Brushhead for a Toothbrush

This invention relates generally to acoustic (power) toothbrushes as well as manual toothbrushes, and more specifically concerns a particular brushhead configuration for use with such toothbrushes.

Conventional toothbrush brushhead configurations tend to focus on the mechanical cleaning of the large, easily accessible buccal (exterior) and lingual (interior, adjacent the tongue) surfaces of the teeth. However, other areas of the dental region, including those teeth at the very rear of the mouth, and the interdental areas between the teeth, are more difficult to clean and are therefore often the site of dental disease. While there are some toothbrush brushhead configurations which are indicated to be effective for interdental regions, little improvement is typically experienced with such brushhead configurations. Hence, one significant issue with existing toothbrush configurations is the lack of effectiveness in difficult-to-reach areas. In some cases, interdental regions are reached beyond the tips of the bristles by the action of the toothbrush itself, such as with the toothbrush shown in U.S. Pat. No. 5,378,153, owned by the assignee of the present invention. However, even with such toothbrushes, it would be desirable to have a brushhead design which could give better coverage and/or penetration for the difficult-to-reach areas.

In addition to the problem of difficult-to-reach areas, many brushhead designs which are quite effective in removing plaque from teeth produce damage to the surrounding oral tissues which the bristles contact in the oral cavity. This is particularly true for power toothbrushes. Accordingly, it would be desirable for a brushhead to have a design which results in an enhanced cleansing effect in the difficult-to-reach areas, including the rear teeth surfaces and the interdental surfaces, but which also minimizes abrasion of the surrounding oral tissue.

Accordingly, the present invention is a brushhead for use with a toothbrush, either an electric powered toothbrush or a manual toothbrush, comprising: a base member for supporting a plurality of separate bristle tufts, wherein each tuft comprises a plurality of individual bristles; and a plurality of bristle tufts mounted in said base portion arranged in an array comprising nine rows and three columns, wherein the columns extend longitudinally of the base member and the rows extend laterally thereof, wherein from a distal end of the base member, first and second rows form a first set of tall bristle tufts, fifth and sixth rows form a second set of tall bristle tufts and eighth and ninth rows form a third set of tall bristle tufts, wherein each set of tall bristle tufts is approximately the same height and wherein the third, fourth and seventh rows are rows of bristle tufts which are relatively shorter than the tall bristle tufts.

FIG. 1 is a perspective view of a power toothbrush with the brushhead configuration of the present invention.

FIG. 2 is a perspective view of the brushhead shown in FIG. 1.

FIG. 3 is a side elevational view of the brushhead of FIG. 2.

FIG. 4 is a top view of the brushhead of FIG. 2.

FIG. 5 is a side elevational view of another embodiment of an improved brushhead.

FIG. 6 is a perspective view of the brushhead of FIG. 5.

FIG. 7 is a top view of the base member portion of the brushhead of FIG. 5.

FIG. 8 is a side elevational view of a modification of the brushhead of FIG. 5.

FIG. 9 is a perspective view of the brushhead of FIG. 8.

FIG. 10 is a cross-sectional view of a portion of the brushhead of FIG. 5.

FIG. 1 shows a power toothbrush generally at 10. The brushhead of the present invention, shown at 12, is positioned at the distal end of a lever arm portion of the power toothbrush. Toothbrush 10 operates with a brushhead frequency and amplitude which disrupts bacteria and removes plaque from the teeth of the user, including in the interdental regions, i.e. the regions between the teeth, and/or the subgingival regions between the gum and the teeth, as well as the hard-to-reach surfaces at the very rear of the mouth.

With the toothbrush shown, a fluid environment is maintained in the mouth so that the acoustic pressure created by movement of the brushhead within the mouth is coupled to the fluid in the interdental and subgingival regions of the teeth, while at the same time the sweeping action of the bristles mechanically removes plaque from the exposed areas of the teeth. While the brushhead 12 of the present invention is shown in the context of a particular power toothbrush, it should be understood that the brushhead could be used with a variety of power toothbrushes, particularly those within a certain frequency range, i.e. 150-400 Hz. A more precise operating frequency for the toothbrush is approximately 260 Hz.

