Adapter template

Abstract

The present disclosure discusses adapter templates and the use of adapter templates to couple adapters or other devices to the teeth of a patient. An adapter template is a dental appliance conformal with one or more teeth of a patient, comprising a polymeric sheet composition having at least one layer. The polymeric sheet has a thickness of about 0.2 mm to 0.5 mm and an elastic modulus of about 150,000 psi to 300,000 psi. The adapter template further includes at least one recessed portion on the inner surface that is at least partially conformal with the patient's teeth. The recessed portion is shaped to receive the composite material prior to positioning on the patient's teeth.

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 579,574 entitled “Connector Template”, filed August 30, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This technology relates to dental appliance manufacturing technology. More specifically, this technology relates to techniques for manufacturing and using connector templates. Background Technology

[0003] Orthodontic appliances are devices designed to correct the position of a series of discrete teeth to achieve proper alignment. Appliances offer many advantages over traditional braces / wire frames used in orthodontic treatment. For example, appliances are typically clear or translucent, more comfortable than wire frames, and removable for cleaning and eating. The manufacture of appliances traditionally begins with creating a digital model of the patient's teeth by scanning them or by making impressions of the teeth and then scanning those impressions. Once the digital model of the patient's teeth is obtained, physical models of the teeth can be created (e.g., using 3D printing technology) to provide an orthodontic model.

[0004] When an intraoral scanning device (IOS device) is used to scan a patient's teeth, a three-dimensional computer-aided design (CAD) representation can be imported via custom software. This custom software allows operators (such as dental technicians or dentists) to move individual teeth in specific and discrete movements, as well as in multiple stages, according to the treatment plan, to achieve the final aligned dental arch.

[0005] For each stage of the patient's treatment plan, a 3D-printed model of the dental arch is manufactured, and a thermoformed polymer sheet can be placed on top of the 3D-printed dental arch model to form a transparent orthodontic appliance.

[0006] The thermoformed parts are then marked with part identification. The marked and thermoformed parts are then cut using one of several methods, allowing the orthodontic appliance arriving at the customer to be separated from excess appliance material.

[0007] The aligners are then polished to remove burrs and sharp edges, inspected, and then packaged for transport to the patient's orthodontist, or directly to the patient. To provide more targeted force to individual teeth, various connectors or attachments can be fixed to the patient's teeth; these connectors or attachments can interact with the cavity or features of the aligner. Attaching or fixing these connectors to the patient's teeth presents many non-trivial challenges. Summary of the Invention

[0008] This technology relates to techniques for manufacturing and using engagement templates. According to one aspect of this disclosure, a dental appliance conforming to one or more of a patient's teeth is disclosed. The dental appliance comprises a polymer sheet composition having at least one layer with a thickness between about 0.2 mm and 0.5 mm and an elastic modulus between about 150,000 psi and 300,000 psi. The dental appliance also includes at least one recessed portion on an inner surface of the appliance conforming to one or more of the patient's teeth, wherein the recessed portion is shaped to receive the composite material before being positioned on the patient's teeth.

[0009] In some embodiments, the polymer sheet composition comprises a copolyester with an elastic modulus of about 150,000 psi to 300,000 psi; 160,000 psi to 290,000 psi; 170,000 psi to 280,000 psi; 160,000 psi to 270,000 psi; 170,000 psi to 260,000 psi; 180,000 psi to 250,000 psi; 190,000 psi to 230,000 psi; 195,000 psi to 225,000 psi; 200,000 psi to 220,000 psi; 205,000 psi to 220,000 psi; or 215,000 psi to 220,000 psi.

[0010] In some embodiments, the polymer sheet composition comprises a copolyester with an elastic modulus of about 180,000 psi to 220,000 psi; 185,000 psi to 215,000 psi; 190,000 psi to 210,000 psi; or 195,000 psi to 205,000 psi.

[0011] In some implementations, the dental appliance also includes a trimming line extending from approximately -1 mm to 4.0 mm beyond the apex of the gingival line of the tooth.

[0012] In some implementations, the dental appliance also includes a trimming line extending from about 0 mm to 2.0 mm beyond the apex of the gingival line of the tooth.

