Improved dental dam and method of making same

Abstract

There is a provided a dental tool and a use and method of making the dental tool. The dental tool comprises a water impermeable and gas resistant sheet having an opening, and a hydrophobic mesh secured to the sheet and overlying the opening. Presence of the hydrophobic mesh in the sheet allows a user to breath orally when the dental tool is placed over the user's mouth.

Description

IMPROVED DENTAL DAM AND METHOD OF MAKING SAMEFIELD

[0001] The present disclosure relates to the field of dental equipment used in dental procedures. More specifically, the embodiments of the present disclosure relate to a dental dam for use during dental operations.BACKGROUND

[0002] In dental procedures, isolating teeth is crucial to prevent contamination and ensure a dry working area. Dental dams play a vital role by providing effective isolation and acting as a barrier against saliva, blood, and chemicals. They help to ensure a dry field, to facilitate the accurate placement and curing of restorative materials, and to protect patients from ingesting or aspirating dental instruments and materials. In endodontic treatments, dental dams are particularly important as they prevent contaminants from entering the root canal system and protect patients from harmful substances, like sodium hypochlorite. Successful restorations depend on moisture and microbe control, which dental dams provide by excluding moisture and saliva from the tooth or root being treated, thereby reducing the risk of infection or reinfection. Additionally, dental dams can assist with tongue retraction, which helps to improve visibility and access for the dentist, and enhance safety for both the dentist and the patient.

[0003] Despite these benefits, traditional dental dams often cause discomfort and anxiety by obstructing mouth breathing. Tidal volume may refer to the amount of air inhaled or exhaled during a normal breath, while respiratory duration may refer to the time taken for one complete cycle of inhalation and exhalation. Use of dental dams can lead to both lower tidal volume and respiratory duration for a patient during a procedure, resulting in shallower breaths, air hunger, and increased anxiety. Patient discomfort can negatively affect the success of dental procedures. The inability to breathe comfortably through their mouth is one of the primary reasons for patient non-compliance during a dental procedure.

[0004] This has been commonly addressed in the past by dentists by creating a hole in the dental dam to ensure patient ventilation. However, this practice prevents teeth from proper isolation and puts the patient at risk of swallowing or aspirating dental-related substances ortooth debris. Alternatively, dentists have resorted to taking frequent breaks to allow patients time to breathe comfortably. However, frequent breaks can interrupt the flow of the procedure and reduce overall efficiency. A dental dam that combines effective isolation with enhanced patient comfort is, therefore, desirable.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 illustrates a dental tool according to a first example embodiment of the present disclosure in use with a patient.

[0006] FIG. 2A is a front view of the dental tool of FIG. 1 in isolation.

[0007] FIG. 2B is a rear view of the dental tool of FIG. 1 in isolation.

[0008] FIG. 3 is a front view of a dental tool according to a second example embodiment of the present disclosure.

[0009] FIG. 4 is an exploded perspective view of the dental tool of FIG. 2B.

[0010] FIG. 5 is an exploded perspective view of a dental tool according to a third example embodiment of the present disclosure.

[0011] FIG. 6A is a front view of an example embodiment of a hydrophobic mesh in isolation.

[0012] FIG. 6B is a front view of another example embodiment of a hydrophobic mesh in isolation.

[0013] FIG. 7 is a front view of a dental tool according to a fourth example embodiment of the present disclosure.

[0014] FIG. 8 is a front view of a dental tool according to a fifth example embodiment of the present disclosure.

[0015] FIG. 9 is an exploded perspective view of the dental tool of FIG. 8.DETAILED DESCRIPTION

[0016] Described herein are example embodiments of an improved dental dam, and methods for producing the improved dental dams. The present disclosure provides a breathable dental dam that allows patients to breathe through their mouth while simultaneously isolating thetreatment area, providing a more comfortable experience for patients and a more efficient working environment for dental professionals.

[0017] One aspect of the present disclosure relates to a dental tool comprising: a water impermeable and gas resistant sheet comprising an opening; and a hydrophobic mesh secured to the sheet and overlying the opening; wherein presence of the hydrophobic mesh in the sheet allows a user to breath orally when the dental tool placed over the user’s mouth.