FIGS. 2, 3 and 4 show the brushhead arrangement of the present invention. Brushhead 12 includes a flat base portion 18. In the embodiment shown, base portion 18 is approximately 1.85 inches long by approximately 0.35 inches wide, and approximately 0.15 inches thick, with all dimensions being .+-.10%. At the proximal end of brushhead 12 is a connecting portion 20 which is hollow so it can receive a free end of a lever arm portion of the toothbrush.

The bristles on the brushhead are arranged in a pattern of four columns and eight rows of bristle groups in the embodiment shown with the columns extending longitudinally of the brushhead and the rows extending laterally thereof. In the embodiment shown, each bristle group comprises approximately 38.+-.4 bristle strands, with the bristle strands in the embodiment shown being made from nylon, in one embodiment Dupont Tynex.

Using four columns instead of the conventional three results in a significant increase in bristle density. This increase in density, by increasing the total number of bristle strands, also known as tufts, in the same base area, produces both an improvement in the effect of the brushing and also, surprisingly, reduces abrasion; there is hence a reduction in harm to the oral tissue regions. Thus, the particular density of the individual bristle groups of the toothbrush are a significant aspect of the present invention. In the embodiment shown, the centerlines of the four columns are separated by approximately 0.07 inches and the centerlines of the rows are separated by approximately 0.1 inches.

In the embodiment shown, the brushhead has a particular arrangement of bristle strand or tuft lengths. Adjacent rows 24 and 26 at the distal end 28 of the brushhead are long bristles, having a total length from the base portion 18 of the brushhead of approximately 0.41 inches.+-.0.01 inches. The two adjacent rows 30 and 32 at the proximal end of the brushhead are also long bristles, also having a maximum length of 0.41.+-.0.01 inches.

Rows 36 and 38, which are two adjacent, successive rows of bristle portions inboard of distal rows 24 and 26 are both relatively short, approximately 0.26.+-.0.01 inches long from base portion 18.

The next row of bristle portions inboard of row 38 is a single row 39 having a longest bristle strand length of 0.435 inches.+-.0.02 inches. This row of bristle portions has bristle strands with a slightly smaller diameter than the bristle strands in the other bristle portions, in particular a 0.005 inch diameter as opposed to a 0.006 inch diameter. The combination of a single row with the bristle strands therein (1) being slightly longer than the long bristle strands of rows 24 and 26, (2) located approximately in the middle of the brushhead and (3) having a slightly smaller diameter than the other bristle strands, provides an increase in penetration of the bristles into, and a better fit for, the interdental region. Further, the extra long, small diameter bristles are less harmful to the gum tissue than conventional bristles.

The next row 40 of bristle portions is another short bristle length row, also approximately 0.26.+-.0.01 inches long, similar to rows 36 and 38. Row 40 is located between the longest bristle length row 39 and the two rear proximal end rows 30 and 32. The total spacing between the distal long rows 24 and 26 and the central longest row 39 is designed to accommodate the posterior teeth, i.e. those teeth toward the rear of the mouth, while the total space between the longest row 39 and the proximal end long row 30 is designed to accommodate the anterior teeth, i.e. the teeth toward the front of the mouth. The short rows 36 and 38 brush against the sides of the posterior (molar) teeth, while the short row 40 brushes against the sides of the anterior teeth.

Hence, the overall brushhead configuration shown in FIGS. 2-4 tends to more accurately accommodate the actual arrangement and various sizes of the teeth in the mouth, so as to provide better and more uniform bristle coverage for the teeth and hence better cleansing action. The bristle portions of the embodiment shown as a unit thus better fits the variety of teeth sizes actually present in the human mouth.