[0013] In some embodiments, the polymer sheet composition comprises a copolyester with a thickness of about 0.25 mm to 0.45 mm, 0.3 mm to 0.4 mm, 0.35 mm to 0.4 mm, or 0.34 mm to 0.42 mm.

[0014] In some embodiments, the polymer sheet composition has a pull-out force of less than 22 Newtons (i.e., 22 N) with the cured dental composite material.

[0015] In some embodiments, the polymer sheet composition has a pull-out force of 5N-22N, 5N-20N, 5N-15N, 5N-10N, 1N-10N, 2N-10N, 3N-10N, or 4N-10N with the cured dental composite material.

[0016] In some embodiments, the polymer sheet composition comprises a copolyester.

[0017] According to another aspect, this disclosure relates to a method of bonding one or more adhesive devices to a patient's teeth. The method includes depositing a composite material into at least one recessed portion of an inner surface of a dental appliance. The inner surface of the dental appliance is conformal to one or more of the patient's teeth. The method further includes positioning an adhesive device template on one or more of the patient's teeth; curing the composite material to form a cured composite adhesive device bonded to the patient's teeth; and removing the adhesive device template from the patient's teeth. The dental appliance comprises a polymer sheet composition including at least one layer with a thickness between about 0.2 mm and 0.5 mm and an elastic modulus between about 150,000 psi and 300,000 psi.

[0018] In some embodiments, the polymer sheet composition comprises a copolyester with an elastic modulus of about 150,000 psi to 300,000 psi; 160,000 psi to 290,000 psi; 170,000 psi to 280,000 psi; 160,000 psi to 270,000 psi; 170,000 psi to 260,000 psi; 180,000 psi to 250,000 psi; 190,000 psi to 230,000 psi; 195,000 psi to 225,000 psi; 200,000 psi to 220,000 psi; 205,000 psi to 220,000 psi; or 215,000 psi to 220,000 psi.

[0019] In some embodiments, the polymer sheet composition comprises a copolyester with an elastic modulus of about 180,000 psi to 220,000 psi; 185,000 psi to 215,000 psi; 190,000 psi to 210,000 psi; or 195,000 psi to 205,000 psi.

[0020] In some implementations, the dental appliance includes a trimming line extending from approximately -1.0 mm to 4.0 mm beyond the apex of the gingival line of the tooth.

[0021] In some implementations, the dental appliance includes a trimming line extending from approximately 0 mm to 2.0 mm beyond the apex of the gingival line of the tooth.

[0022] In some embodiments, the polymer sheet composition comprises a copolyester with a thickness of about 0.25 mm to 0.45 mm, 0.3 mm to 0.4 mm, 0.35 mm to 0.4 mm, or 0.34 mm to 0.42 mm.

[0023] In some embodiments, the polymer sheet composition has a pull-out force of less than 22 Newtons (i.e., 22 N) with the cured dental composite material.

[0024] In some embodiments, the polymer sheet composition has a pull-out force of 5N-22N, 5N-20N, 5N-15N, 5N-10N, 1N-10N, 2N-10N, 3N-10N, or 4N-10N with the cured dental composite material.

[0025] In some embodiments, the polymer sheet composition comprises a copolyester. Attached Figure Description

[0026] This technology will be more fully understood through the following detailed description taken in conjunction with the accompanying drawings, in which: Figure 1 An example connector template for attaching a connector to a patient's teeth is shown according to an embodiment of the present disclosure.

[0027] Figure 2 An example of an adhesiograph template placed on a patient's upper teeth according to an embodiment of the present disclosure is shown.

[0028] Figure 3 A graph showing the adhesive properties of various joint template materials according to embodiments of the present disclosure is provided.

[0029] Figure 4 A graph showing the adhesion properties of various composite materials according to embodiments of the present disclosure is provided.

[0030] Figure 5 The graphs show the adhesion test results of various joint templates and composite materials according to embodiments of this disclosure.

[0031] Figure 6 An example connector template trimming line according to an embodiment of this disclosure is shown.