[0018] In some implementations of the dental tool, the hydrophobic mesh is made of hydrophobic polymers, including one or more of expanded polytetrafluoroethylene (ePTFE), polyvinylidene fluoride (PVDF), sintered polyethylene (PE), and sintered polypropylene (PP).

[0019] In some implementations of the dental tool, the hydrophobic mesh is made of one or more of treated nylon, treated polyester, and treated polyethylene.

[0020] In some implementations of the dental tool, the treated nylon, the treated polyester, and the treated polyethylene are treated with a hydrophobic non-fluorocarbon-based coating or a hydrophobic fluorocarbon-based coating.

[0021] In some implementations of the dental tool, the hydrophobic mesh is secured to the sheet with an adhesive.

[0022] In some implementations of the dental tool, the adhesive comprises one or more of a silicone-based adhesive, a polyurethane-based adhesive, an epoxy, an acrylic, and a rubberbased adhesive.

[0023] In some implementations of the dental tool, the adhesive comprises ethyl cyanoacrylate.

[0024] In some implementations of the dental tool, the hydrophobic mesh is stitched to the sheet.

[0025] In some implementations, the dental tool further comprises a grommet, wherein the grommet mechanically secures the hydrophobic mesh to the sheet over the opening.

[0026] In some implementations, the grommet may be made of polypropylene, nylon, polyethylene, or polyvinyl chloride (PVC).

[0027] In some implementations, the dental tool further comprises another mesh secured to the sheet and overlying the opening.

[0028] In some implementations of the dental tool, the other mesh is untreated.

[0029] In some implementations of the dental tool, the pore size of the hydrophobic mesh is from 10 pm to 40 pm.

[0030] Another aspect of the present disclosure relates to a method of forming a dental tool comprising: providing a water impermeable and gas resistant sheet comprising an opening; and securing a hydrophobic mesh to the sheet overlying the opening.

[0031] In some implementations of the method, securing the hydrophobic mesh to the sheet comprises adhering the hydrophobic mesh to the sheet with an adhesive.

[0032] In some implementations of the method, securing the hydrophobic mesh to the sheet comprises stitching the hydrophobic mesh to the sheet with a biocompatible thread.

[0033] In some implementations of the method, securing the hydrophobic mesh to the sheet comprises attaching the hydrophobic mesh to the sheet with a grommet.

[0034] In some implementations of the method, the method further comprises securing another mesh to the sheet overlying the opening.

[0035] In some implementations of the method, the hydrophobic mesh is coated with a hydrophobic coating, the other mesh is uncoated, and the method comprises securing the hydrophobic mesh to one side of the sheet overlying the opening; and securing the other mesh to another side of the sheet overlying the opening.

[0036] Another aspect of the present disclosure relates to use of a dental tool during a dental procedure, the dental tool comprising a water impermeable and gas resistant medical grade sheet comprising an opening, and a hydrophobic mesh secured to the sheet and overlying the opening, the use comprising: aligning a portion of the sheet over a procedure area in a user’s mouth; positioning the hydrophobic mesh over the user’s mouth to allow the user to breath orally; and securing the dental tool to the procedure area in the user’s mouth.

[0037] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the features illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope ofthe disclosure is thereby intended. Any alterations and further modifications, and any further applications of the principles of the disclosure as described herein are contemplated as would normally occur to one skilled in the art to which the disclosure relates. It will be apparent to those skilled in the relevant art that some features that are not relevant to the present disclosure may not be shown in the drawings for the sake of clarity.

[0038] Certain terms used in this application and their meaning as used in this context are set forth in the description below. To the extent a term used herein is not defined, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Further, the present processes are not limited by the usage of the terms shown below, as all equivalents, synonyms, new developments and terms or processes that serve the same or a similar purpose are considered to be within the scope of the present disclosure.

