Brush head assembly and methods of manufacture

1. A brush head comprising:

a hard neck having a brush neck;

a plurality of bristle tufts, each of which comprises a plurality of bristle strands having a free end and a proximal end, the proximal end comprising a proximal end head portion;

a plurality of retention rings, each configured to receive the proximal end of at least one of the plurality of bristle tufts; and,

an elastomeric matrix bonded to at least a portion of the brush neck, the plurality of retention rings, and the proximal end of the plurality of bristle tufts, wherein the proximal end head portion of each of the plurality of bristle tufts is configured to comprise a space between the proximal end head portion and the respective retention ring, and wherein the elastomeric matrix at least partially encompasses the brush neck, the plurality of retention rings, and the proximal end head portion of each of the plurality of bristle tufts.

2. The brush head of claim 1 , wherein the plurality of retention rings is at least partially interconnected by a network of webbing.

3. The brush head of claim 2 , wherein the network of webbing is at least partially encompassed within the elastomeric matrix.

4. The brush head of claim 1 , wherein the elastomeric matrix completely encompasses the brush neck and the proximal end head portion of each of the plurality of bristle tufts.

5. The brush head of claim 1 , wherein the bristle strands are made of nylon, and further wherein the elastomeric matrix comprises a flexible thermoplastic elastomer.

6. A method for manufacturing a brush head, the method comprising the steps of:

providing a plurality of retention rings and a plurality of bristle tufts, wherein each of the plurality of bristle tufts comprises a plurality of bristle strands having a free end and a proximal end;

inserting at least one of the plurality of bristle tufts into a respective one of the plurality of the retention rings;

applying heat to each of the bristle tuft proximal ends at a temperature and distance sufficient to at least partially melt the bristle tuft proximal end to create a proximal end head portion;

creating a first space between the each of the proximal end head portions and the respective retention ring;

positioning a brush neck in relation to the proximal end head portions, wherein the positioning of the brush neck defines a second space in relation to the proximal end head portions; and

injecting a thermoplastic elastomer to create an elastomeric matrix that at least partially encompasses the brush neck, the plurality of retention rings, and the proximal end head portions, wherein the elastomeric matrix fills the first and second spaces.

7. The method of claim 6 , wherein said creating step comprises applying a force to the free end of each of the plurality of bristle tufts.

8. The method of claim 6 , wherein said creating step comprises using a guide to create the first space.

9. The method of claim 6 , wherein the plurality of retention rings are at least partially interconnected by a network of webbing.

10. The method of claim 6 , wherein the elastomeric matrix completely encompasses the brush neck and the proximal end head portion of each of the plurality of bristle tufts.

11. The method of claim 6 , wherein the bristles are made of nylon, and further wherein the elastomeric matrix is a flexible thermoplastic elastomer.

12. A brush head assembly for a power toothbrush, comprising:

a neck having a brush neck; and

a brush head, the brush head comprising:

a plurality of retention rings each containing a bristle tuft, each bristle tuft comprising a proximal end head portion at a proximal end thereof, the proximal end head portion separated from a respective one of the retention rings by a first space;

the brush neck positioned relative to the plurality of proximal end head portions to create a second space;

an elastomeric matrix at least partially encompassing the plurality of retention rings, the proximal end head portions, and the brush neck, wherein the elastomeric matrix fills the first and second spaces.

13. The brush head assembly of claim 12 , wherein the plurality of retention rings is at least partially interconnected by a network of webbing.

14. The brush head assembly of claim 13 , wherein the network of webbing is at least partially encompassed within the elastomeric matrix.

15. The brush head assembly of claim 12 , wherein the elastomeric matrix completely encompasses the brush neck and the proximal end head portion of each of the plurality of bristle tufts.