[0032] Figure 7 A flowchart is depicted for a method of attaching an adhesive device to a patient's teeth according to an embodiment of the present disclosure. Detailed Implementation

[0033] This disclosure relates to techniques for attaching an adhesive device or other device to a patient's teeth using an adhesive device template, and to materials and designs for such templates. Adhesive devices or other features can be attached to a patient's teeth to apply more precise forces to the teeth during orthodontic treatment. These adhesive devices are typically formed from a composite material that is cured onto specific portions of the patient's teeth to provide anchoring points to which the orthodontic appliance can interact. These adhesive devices create protrusions that extend from the patient's teeth and can be formed in a variety of different shapes and sizes. Typically, these adhesive devices are made from a composite material that substantially matches the color of the patient's teeth, making them less noticeable. The adhesive device can be fitted into a corresponding cavity or recess on the inner surface of a clear aligner (the surface of the aligner that contacts the patient's teeth).

[0034] An orthodontic appliance can be attached to a patient's teeth using an appliance template, which is a clear or translucent dental instrument shaped to fit the patient's teeth and includes a recessed portion whose size and shape are designed to match the desired geometry of the appliance. Because this appliance template is not intended to move the patient's teeth, its material properties and design can differ from those of a clear aligner.

[0035] To attach the occluder to a patient's teeth, an occluder template is first placed on the patient's teeth to confirm proper fit, and the recessed portions of the occluder template align with the desired final placement of the occluder(s). Once proper fit is confirmed, the positions of all occluders on the patient's teeth can be identified. The occluder template can then be removed, and one or more of the patient's teeth can be etched and rinsed in the areas where the occluders will be attached.

[0036] Once the patient's teeth have been etched and flushed in the area where the connector will be bonded, the connector cavity on the inner surface of the connector template can be filled with a composite material. In some embodiments, it may be desirable to apply a light coating of petroleum jelly or some other lubricant to the connector cavity to prevent the composite material from bonding to the connector template material. In some embodiments, the connector cavity is first filled with approximately two-thirds full of a paste-like compound, and then the remaining one-third of the connector cavity is filled with a flowable composite material. It should be understood that various different types of composite materials can be used to form the connector in this process. The techniques described herein can be implemented with any suitable flowable or paste-like compound or any combination of both.

[0037] Before the adapter template is placed back onto the tooth, the bonding agent can be applied and cured onto the etched portion of the patient's tooth. After the adapter template is placed back onto the patient's tooth and the composite material is contained within the adapter cavity, the composite material can be cured to form a solid adapter bonded to the tooth. Once the composite material has cured, the adapter template can be removed from the patient's tooth, and any excess material around the adapter can be removed with a scraper. Now that the physical adapter has been placed on the desired tooth, the fit of the orthodontic appliance can be checked. Various types of adapters with different geometries can be applied in this way, and multiple adapters can be applied to different teeth simultaneously.

[0038] During the application of the connector, numerous challenges may arise for the provider. In some cases, the provider may find it difficult to remove the connector template after the connector has been attached to the tooth. Many factors can contribute to these challenges, including but not limited to the flexibility or rigidity of the connector template material, the tendency of the connector template material to inappropriately bond with composite materials, or the size of the connector template that makes it more challenging than removal is required.

[0039] The connector templates disclosed herein can be made of polymeric materials, such as thin, thermoformable materials. In some cases, the connector template is manufactured by thermoforming a polymeric material around a dental model of the patient's teeth, wherein the dental model includes protrusions that match the final geometry and position of the connector. The polymeric material should be thick enough to thermoform around the dental model.

[0040] Figure 1 An example connector template 101 for attaching a connector to a patient's tooth is shown according to an embodiment of the present disclosure. In this exemplary embodiment, the connector template 101 is in the form of a transparent thermoformed dental appliance and includes a concave connector cavity 103 formed in the inner surface of the connector template 101 (i.e., the surface of the connector template that contacts the patient's tooth). Although only one connector cavity 103 is shown in this embodiment, multiple connector cavities with different geometries and different locations may be included within a single connector template to attach different connectors to different teeth.