[0039] FIG. 1 illustrates a dental tool 100 according to a first example embodiment of in use with a patient or user 105. Conventionally, use of a dental tool or dental dam involves a dam sheet 110, clamps 120, dam frame 130, a dam punch, and forceps (not shown). The appropriate size and type of dam sheet 110 is selected, then stretched over the dam frame 130 to create a taut surface. Using the dam punch, punch holes are created in dam sheet 110 corresponding to where the patient or user’s teeth 140 are, which will be undergoing the dental procedure. The clamps 120, held by the forceps, are placed around the selected teeth 140 undergoing treatment. The dam sheet 110 is then positioned over the patient’s oral cavity, and the punch holes are fitted around the clamps 120 and the teeth 140 undergoing treatment, ensuring a tight seal and isolating the treatment area.

[0040] In the dental tool 100, the dam sheet 110 comprises an opening 160 over which a hydrophobic mesh 150 is secured. As depicted in FIGS. 2A - 2B, for example, the opening 160 and the hydrophobic mesh 150 may be positioned in the center of the dam sheet 110. In alternative embodiments, the opening 160 and the hydrophobic mesh 150 may be positioned in a different position in the dam sheet 110. For example, as depicted in FIG. 3, the opening 160 and the hydrophobic mesh 150 may be positioned proximate an edge of the dam sheet 110. Notably, in use, the opening 160 and the hydrophobic mesh 150 are to be positioned over the patient’s oral cavity to allow the patient to orally breath through the opening 160 and thehydrophobic mesh 150. This setup helps to isolate the teeth 140 from the oral cavity, providing a dry and clean working area for dental procedures, while also helping to enhance the breathability of the dental tool 100 for the patient / user.

[0041] The dam sheet 110 may be fabricated or made from sheet material that is water impermeable and gas resistant, and preferably medical grade for use in dental procedures. For example, the material may be latex, nitrile, silicone, or polyisoprene. Due to the prevalence of latex allergies, a preferred material for the dam sheet 110 is nitrile. In some implementations, for example, dam sheet 110 may be Flexi Dam®. In that regard, the dam sheet 110 may be 12.7cm by 12.7cm (5 inches) or 15.2cm by 15.2 cm (6 inches), with a thickness ranging from 0.18 mm to 0.22 mm.

[0042] As shown in FIG. 4, the opening 160 may be cut in the dam sheet 110, such as through die-cutting, which helps maintain uniformity and precision in both size and placement of the opening 160 in the dam sheet 110. Alternatively, the dam sheet 110 may be fabricated with the opening 160 formed therein already.

[0043] In the implementation depicted in FIG. 4, the opening 160 may have a diamond shape with vertices pointing towards the edges of the dam sheet 110. The pre-cute diamond shape opening in the present embodiment may measure 2cm by 2cm to provide a channel for air. However, in other embodiments, the size and shape of the opening 160 may be different depending on the needs of the procedure and / or patient. For example, if the patient is a child, the opening 160 may be smaller, such as 1.4cm by 1.4cm to correspond with smaller dental arches. Alternatively, the opening 160 may be circular (as shown in FIG. 9).

[0044] The hydrophobic mesh 150 is sized and shaped to generally correspond with the opening 160 in order to overlie the opening 160. For example, in applications where the opening 160 is 2cm by 2cm and diamond shaped, the hydrophobic mesh 150 may also be diamond shaped and slightly larger (such as 2.5cm by 2.5cm) for it to be secured to the dam sheet 110. FIG. 2A illustrates the front side of the dental tool 100 showing overlap 210 of the hydrophobic mesh 150 with the dam sheet 110, while FIG. 2B shows the back side of the dental tool 100.

[0045] The hydrophobic mesh 150 is made of hydrophobic polymers that repel water and enhance the moisture resistance of the mesh. The material of the hydrophobic mesh 150 isalso biocompatible and selected to be durable so it maintains its structure well under mechanical stress. In some implementations, the hydrophobic mesh 150 may be made from materials which are inherently hydrophobic, such as one or more of expanded polytetrafluoroethylene (ePTFE), polyvinylidene fluoride (PVDF), sintered polyethylene (PE), and sintered polypropylene (PP). Additionally, or alternatively, the hydrophobic mesh 150 may be made from woven or nonwoven fabric, such as polyester, nylon, or polyethylene, treated with a hydrophobic coating, as treated polyester, treated nylon, or treated polyethylene. Other medically acceptable mesh substrates that provide airflow while maintaining isolation may also be used.

