Brush head manufacturing methods

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

• providing a plurality of nylon bristle tufts, each comprising a proximal end;
• applying heat to each bristle tuft proximal end at a temperature sufficient to at least partially melt the bristle tuft proximal end and create a proximal head portion;
• providing a polypropylene bristle tuft retention ring having an exterior wall around the proximal end of each respective bristle tuft adjacent to the proximal head portion, wherein the exterior wall is polygonal and includes a straight taper;
• positioning a platen portion of a neck of the brush head in relation to the proximal head portions, wherein the positioning of the platen portion of the neck defines a space in relation to the proximal head portions for injection of a thermoplastic elastomer;
• and
• injecting the thermoplastic elastomer into the space to create an elastomeric matrix that at least partially encompasses the platen, the proximal head portions, and the straight tapers of the polypropylene bristle tuft retention rings.

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

• providing a plurality of polypropylene bristle tuft retention rings having an exterior wall that is polygonal;
• inserting a respective nylon bristle tuft into each of the bristle tuft retention rings;
• applying heat to each bristle tuft proximal end at a temperature sufficient to at least partially melt the bristle tuft proximal end and create a proximal head portion;
• positioning a platen portion of a neck of the brush head in relation to the proximal head portions, wherein the positioning of the platen portions of the neck defines a space in relation to the proximal head portions for injection of a thermoplastic elastomer;
• forming an area adjacent to the proximal head portion to be void of elastomeric matrix;
• and
• injecting the thermoplastic elastomer into the space and around the area adjacent to the proximal head portions to create an elastomeric matrix that at least partially encompasses the platen and the proximal head portions.