[0041] According to one embodiment, the connector template 101 can be formed from a polymer sheet, such as a copolyester, which is thermoformed onto a positive model of the patient's dentition. In an alternative embodiment, the connector template 101 can be formed from low-density polyethylene, polyurethane, or ethylene vinyl acetate. In some embodiments, the model of the patient's dentition can be manufactured using 3D printing or other additive manufacturing processes and can include protrusions on one or more teeth corresponding to the desired connector to be attached to the patient's teeth. Such a physical model of the patient's teeth with connectors can be modeled and designed using various software products based on digital scans of the patient's teeth. During the treatment planning process, a technician or dental provider can manipulate the 3D digital model of the patient's dentition and position virtual connectors on the individual teeth. This digital model can then be used to manufacture a physical model of the patient's dentition, which can be used to thermoform the connector template 101.

[0042] Figure 2 An example of an adhesive template 201 placed on a patient's upper teeth according to an embodiment of the present disclosure is shown. In this embodiment, as described above, the patient's teeth receiving the adhesive have been treated, and a composite material is placed within the adhesive cavity 203. Once the adhesive template 201 is placed on the patient's teeth, the composite material within the adhesive cavity 203 can be cured, and the adhesive template 201 can then be removed to leave a solid adhesive bonded to the patient's teeth.

[0043] Material properties Because the connector template is used to attach the connector to the patient's teeth, rather than moving the teeth during steps of the orthodontic treatment plan, the material properties of the connector template can differ from those of the clear aligner.

[0044] To examine the effectiveness of various connector template materials and designs, numerous experiments and tests were conducted, and are discussed below. In these experiments, connector template materials with different thicknesses, flexibility, and rigidity properties were tested to determine the ease of application and removal. Different connector template materials were also tested with different composite materials to determine material adhesion properties. Different connector template trimming lines were also tested to determine the ease of connector application and connector template removal.

[0045] In one example, a material that is more flexible than the orthodontic material was found to be an improvement for effectively attaching the connector and removing the connector template from the patient's mouth.

[0046] In one specific implementation, when tested at a test thickness of 9.8 mils according to the ASTM D882 test method, the copolyester with suitable flexibility and low composite adhesion properties includes an amorphous copolyester having a transverse (TD) modulus of elasticity of about 200,000 psi (about 1,380 MPa) and a longitudinal (MD) modulus of elasticity of about 210,000 psi (about 1,460 MPa).

[0047] The term "elastic modulus" is used as a measure of a material's resistance to elastic deformation under load. Elastic modulus is defined as the ratio of the force applied to a material to the resulting deformation. The term "flexibility" describes a material's ability to elastically deform and return to its original shape when the force is removed. Therefore, a stiffer material will have a higher elastic modulus (i.e., it requires a higher force to induce deformation), while a more flexible material will have a lower elastic modulus (i.e., it requires a smaller force to induce deformation). Material thickness also affects flexibility, such that a thicker sheet of the same material may be less flexible than a thinner sheet.

[0048] In other embodiments, thermoplastics with an elastic modulus of approximately 150,000 psi-300,000 psi; 160,000 psi-290,000 psi; 170,000 psi-280,000 psi; 160,000 psi-270,000 psi; 170,000 psi-260,000 psi; 180,000 psi-250,000 psi; 190,000 psi-230,000 psi; 195,000 psi-225,000 psi; 200,000 psi-220,000 psi; 205,000 psi-220,000 psi; or 215,000 psi-220,000 psi can be used.

[0049] In one specific implementation, when tested at a test thickness of 9.8 mils according to the ASTM D882 test method, the copolyester with suitable flexibility and low composite adhesion includes a TD yield tensile strength of about 5,800 psi (about 39.9 MPa) and an MD yield tensile strength of about 5,950 psi (about 41 MPa).

[0050] In other embodiments, thermoplastics with tensile strengths of about 5,500 psi to 6,300 psi; 5,600 psi to 6,200 psi; 5,700 psi to 6,100 psi; or 5,800 psi to 6,000 psi can be used.

[0051] In other embodiments, thermoplastics with tensile strengths of about 5,000 psi to 11,000 psi; 5,500 psi to 10,500 psi; 6,000 psi to 10,000 psi; 6,500 psi to 9,500 psi; 7,000 psi to 9,000 psi; or 7,500 psi to 8,500 psi can be used.