[0046] FIG. 4 illustrates an embodiment with one hydrophobic mesh 150. However, the dental tool 100 may comprise multiple meshes. For example, as shown in FIG. 5, the dental tool 100 may comprise the hydrophobic mesh 150 and another mesh 170 also overlying the opening 160. The other mesh 170 may also be made of medical grade hydrophobic polymers and durable under mechanical stress. In that regard, the other mesh 700 may be the same material as hydrophobic mesh 150, or may have different properties than the hydrophobic mesh 150, such as a different thickness, different pore sizes, or be made from different materials. The other mesh 170 may be secured to the same side of the dam sheet 110 as the hydrophobic mesh 150, or to the opposite side of the dam sheet 110 as the hydrophobic mesh 150 (as shown in FIG. 5).

[0047] To provide airflow, while maintaining isolation, the pore size of the hydrophobic mesh 150 and the other mesh 170 may be from 10 pm to 40 pm. Performance characteristics such as airflow resistance and water entry pressure may vary depending on the selected pore size and fabrication method but are selected to ensure a balance between breathability and fluid resistance suitable for dental applications.

[0048] In applications where the hydrophobic mesh 150 and / or the other mesh 170 is made of ePTFE, the ePTFE mesh may have a pore size in the range of 10-30 pm and may be used in either single-layer or double-layer configurations. ePTFE is an inherently hydrophobic and microporous material commonly used in medical barrier applications.

[0049] In applications where the hydrophobic mesh 150 and / or the other mesh 170 is composed of PVDF, the PVDF mesh may have a nominal pore size of 20 pm, with anacceptable range of 10-30 pm, and a thickness of approximately 30-32 pm. PVDF is also an inherently hydrophobic and chemically resistant polymer.

[0050] In applications where the hydrophobic mesh 150 and / or the other mesh 170 is formed from sintered polyethylene (PE) or sintered polypropylene (PP), these meshes are manufactured as porous membranes with controlled pore structure and airflow characteristics. The pore size may range from 15 pm to 40 pm, with a thickness range of approximately 50 pm to 1.5 mm. Sintered PE and PP are both inherently hydrophobic materials.

[0051] In applications where the hydrophobic mesh 150 and / or the other mesh 170 are made from woven or nonwoven fabric, such as polyester, nylon, or polyethylene, the appearance of the meshes can vary. They may include patterns, such as a diagonal mesh (FIG. 6B), a circular mesh, or a grid mesh (FIG. 6A), as long as there is a uniform distribution of openings or pores to ensure consistent airflow and filtration.

[0052] When woven, the fabric may utilize a plain weave involves interlacing the warp and weft threads in an alternating pattern, creating a robust and stable fabric that resists fraying and tearing. In other embodiments, twill, satin, and basket weave may also be employed. Twill weave can be employed by interlacing the threads to form a diagonal rib pattern. A satin weave involves floating the warp or weft threads over multiple threads. Basket weave, an enhanced plain weave, is created by interlacing two or more threads as one.

[0053] In certain implementations, a smooth monofilament fiber may be used for the mesh. Monofilament threads consist of a single continuous fiber, which allows for smaller pore sizes that effectively block fluids while allowing air to pass through. The smooth surface of the monofilament polyester is gentler on the patient’s skin and oral mucosa, reducing irritation and increasing comfort during use. Other embodiments might include multifilament fiber, which consists of multiple smaller fibers twisted together. Multifilament threads can offer flexibility and soft texture but might have larger pore sizes, affecting the hydrophobicity and filtration properties.

[0054] The fabric may then be treated with a hydrophobic coating to enhance its hydrophobicity. Prior to applying the hydrophobic coating, the mesh substrate surface may undergo pretreatment to enhance coating adhesion and durability. This typically includessolvent cleaning (e.g., ethanol or isopropanol) to remove surface contaminants, followed by optional plasma treatment using gases such as oxygen, nitrogen, argon, or mixtures thereof.

[0055] Hydrophobic coatings may include two general categories: non-fluorocarbon-based coatings and fluorocarbon-based coatings.

