# US 2021/0274927 A1 · Method of Making Composite Head Safety Toothbrush > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0274927 A1 - Document ID: US20210274927A1 - Status: Published application - Kind: A1 - Application number: 17/327,734 - Filed: 2021-05-23 - Published: 2021-09-09 - Earliest claimed: 2006-11-27 - Assignees: Loops, LLC - Inventors: Steven L. Kayser - Web page: https://patentgrep.com/patent/US20210274927A1 ## CPC - A46B 3/04: by mouldable materials, e.g. metals, cellulose derivatives, plastics (A46B1/00 takes precedence) - A46D 3/00: Preparing, {i.e. Manufacturing} brush bodies - A46B 5/0029: {Head made of soft plastics, rubber or rubber inserts in plastics matrix} - A46B 5/0066: {Flexible resilience by elastic deformation of the material} - A46B 5/02: specially shaped for holding by the hand - A46B 5/021: {Grips or handles specially adapted to conform to the hand} - A46B 5/025: {Grips or handles specially adapted for handicapped persons} - A46B 9/04: {Arranged like in or} for toothbrushes - A46D 3/005: {by moulding or casting a body around bristles or tufts of bristles} - B29C 45/17: Component parts, details or accessories; Auxiliary operations - A46B 5/0037: {Flexible resilience by plastic deformation of the material} - A46B 2200/1066: Toothbrush for cleaning the teeth or dentures (A61C17/16 takes precedence; bristles arrangements for toothbrushes A46B9/04) - A46B: BRUSHES (handles not integral with brushware B25G) - A46D: MANUFACTURE OF BRUSHES - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) ## Abstract A composite safety toothbrush is disclosed, and in particular, methods for making and forming the composite. The toothbrush apparatus detailed herein employs a composite head made from a rigid inner polymer material and a softer thermoplastic material surrounding the inner material. The softer material provides safety for prison toothbrush applications as well as elderly and patient care where care givers may brush the teeth of a patient. Innovative pin connectors in the inner toothbrush head assist in the composite formation. The toothbrush solution herein further importantly provides for a toothbrush having a flexible handle, also providing safety in a prison environment. ## Claims ### Claim 1 A method for making a toothbrush comprising: molding an inner toothbrush head with a first material, the first material being rigid; and molding an outer toothbrush head with a second material at least partially around the inner toothbrush head, the second material being pliable, wherein the outer toothbrush head and inner toothbrush head together form a composite toothbrush head, wherein a method step of molding the inner toothbrush head precedes a method step of molding the outer toothbrush head, wherein the outer toothbrush head having the second pliable material thereby provides a safety toothbrush; providing a toothbrush handle extending from the outer toothbrush head for holding by a user; and attaching a plurality of bristles to the inner toothbrush head providing brushing to the user. ### Claim 2 (depends on 1) The method for making a toothbrush of claim 1, wherein the toothbrush is a composite head toothbrush devoid of glue or other adhesives. ### Claim 3 (depends on 1) The method for making a toothbrush of claim 1, wherein the method employs two single cavity molds. ### Claim 4 (depends on 1) The method for making a toothbrush of claim 1, wherein the molding an inner toothbrush head provides a pair of pin connectors protruding downwardly further providing for a pair of pin connectors at an interface of the inner toothbrush head and the outer toothbrush head, wherein further the pins are offset diagonally with respect to a longitudinal axis of the flexible handle toothbrush, the pair of pin connector thereby providing an increase in the interface between the inner toothbrush head and the outer toothbrush head. ### Claim 5 A method for making a safety toothbrush comprising: providing a first mold for an inner toothbrush head; selecting a first rigid material for use in the first mold; molding an inner toothbrush head with the first mold; providing a second mold for an outer toothbrush head; molding the outer toothbrush head with a second mold at least partially around a side outer periphery of the inner toothbrush head, the inner and outer toothbrush head together forming a composite toothbrush head; selecting a second pliable material for the second mold, the second pliable material having a softness preventing damage to a patient's teeth or gums due to brushing wherein the molding the outer toothbrush head further comprises molding the second pliable material substantially covering a back of the inner toothbrush head, the pliable material providing safety features to the safety toothbrush; providing a toothbrush handle extending from the outer toothbrush head for holding by a user; and attaching a plurality of bristles to the inner toothbrush head providing brushing to the user. ### Claim 6 (depends on 5) The method for making the safety toothbrush of claim 5 further comprising curing the second material around the first material thereby bonding same without using glue. ### Claim 7 (depends on 5) The method for making the safety toothbrush of claim 5, further comprising: drilling a multiplicity of bristle holes on a surface of the inner toothbrush head, the drilling precedent to the molding the outer toothbrush head; and filling the multiplicity of bristle holes with steel pins so that during molding the outer toothbrush head, no outer toothbrush head material flows into the bristles holes. ### Claim 8 (depends on 5) The method for making the safety toothbrush of claim 5, wherein said molding the inner toothbrush head precedes said molding the outer toothbrush head. ### Claim 9 (depends on 5) The method for making the safety toothbrush of claim 5, further comprising employing two single cavity molds. ### Claim 10 (depends on 5) The method for making the safety toothbrush of claim 5, wherein said molding the inner toothbrush head and said molding the outer toothbrush head allowing for a pair of pin connectors at an interface of the inner toothbrush head and the outer toothbrush head, wherein further the pair of pin connectors are offset diagonally with respect to a longitudinal axis of the safety toothbrush, the longitudinal axis further passing equidistant between the pair of pin connectors. ### Claim 11 (depends on 5) The method for making the safety toothbrush of claim 5, further comprising molding a toothbrush handle from the second pliable material thereby providing a flexible handle safety toothbrush.