[0052] In other embodiments, thermoplastics with yield stresses of about 4,000 psi to 9,000 psi; 4,500 psi to 8,500 psi; 5,000 psi to 8,000 psi; 5,500 psi to 7,500 psi; 5,500 psi to 7,000 psi; 5,500 psi to 6,500 psi; or 5,500 psi to 6,000 psi can be used.

[0053] In other embodiments, thermoplastics having an elongation at break between about 110%-130% or 115%-125% can be used.

[0054] In one specific implementation, when tested according to ASTM D1505 test method, the copolyester exhibiting suitable flexibility and low composite adhesion properties comprises approximately 1.2 g / cm³. 3 The density.

[0055] In other embodiments, a density of approximately 0.9 g / cm³ can be used. 3 -1.3g / cm 3 1.0 g / cm 3 -1.25g / cm 3 1.05 g / cm 3 -1.2g / cm 3 1.1 g / cm 3 -1.2g / cm 3 ; or 1.15 g / cm 3 -1.2g / cm 3 Thermoplastic.

[0056] In one specific embodiment, the copolyester having suitable flexibility and low composite adhesion properties includes a glass transition temperature of about 230℉ (100°C). In other embodiments, thermoplastics with glass transition temperatures of about 200℉ to 260℉, 210℉ to 250℉, or 220℉ to 240℉ can be used.

[0057] Table 1 Table 1 shows a set of acceptance criteria for various material parameters of a suitable copolyester with a thickness of about 0.38 mm according to embodiments of the present disclosure. In alternative embodiments, materials of different thicknesses may be used, and due to the increased thickness, they may have slightly different material parameters, or they may have the same material parameters as those shown in Table 1.

[0058] Material thickness In one embodiment, a copolyester sheet with a thickness equal to or less than 0.5 mm results in a lower tendency for a more flexible coupler template and coupler template to attach to the composite material after thermoforming. Possible thickness ranges may include, for example, between 0.2 mm and 0.5 mm, 0.25 mm and 0.45 mm, 0.3 mm and 0.4 mm, 0.35 mm and 0.4 mm, or 0.34 mm and 0.42 mm. In one specific embodiment, a copolyester sheet having a thickness of about 0.38 mm prior to thermoforming results in a lower tendency for a suitably flexible coupler template and coupler template to attach to the composite material.

[0059] Table 2 Table 2 provides a set of acceptable physical dimensions for a suitable copolyester roll with a nominal thickness of about 0.38 mm according to one specific embodiment of this disclosure. In some embodiments, a material thicker than 0.38 mm (e.g., about 0.5 mm) may be used. In this case, the slightly thicker material will result in reduced flexibility.

[0060] Material adhesion Figure 3 The graphs showing the adhesion properties of various joint template materials according to embodiments of the present disclosure are illustrated. Figure 3 In the experiment shown, a dental composite material labeled as Composite A was cured into sheets of connector template material candidates labeled as Materials 1, 2, 3, and 4. A mechanical testing instrument was used to measure the force required to separate the composite material from the connector template material.

[0061] from Figure 3 As can be seen, materials 1-3 exhibit superior adhesion properties compared to material 4 (i.e., they adhere less to the composite material, and less force is required to separate them). Each of these tests was conducted without the use of petroleum jelly or any other lubricant between the test materials and the composite material.

[0062] In one embodiment, a suitable thermoplastic material used with the connector template disclosed herein may have a material adhesion-pull-off force of less than 22 Newtons (i.e., 22 N). In other embodiments, a suitable thermoplastic material used with the connector template disclosed herein may have a material adhesion-pull-off force between about 5 N to 22 N, 5 N to 20 N, 5 N to 15 N, 5 N to 10 N, 1 N to 10 N, 2 N to 10 N, 3 N to 10 N, or 4 N to 10 N.

[0063] Figure 4 Graphs showing the adhesion properties of various composite materials according to embodiments of this disclosure are illustrated. Figure 4 In the experiments shown, samples from many different dental composite materials were tested. Figure 3 Material 1 comprises a copolyester material having advantageous adhesion properties and other material properties within the aforementioned advantageous range. These various dental composite materials, identified as composite material A, composite material B, composite material C, and composite material D, are cured into material sheet 1, and a mechanical testing instrument is used to measure the force required to separate the composite material from material 1. Figure 4 As can be seen, material 1 performs well and has appropriately low material adhesion to composite materials, especially to composite materials A and D.