[0056] Non-fluorocarbon-based coatings that may be used in the present disclosure include Poly(dimethylsiloxane) (PDMS), a curing agent such as SYLGARD® 184 Elastomer Kit (Sigma Aldrich), and Carnauba Wax #2 (Museum Corporation). To apply, PDMS and Carnauba Wax are dissolved in a solvent, typically isopropanol or ethanol, to achieve concentrations of approximately 0.04 g / ml PDMS and 0.02 g / ml Carnauba Wax. The solution is heated to approximately 80°C and stirred at around 300 RPM until homogeneous, followed by filtration to remove impurities.

[0057] The coating may be uniformly applied to one or both sides of the mesh using standard application techniques, such as padding, spraying, kiss-roll, engraved-roll, or knife-over-roll methods. Padding involves passing the mesh through a coating solution bath and squeezing out the excess. Spraying uses fine nozzles to distribute the coating evenly. Kiss roll and engraved roll methods involve rolling the mesh against a coated roll, while knife over roll applies the coating by spreading it with a blade. After coating, the mesh is dried under controlled conditions, allowing solvent evaporation and proper setting of the hydrophobic coating.

[0058] Other suitable non-fluorocarbon-based hydrophobic coatings include Deva Repel (Devan Chemicals), OC-AQUASIL Tex™ (Organoclick), BIONIC-FINISH® ECO (Rudolf), ECOPERL (CHT), HydrECO Concept (Tanatex Chemicals), Arkophob® FFr (Archroma), Nasiol T-series (Nasiol), BARRIER ECO (HeiQ), Ecorepel® (Schoeller Technologies), and Impermea HYDRO-TEX™ (Impermea Materials), among others.

[0059] Fluorocarbon-based hydrophobic coatings may also be used to treat mesh surfaces. These coatings may include C6- and C4-based durable water repellent (DWR) finishes. Examples of suitable fluorocarbon-based coatings include NUVA® (Archroma), Scotchgard™ Protector (3M), and RUCO-GUARD® (Rudolf), among others. Other equivalent formulations known in the art may also be used.

[0060] In applications where C6 fluorocarbon-based coatings are used, such as NUVA®, the coatings are applied to the hydrophobic mesh using the padding process, where the mesh is passed through a bath containing the fluorocarbon solution and then squeezed between rollers to remove excess liquid. The treated mesh is subsequently dried and cured, ensuring the formation of a thin, durable fluorocarbon layer on the surface, providing the desired repellent properties. As another coating embodiment, SAATIFIL ACOUSTEX® hydrophobic acoustic meshes are utilized to repel water while preserving ventilation. Their C6-based hydrophobic coated meshes are beneficial for environments where moisture resistance is crucial without compromising ventilation.

[0061] In applications where a coating is applied to the hydrophobic mesh 150, the two-layer mesh configuration illustrated in FIG. 5 may be used. In such cases, the other mesh 170 may be untreated. When in use, the side of the dental tool 100 comprising the untreated mesh 170 may be placed facing the patient. In this manner, direct contact between the treated surface of the hydrophobic mesh 150 and the patient's oral tissues may be minimized.

[0062] Generally, the hydrophobic mesh 150 may have a thickness from about 40pm to 50pm, a tensile strength greater than 230 N / 5cm, an open area of about 15% to 22%, and a pore size of 15 pm to 40 pm. In one implementation, the hydrophobic mesh 150 may have a thickness of 44 pm, a tensile strength greater than 250 N / 5cm, an open area of 18%, and a pore size of 18 pm. These specifications help provide an optimal balance of strength, flexibility, and breathability, ensuring the hydrophobic mesh 150 can withstand the stresses of dental procedures while maintaining its structural integrity and functional performance. The thickness ensures durability, while the tensile strength helps the mesh to endure significant force without tearing. The specified open area and pore size enhances breathability and moisture resistance. Of course, variations are possible. For example, increasing the pore size and, therefore, the open area, might be done in applications requiring higher airflow or different filtration needs.

[0063] The specifications for the hydrophobic mesh 150 may also vary depending on how the hydrophobic mesh 150 is (to be) secured to the dam sheet 110. In that regard, the hydrophobic mesh 150 (and, optionally, the other mesh 170) may be secured to the dam sheet110 using one of a number of attachment means, including an adhesive, stitching, and a fastening tool.

