of each of the pluralities of bristles.

12. The method of any one of claims 1 to 11 wherein, prior to step a), the flexible sheet is etched on the second side, the melt matte formed in step c) adhered to the second side of the flexible sheet.

13. The method of any one of claims 1 to 12 wherein, in step a), the flexible sheet comprises a metalized layer and a polymer layer, the metalized layer forming the second side of the flexible sheet and the polymer layer forming the first side of the flexible sheet.

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

15. A method of forming a bristled sheet for an oral care implement comprising: a) inserting a bristle bundle within a bristle container of a fixture; b) securing a flexible sheet to a lid of the fixture and compressing the flexible sheet between the lid and the bristle container of the fixture;c) inserting a plurality of protuberances of a bristle pusher plate of the fixture through a plurality of apertures formed in a floor of the bristle pusher plate, the plurality of protuberances causing a first plurality of bristles to pass through a first hole formed in the flexible sheet; d) removing the lid of the fixture while retaining the flexible sheet against the bristle container; e) melting base portions of the first plurality of bristles so that the base portions join with a second side of the flexible sheet; and f) removing 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 protuberances further causes a second plurality of bristles to pass through a second hole formed in the flexible sheet.

17. The method of claim 16 wherein the melt matte comprises base portions of the second plurality of bristles and the base portions of the first plurality of bristles.

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

19. A bristled sheet for an oral care implement comprising: a flexible sheet formed of a metalized polymer film or a fluorine compound; a first bristle tuft formed of 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; a melt matte formed of base portions of the first plurality of bristles, the melt matte bonded to a second side of the flexible sheet.

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

21. An oral care implement comprising: a handle comprising a grasping portion, a first neck portion, and second neck portion; and a head coupled to the handle, the head comprising:a first head portion comprising a base portion comprising a facial wall and a plurality of fingers extending from the facial wall, each of the plurality of fingers comprising a bend, a plurality of upper facial wall bristle tufts extending from an interior surface of the facial wall and a first plurality of finger bristle tufts extending from a first finger of the plurality of fingers, the first head portion coupled to the first neck portion; and a second head portion comprising a base portion comprising a facial wall and a plurality of fingers extending from the facial wall, each of the plurality of fingers comprising a bend, a plurality of lower facial wall bristle tufts extending from an interior surface of the facial wall and a first plurality of finger bristle tufts extending from a first finger of the plurality of fingers, the second head portion coupled to the second neck portion; wherein the base portions of the first portion and the second portion are each formed from a hard plastic material.

22. The oral care implement of claim 21 wherein the first plurality of finger bristle tufts of the first head portion extends at an angle to the plurality of upper facial wall bristle tufts of the first head portion.

23. The oral care implement of claim 21 or claim 22 wherein the facial wall of the first head portion comprises a bend.

24. The oral care implement of any one of claims 21 to 23 wherein the first and second head portions are detachably coupled from the handle.

25. The oral care implement of any one of claims 21 to 24 wherein the first and second neck portions diverge.

26. A method of forming an oral care implement comprising: a) forming a base portion of a first head portion having a facial wall and a plurality of fingers;b) inserting a plurality of bristle filaments into tuft holes in the facial wall and the plurality of fingers to form a plurality of bristle tufts, the plurality of bristle tufts comprising a plurality of facial wall bristle tufts and a plurality of finger bristle tufts, each tuft of the plurality of facial wall bristle tufts and the plurality of finger bristle tufts extending along a tuft axis, the tuft axes of the plurality of facial wall bristle tufts being substantially parallel to the tuft axes 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 tuft axis of at least one bristle tuft of the plurality of finger bristle tufts is no longer parallel to the tuft axes of the plurality of facial wall bristle tufts; and d) coupling the first head portion to a first neck portion of a handle.

27. The method of claim 26 wherein the base portion of the first head portion is formed of a hard 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 a facial wall 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 tuft holes in the facial wall and the plurality of fingers of the base portion of the second head portion.

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

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