[0064] Figure 5 Adhesion test graphs for various joint templates and composite materials according to embodiments of this disclosure are shown. Figure 5 As shown, materials 1-3 performed better and exhibited less adhesion to each of the tested composites compared to material 4. Notably, material 1, which includes copolyester materials with other material properties within the aforementioned advantageous range, performed significantly better than material 4 and had the lowest detachment force for composite D.

[0065] Coupler template trimming line Figure 6 An example connector template trimming line according to an embodiment of the present disclosure is shown. In this example embodiment, the connector template 601 has been thermoformed onto a model of the patient's dental arch 603. The connector template 601 has been trimmed along trimming line 605 to remove excess thermoplastic material.

[0066] Because the adapter template is not intended to move teeth, the trimming line of the adapter template does not need to be the same as the trimming line of the future orthodontic appliance that the patient will use during the treatment plan. In some implementations, a higher or lower trimming line can provide increased flexibility or reduce unnecessary retention and rigidity, and thus help prevent the adapter from being pulled off when the adapter template is removed after the curing process.

[0067] exist Figure 6 In the example shown, the trimming line 605 may be defined by a distance 607 extending from the apex 609 of the gingival line beyond the patient's teeth by the connector template 601. In one exemplary embodiment, a trimming line extending from the apex 609 beyond the teeth by a distance 607 of approximately 0-2 mm results in a better fit for placing the connector without significantly sacrificing ease of template removal. In some embodiments, a suitable trimming line may extend from the apex 609 beyond the teeth by a distance 607 of approximately -1.0 mm to 4.0 mm; -0.5 mm to 4.0 mm; 0 mm to 4.0 mm; 0 mm to 3.5 mm; 0 mm to 2.5 mm; 0 mm to 2.0 mm; 0 mm to 1.5 mm; 0 mm to 1.0 mm; or 0 mm to 0.5 mm. In the example characterized by a negative distance of 607, trim line 605 is positioned such that joiner template 601 ends before vertex 609, that is, trim line 605 is before vertex 609, so that the vertex is not covered by joiner template 601.

[0068] In some implementations, the trimming line of the connector template can vary across different teeth of the patient. Depending on the size, position, and many other factors of the patient's teeth, forming a smooth trimming line that cuts at the same distance from the apex of the gingival line relative to each tooth in the patient's dentition can be challenging. Therefore, the trimming line of a single connector template can be measured with different values ​​relative to different teeth.

[0069] According to some embodiments, the trimming line can vary within certain values ​​(such as those ranges disclosed above) within the engagement template. In a preferred embodiment, when measured along all or most of the teeth in the patient's dentition, the trimming line is preferably between about 0 mm and 2 mm.

[0070] In some cases, the trimming line may also have a minimum distance relative to the position of the connector itself. For example, the connector template may have a trimming line that ensures a distance of at least 1 mm between the trimming line and the nearest part of the connector to the tooth. This minimum trimming line distance ensures that there is sufficient material in the connector template for precise placement of the connector.

[0071] method Figure 7 A flowchart depicts a method for attaching an adhesive device to a patient's tooth according to an embodiment of this disclosure. In this example embodiment, at 701, the method begins by etching and rinsing the portion of the tooth where the adhesive device will be placed. In some cases, additional steps may be performed before 701, such as testing the proper fit of the adhesive device template. Depending on the type of composite material used, different preparation steps may also be involved.

[0072] At point 703, the connector template cavity is filled with a composite material. In some alternative embodiments, it may be desirable to apply a light coating of petroleum jelly or some other lubricant to the connector cavity to prevent the composite material from bonding to the connector template material. In some embodiments, the connector cavity is first filled with a paste-like compound, and then the remainder of the connector cavity is filled with a flowable composite material. It should be understood that various different types of composite materials can be used to form the connector in this process.

[0073] Before placing the connector template on the tooth at 707, the bonding agent can be applied and cured to the etched portion of the patient's tooth at 705. As described above, the various material properties, thicknesses, and trimming lines of the connector template can facilitate easy placement of the connector template on the patient's tooth, thereby accurately positioning the connector in the desired location.