[0064] In applications where the hydrophobic mesh 150 and / or the other mesh 170 is / are secured to the dam sheet 110 using an adhesive, a precise applicator may be used to evenly apply the adhesive around the edges of the pre-cut opening 160 in the dam sheet 110. The hydrophobic mesh 150, being slightly larger than the pre-cut opening 160 (such as a 2.5cm by 2.5cm mesh for a 2cm by 2cm opening), may be aligned over the opening 160, creating an overlap 210 of 0.25 cm on each side of the opening 160. This overlap helps to increase the surface area for adhesion to enhance bond strength and to reduce the chance of tearing. The dam sheet 110 and the hydrophobic mesh 150 are left to cure, allowing the adhesive to fully set. FIG. 2 A shows the front of the dental tool 100, where the dashed line 210 illustrates the overlap and highlights where the mesh extends in the back of the dam sheet 110. FIG. 2B shows the back of the dental tool 100. Note that the dashed lines in FIG. 2A are for illustrative purposes only and may not appear in the actual product.

[0065] The adhesive used for securing the hydrophobic mesh 150 to the dam sheet 110 may be a cyanoacrylate-based glue, such as ethyl cyanoacrylate. This adhesive may be selected due to its affordability, non-toxic nature, and strong bonding properties. Ethyl cyanoacrylate is composed of cyanoacrylate ester, which polymerizes rapidly in the presence of moisture, forming long chains that create a strong bond. This chemical composition ensures biocompatibility and safety for dental applications. In other embodiments, suitable adhesives may include silicone-based adhesives, polyurethane-based adhesives, epoxy, acrylic, and rubber-based adhesives. The adhesive may be selected depending on application-specific requirements.

[0066] In applications where the hydrophobic mesh 150 and / or the other mesh 170 is / are secured to the dam sheet 110 with an adhesive, the hydrophobic mesh 150 may have pore sized of approximately 20 pm ± 2 (acceptable range: 10-40 pm), an open area of 20% (+5 / - 5), a tensile strength greater than 250 N / 5 cm, and a thickness between 20 pm and 100 pm to maintain flexibility. Variations to these dimensions may alternatively be used when the hydrophobic mesh 150 and / or the other mesh 170 is / are secured to the dam sheet 110 with the adhesive.

[0067] FIG. 7 illustrates an embodiment of the dental tool 100 where the hydrophobic mesh 150 and / or the other mesh 170 is / are secured to the dam sheet 110 using stitching. In the depicted embodiment, the hydrophobic mesh 150 is sewn along the perimeter of the opening 160 to the dam sheet 110 using biocompatible thread 710, such as a continuous hydrophobic polyester thread. An overlock stitch (serger) may be used to sew the hydrophobic mesh 150 to the dam sheet 110, which provides a strong, flexible, and secure seam. To maintain fluid impermeability at the attachment interface, an adhesive sealant may be applied along the stitched perimeter. Alternative embodiments may incorporate overlapping lamination or thermal bonding.

[0068] FIG. 8 illustrates an embodiment of the dental tool 100 where the hydrophobic mesh 150 and / or the other mesh 170 is / are secured to the dam sheet 110 using a fastening tool. In the embodiment of FIG. 8, the fastening tool is a grommet 800.

[0069] In application shown in FIG. 8, the opening 160 in the dam sheet 110 may be circular, and the grommet 800 may comprise of two interlocking components: a male component 810 and a female component 820 (see FIG. 9). Suitable materials for these grommet eyelets include polypropylene, nylon, polyethylene, or polyvinyl chloride (PVC). In one example embodiment, the opening 160 may be an 8 mm diameter circular hole and the grommet 800 may have an outer diameter of approximately 24 mm. During assembly, the male grommet component 810 may be inserted through the 8 mm hole from the underside of the dam sheet 110. A hydrophobic mesh 150, preferably correspondingly circular and larger than the opening 160 (such as approximately 40 mm in diameter), may then be positioned over the protruding male component 810. Subsequently, the female grommet component 820 may be securely snapped onto the male component 810, firmly sandwiching the hydrophobic mesh 150 between the two components. Use of the grommet 800 may have the added advantage of reinforcing the edges of the opening 160.