The short bristle rows 36, 38 and 40 all have flat tops, although each individual bristle strand is rounded. On the other hand, the long distal end rows 24 and 26, the long proximal end rows 30 and 32, and the intermediate longest row 39 all have angled bristle portions, as shown in FIGS. 2 and 3, even though each individual bristle strand is rounded, as indicated above. The distal end long row pair and the proximal end long row pair angle to a point, while longest row 39 is itself configured to a point. The bristle angle 41 (shown in FIG. 3) is within the range of 56.degree. to 72.degree.. It has been discovered that this range of angle is actually quite significant in improving the effects of the brush. The range of angle improves plaque removal on all the teeth, and especially improves interdental cleaning.

FIGS. 5-10 show additional embodiments of brushhead designs. These brushheads can be used in a power toothbrush or a manual toothbrush. These embodiments provide good interdental cleaning as well as good cleaning along the edges of adjacent teeth and along the gum line. The spacing and configuration of the bristle tufts are optimized to match the interdental spacing of a typical mouth, as described in more detail below. FIGS. 5-7 show one of the additional embodiments. This embodiment includes a brushhead base member 100 similar in configuration and size to the brushhead base member of the previous embodiments. Basically, the base member 100 has approximate dimensions as follows: 0.35 inches wide by 0.15 inches thick and 0.84 inches long from a distal end 102 to the point where the base member begins to decrease in width at 104. These dimensions could be varied.

In the embodiment shown, the bristles are arranged into columns and rows of bristle (filament) groups, referred to as tufts. In the particular embodiment shown, there are three bristle tuft columns 106, 107 and 108, which extend longitudinally of the base member, and nine bristle tuft rows 112-120, which extend laterally of the base member. Rows 112, 113, 116, 117, 119 and 120 are all tall bristle tufts, with the individual bristles having a diameter of 0.006 inches (with a possible range of 0.003-0.007 inches), while rows 114, 115 and 118 are shorter bristle tufts, the individual bristles having a diameter of 0.005 inches (with a possible range of 0.003-0.007 inches). However, bristles in the shorter rows 114, 115 and 118 will have a smaller diameter than the tall bristles so that they have the same "soft" feel and flexibility to the user as the taller bristle rows while still providing good cleansing action for the teeth adjacent the gum line with only minimal, if any, abrasion effect on the gums and/or teeth.

The bristle (filament) tufts in tall bristle rows 112, 113, 116, 117, 119 and 120 are inserted into D-shaped openings 124--124, with the tufts in adjacent rows (112 and 113, 116 and 117, and 119 and 120) having the flat side of the D-shaped openings facing each other, as shown most clearly in FIG. 7. The D-shaped openings are approximately 0.020 inches apart in the embodiment shown. The actual shape of the "D" could be somewhat oblong or oval. The bristle tufts in the shorter bristle rows 114, 115 and 118 are positioned in openings having a circular cross-section, although this shape could be varied including oval or oblong. The bristle tufts are inserted into the D-shaped openings 124--124 around solid staples 128--128. Each staple 128 is a rectangle, approximately 0.08 inches long and 0.06 inches wide and 0.01 inches thick, in one example. Other staple sizes and configurations of staples could be used. The plurality of individual bristles, in accordance with standard practice, are looped around the lower edge of the staple. The total length of each bristle is somewhat more than twice the length of the height of the bristles from the base member. The staple is inserted into the opening, with the loop bristles, to form a bristle tuft. The bristles could also be molded into the base member.

The staples 128--128 are oriented at 90.degree. to the longitudinal axis of the brushhead, i.e. laterally of the brushhead. This is quite different than traditional arrangements, in which the staples are oriented either along the longitudinal axis or at a relatively small angle (e.g. 15.degree.) relative to the longitudinal axis. The orientation of the staple in the embodiment shown permits adjacent tufts in a given column to be positioned closer to each other than otherwise, which provides advantages in brushing. The adjacent bristle tufts in any column for rows 112, 113 and 116, 117 and 119, 120 are referred to as bristle tuft pairs.

