Dental floss manufacturing process and product

Abstract

A continuous process for manufacturing a continuous floss brush comprises steps of first applying a polymer solution at a repeated preselected distance interval to a continuous length of floss yarn under tension and solidifying the polymer while the floss yarn is under tension to produce a continuous floss product of yarn sections which stretch under slight tension separated by thread sections which do not significantly stretch under tension. The floss yarn is treated to expand the yarn sections to form brush sections. The passage of a predetermined number of segments comprising thread and brush portions is determined while the continuous floss brush is under substantially zero tension using a optical detector. Finally, a length of the continuous floss segments containing the predetermined number of segments comprising thread and brush portions is cut for packaging. Preferably, a dye marker is applied to at least a portion of the thread portion, whereby the accuracy of the optical detection of the thread portions of the continuous floss brush is increased. The yarn is a nylon yarn, and the yarn sections are expanded by treatment with heat and water vapor when under zero tension to yield a product with a highly expanded brush portion which is stretched under slight tension. The floss brush product comprises a continuous length of floss having segments comprising alternating portions of yarn sections which stretch under slight tension separated by thread sections which do not significantly stretch under tension, at least a portion of each thread section being preferably marked with a dye.