[0070] In applications where the hydrophobic mesh 150 and / or the other mesh 170 is / are secured to the dam sheet 110 with the grommet 800, thicker meshes ranging from 40 pm to 1.5 mm are preferred. Other embodiments may utilize different values based on material properties, manufacturing processes, or specific clinical requirements.

[0071] In the preceding description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the embodiments. However, it will be apparent to one skilled in the art that certain details are not provided, such as to whether the embodiments described herein are implemented as a software routine, hardware circuit, firmware, or a combination thereof. The above-described embodiments are intended to be examples only. Alterations, modifications and variations can be effected to the particular embodiments by those of skill in the art.

Claims

CLAIMSWhat is claimed is:

1. A dental tool comprising: a water impermeable and gas resistant sheet comprising an opening; and a hydrophobic mesh secured to the sheet and overlying the opening; wherein presence of the hydrophobic mesh in the sheet allows a user to breath orally when the dental tool is placed over the user’s mouth.

2. The dental tool of claim 1, wherein the hydrophobic mesh is made of hydrophobic polymers, including one or more of expanded polytetrafluoroethylene (ePTFE), polyvinylidene fluoride (PVDF), sintered polyethylene (PE), and sintered polypropylene (PP).

3. The dental tool of claim 1, wherein hydrophobic mesh is made of one or more of treated nylon, treated polyester, and treated polyethylene.

4. The dental tool of claim 3, wherein the treated nylon, the treated polyester, and the treated polyethylene are treated with a hydrophobic non-fluorocarbon-based coating or a hydrophobic fluorocarbon-based coating.

5. The dental tool of claim 1, wherein the hydrophobic mesh is secured to the sheet with an adhesive.

6. The dental tool of claim 5, wherein the adhesive comprises one or more of a silicone- based adhesive, a polyurethane-based adhesive, an epoxy, an acrylic, and a rubber-based adhesive.

7. The dental tool of claim 6, wherein the adhesive comprises ethyl cyanoacrylate.

8. The dental tool of claim 1, wherein the hydrophobic mesh is stitched to the sheet.

9. The dental tool of claim 1, further comprising a grommet, wherein the grommet mechanically secures the hydrophobic mesh to the sheet over the opening.

10. The dental tool of claim 9, wherein the grommet may be made of polypropylene, nylon, polyethylene, or polyvinyl chloride (PVC).

11. The dental tool of claim 4, further comprising another mesh secured to the sheet and overlying the opening.

12. The dental tool of claim 11, wherein the other mesh is untreated.

13. The dental tool of claim 1, wherein the pore size of the hydrophobic mesh is from 10 pm to 40 pm.

14. A method of forming a dental tool comprising: providing a water impermeable and gas resistant sheet comprising an opening; and securing a hydrophobic mesh to the sheet overlying the opening.

15. The method of claim 14, wherein securing the hydrophobic mesh to the sheet comprises adhering the hydrophobic mesh to the sheet with an adhesive.

16. The method of claim 14, wherein securing the hydrophobic mesh to the sheet comprises stitching the hydrophobic mesh to the sheet with a biocompatible thread.

17. The method of claim 14, wherein securing the hydrophobic mesh to the sheet comprises attaching the hydrophobic mesh to the sheet with a grommet.

18. The method of claim 14, further comprising securing another mesh to the sheet overlying the opening.

19. The method of claim 18, wherein the hydrophobic mesh is coated with a hydrophobic coating, and the other mesh is uncoated, and the method comprises securing the hydrophobic mesh to one side of the sheet overlying the opening; and securing the other mesh to another side of the sheet overlying the opening.

20. Use of a dental tool during a dental procedure, the dental tool comprising a water impermeable and gas resistant sheet comprising an opening, and a hydrophobic mesh secured to the sheet and overlying the opening, the use comprising:aligning a portion of the sheet over a procedure area in a user’s mouth; positioning the hydrophobic mesh over the user’s mouth to allow the user to breath orally; and securing the dental tool to the procedure area in the user’s mouth.

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