Also, the flat side of each D-shaped opening 124 is tapered slightly outwardly from the bottom to the top thereof, so that the individual bristles near the flat side of the D-shaped opening in each bristle pair tend to lean toward each other and to contact and intermingle slightly at the very top thereof. More bristles are present in a given area with the use of the staple orientation and the D-shaped opening arrangement. The angled shape of the D-shaped opening is referred to as a "draft" and is shown in FIG. 10 at 129. This is in addition to any small angle (e.g. 1.degree.) which may be present around the entire opening, such as to facilitate manufacture of the base member. This results in a denser brush at the very tops of the bristle pairs, which in turn results in more bristles in the peak area of the bristle pairs and more bristles actually coming into contact with the teeth and the interdental area. This is quite effective in producing a good cleansing effect on and between the teeth. The additional draft angle at the flat side of the D-shaped opening is quite small, in the range of 1-10.degree., preferably approximately 1-2.degree.. The preferred range is applicable when the spacing between the D-shaped openings is approximately 0.020 inches.

The result of this arrangement is shown most clearly in FIG. 5, in which the bristles near the flat side of the D-shaped openings of each bristle pair (rows 112, 113 and 116, 117 and 119, 120 for each column) lean toward each other slightly, resulting in contact and a slight intermingling at the top of each bristle pairs. More specifically, with a 0.degree. draft, there will typically be a slight opening at the top of the bristle pairs. With a 1.degree. draft, there will be an intermingling part of the way down the bristles. A 2.degree. draft will result in an intermingling beginning at slightly less than half the height of the bristles, FIG. 5 shows a 1.degree. draft. Again, this is with a D-shaped opening spacing of 0.020 inches.

The spacing of the bristles is shown in FIG. 5. The distance between the centerline between tall bristle rows 112 and 113 and tall bristle rows 116 and 117 is, in the embodiment shown, within a range of 0.350-0.45 inches, preferably approximately 0.388 inches, while the distance between the centerline between tall bristle rows 116 and 117 and tall bristle rows 119 and 120 is within a range of 0.20-0.30 inches, preferably approximately 0.287 inches. For the preferred spacing, the midbevel distance 123 is approximately 0.46 inches, while midbevel distance 125 is approximately 0.36 inches. The bevel configuration of the tops of the bristles is discussed in more detail below. The short bristle rows, i.e. rows 114, 115 and 118, are spaced equally between the adjacent tall bristle rows.

The spacing of the rows and the arrangement of the tall bristle tufts are optimized to match the interdental distances of typical mouth anatomy. The 0.388 inch distance is designed to accommodate the interdental spacing of teeth toward the rear of the mouth (the molars) and the upper incisors. The 0.287 inch distance is designed for the spacing of teeth toward the front of the mouth (excluding the upper incisors).

The spacing is particularly advantageous when the toothbrush moves in an up/down manner against the teeth (as opposed to an in/out, i.e. back and forth manner). The up/down manner is preferred by a majority of dentists.

The tall bristle tufts are designed to produce effective cleansing action between the teeth and along the vertical edges of the teeth adjacent the interdental region. The shorter bristle tufts are of a length which results in a gentle cleaning action of the exposed surfaces of the teeth and the gum line.

FIGS. 5 and 6 show the particular configuration of the tops of the bristles, which is important for effective cleansing action. The configuration of the bristle tops has several characteristics. The first characteristic is that the tops of the bristles in the tall bristle pairs are trimmed at an angle to a point, 60.degree..+-.5.degree. from the horizontal. Hence, the included angle of the bristles in the tall bristle (filament) pairs is also 60.degree.. The angle from the horizontal could be in the range of 40.degree.-65.degree.. Further, the outer side surface of the taller bristle tufts (rows 112, 113, 116, 117, 119 and 120) are beveled inwardly at 131 at the top portion thereof. In the embodiment shown, this angle is 37.degree..+-.5.degree., but could be within a range of 20.degree.-50.degree.. This beveled arrangement is shown most clearly in FIG. 6. This particular structure of the tall bristle pairs promotes effective cleansing action in the interdental spaces between the teeth and the vertical edges of the teeth, where adjacent teeth come close to or actually contact each other.

