A brush head (10) and a method for manufacturing a brush head. The method includes forming a plurality of retention elements (52) each having an opening (51) therethrough. The retention elements (52) are positioned into corresponding recesses of a plate. A bristle tuft (21) is inserted into each of the openings of the retention elements. A proximal end (23) of each bristle tuft is bonded to the corresponding proximal side of the retention element to form a merged proximal end head portion (26) that secures the bristle tufts and the corresponding retention elements together as a plurality of merged tuft assemblies (20). A neck (40) of the brush head is positioned in relation to the merged tuft assemblies. A platen (42) of the neck and the merged tuft assemblies is at least partially encompassed in a matrix (30).

An oral care implement including a handle and a head. The head has a first surface and a plurality of tuft holes formed into the first surface. Each of the tuft holes has a diameter D.sub.TH. The tuft holes are arranged in a tuft hole pattern such that a singular bounded area A.sub.B of the first surface can be selected that includes X number of tuft holes. In some embodiments, X is an integer that is greater than or equal to 2, D.sub.TH is less than or equal to 1.1 mm, and X/A.sub.B is greater than or equal to 0.54.

The method for manufacturing a makeup brush includes: molding a ferrule and welding bristles to the ferrule. The ferrule includes a ferrule inner end; a ferrule outer end; a ferrule body; an interior; and a well. The well has a well base parallel to the ferrule outer end. The well base has an inner side and an outer side. The step of welding the bristles includes the steps of disposing the bristles in contact with the outer side of the well base and exposing the inner side of the well base to welding.

A method of forming a bristle field for an oral care implement. The method includes providing a bundle of bristles and aligning the bundle of bristles with an insertion opening in a guide member. Upon insertion into the guide member, the guide member divides the bundle of bristles into a plurality of bristle tufts. The guide member can be aligned with tuft holes on a head or head plate of an oral care implement so that the bundle of bristles can be inserted through the guide member and into the tuft holes. As a result, a single bundle of bristles can be used to mount a plurality of bristle tufts to the head or head plate.

According to a method or an apparatus for fastening bristles in a bristle carrier (10) without using an anchor a heating (39) is provided in a tool part configured to transport the bristles. After inserting the bristles into anchoring openings (12) in the bristle carrier (10), the anchoring openings are closed by applying pressure.

According to a method or an apparatus for fastening bristles in a bristle carrier (10) without using an anchor a heating (39) is provided in a tool part configured to transport the bristles. After inserting the bristles into anchoring openings (12) in the bristle carrier (10), the anchoring openings are closed by applying pressure.

A brush head (32) including: a supporting portion (42) of a brush neck (40); a plurality of bristle tufts (21), each of which comprises a plurality of bristle strands having a proximal end (23) and a free end (25), wherein each of the plurality of bristle tufts comprises a proximal end head portion (26) melted into a first shape within a mold; and an elastomeric matrix (30) comprising at least a portion of the hard brush neck and the proximal end head portions, wherein the first shape of the proximal end head portion is configured to engage the elastomeric matrix such that the bristle tufts are retained within the elastomeric matrix.

The method for manufacturing a makeup brush includes: molding a ferrule and welding bristles to the ferrule. The ferrule includes a ferrule inner end; a ferrule outer end; a ferrule body; an interior; and a well. The well has a well base parallel to the ferrule outer end. The well base has an inner side and an outer side. The step of welding the bristles includes the steps of disposing the bristles in contact with the outer side of the well base and exposing the inner side of the well base to welding.

A brush head (32) including a neck (40) having a brush neck (42); a plurality of bristle tufts (21), each of which includes a plurality of bristle strands with a free end (25) and a proximal end (23), the proximal end having a proximal end head portion (26); a plurality of retention rings (50), each configured to receive the proximal end of at least one of the plurality of bristle tufts; an elastomeric matrix (30) 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 (27) between the proximal end head portion and the respective retention ring.

The present invention relates to a brush with fusion interlocking bristle strip and a method of manufacturing the same. The brush includes carrier strips and knotted bristle strips bonded together by ultrasonic welding and interlocking.