In each column of shorter rows 114 and 115, the tops of the bristle tufts are trimmed downwardly toward each other at an angle of 60.degree. from the horizontal, for a total included angle between bristle tufts in rows 114 and 115 in each column of 120.degree..+-.5.degree., as shown most clearly in FIG. 5. This angle could, however, be in a range of 60.degree.-134.degree.. In addition, the outside edge of bristle tufts in columns 106 and 108, rows 114 and 115 are beveled inwardly at 132 at the top portion of the bristle tuft. In the embodiment shown, the angle is 30.degree..+-.5.degree.. This angle can, however, be within a range of 20.degree.-50.degree.. Beveled portion 132 of each bristle tuft intersects the angled portion at the top thereof, producing a complex top surface for the tufts in columns 106 and 108, rows 114 and 115.

In row 118, the top surface of the bristle tuft in the middle column (column 107) is flat, while the bristle tufts in columns 106 and 108 are both beveled inwardly at 134 at the outside edge thereof, at the top portion of the bristle tufts. In the embodiment shown, the angle is 30.degree..+-.5.degree., although this angle can be within a range of 20.degree.-50.degree..

The beveled portion at the outside edges of the tall bristle tufts in columns 106 and 108 is particularly effective in cleaning action when the brushhead is held at an angle with the range of 20.degree.-40.degree. during brushing. The midbevel distance also promotes effective cleaning.

In the embodiment shown, the peak of each of the tall bristle pairs (rows 112, 113 and 116, 117 and 119, 120) is 0.43 inches. The height of the bristle tufts in rows 114 and 115 is approximately 0.34 inches adjacent the tall bristle tufts in rows 113 and 116, respectively, while the height of those tufts at their opposing edges is approximately 0.296 inches. This is due to the angled top surface of those bristle tufts. The height of the entire bristle tuft in row 118, column 107 is 0.32 inches. In row 118 columns 106 and 108, beveled portions 134 of those tufts extend downwardly from that height to the outside edge surface of the bristle tufts. The peak of the tall bristles is within a range of 0.39-0.45 inches, with 0.43 inches preferred, while the peak of the shorter bristles is 0.26-0.36 inches, with 0.32 preferred as an average peak value.

The above-described particular brush configuration has been found to provide significantly improved plaque-removing capability, including surprising improvement even over the improved brush designs of FIGS. 1-4. This is the result of the combination of several of the above specific features. The tall pairs of bristles provide good interdental and edge surface cleansing, while the shorter bristles provide good cleansing along the surfaces of the teeth as well as along the gum line, without producing abrasion of the teeth. Further, this particular configuration of brushhead may be used on manual toothbrushes, as well as power toothbrushes.

FIGS. 8 and 9 show a similar embodiment with similar brush configuration and arrangement to that shown in FIGS. 5-7, with the exception that the very tops of the tall bristle pairs, i.e. those bristle pairs in rows 112, 113, 116, 117, 119 and 120 are rounded or flattened at the top 140 instead of coming to a point (i.e. a narrow line across the brushhead). The width of the flat section is in the embodiment shown approximately 0.02 inches, although this could be varied somewhat.

Hence, a new brushhead configuration for a power or manual toothbrush has been described which incorporates several specific improvements, resulting in improved performance and cleansing, while decreasing abrasion.

Although a preferred embodiment of the invention has been disclosed herein for illustration, it should be understood that various changes, modifications and substitutions may be incorporated in such embodiment without departing from the spirit of the invention, which is defined by the claims as follows.