[0074] In some implementations, acid etching at 701 and bonding agent application at 705 may be optional operations.

[0075] After the connector template is placed on the patient's tooth and the composite material is contained within the connector cavity, the composite material can be cured at 709 to form a solid connector bonded to the tooth.

[0076] At point 711, the connector template can be removed from the patient's tooth, leaving the connector attached to the tooth. Various material properties and design choices for the connector template, such as material adhesion properties, flexibility, thickness, trimming lines, etc., can contribute to the ability to easily remove the connector template without damaging the connector or removing the attached connector from the patient's tooth, as described above. In some embodiments, any excess material around the connector can be removed with a scraper.

[0077] Those skilled in the art will understand that additional processing steps or fewer steps may be performed in order to apply the connector using the connector template disclosed herein.

[0078] The above is merely a description of preferred embodiments and applied technical principles of this application. Those skilled in the art should understand that the scope of this application is not limited to technical solutions formed by specific combinations of the above-described technical features. Without departing from the concept of this invention, the scope of this invention should also cover other technical solutions formed by any combination of the above-described technical features or their equivalents, such as technical solutions formed by replacing (but not limited to) the features disclosed in this application with technical features having similar functions.

Claims

1. A dental appliance conforming to one or more teeth, comprising: a polymeric sheet composition comprising at least one layer having a thickness of about 0.2 mm to 0.5 mm and an elastic modulus of about 150,000 psi to 300,000 psi; and at least one recessed portion on an inner surface of the appliance that at least partially conforms to the one or more teeth of a patient, the at least one recessed portion shaped to receive a composite material prior to being positioned on the teeth of a patient.

2. The dental appliance of claim 1, wherein the polymeric sheet composition comprises a copolyester.

3. The dental appliance of claim 2, wherein, the polymeric sheet composition comprises a copolyester having an elastic modulus of about 150,000 psi to 300,000 psi; 160,000 psi to 290,000 psi; 170,000 psi to 280,000 psi; 160,000 psi to 270,000 psi; 170,000 psi to 260,000 psi; 180,000 psi to 250,000 psi; 190,000 psi to 230,000 psi; 195,000 psi to 225,000 psi; 200,000 psi to 220,000 psi; 205,000 psi to 220,000 psi; or 215,000 psi to 220,000 psi.

4. The dental appliance of claim 2, wherein, the polymeric sheet composition comprises a copolyester having an elastic modulus of about 180,000 psi to 220,000 psi; 185,000 psi to 215,000 psi; 190,000 psi to 210,000 psi; or 195,000 psi to 205,000 psi.

5. The dental appliance of any one of claims 1-4, further comprising a trim line extending between about -1.0 mm to 4.0 mm above the apex of the gum line of the tooth.

6. The dental appliance of any one of claims 1-4, further comprising a trim line extending between about 0 mm to 2.0 mm above the apex of the gum line of the tooth.

7. The dental appliance of any one of Claims 1-6, wherein, the polymeric sheet composition comprises a copolyester having a thickness of between about 0.25 mm to 0.45 mm, 0.3 mm to 0.4 mm, 0.35 mm to 0.4 mm, or 0.34 mm to 0.42 mm.

8. The dental appliance of any one of Claims 1-7, wherein, the polymeric sheet composition has a pull-off force with a cured dental composite material of less than 22 N.

9. The dental appliance of any one of Claims 1-7, wherein, the polymeric sheet composition has a pull-off force with a cured dental composite material of 5 N to 22 N, 5 N to 20 N, 5 N to 15 N, 5 N to 10 N, 1 N to 10 N, 2 N to 10 N, 3 N to 10 N, or 4 N to 10 N.

10. A method of incorporating one or more connectors to a patient’s teeth, comprising: depositing a composite material within at least one recessed portion on an inner surface of a dental appliance that at least partially conforms to one or more teeth of a patient, positioning an adapter template on one or more teeth of a patient; curing the composite material to form a cured composite adapter bonded to at least one tooth of the patient; and removing the adapter template from the one or more teeth of the patient, wherein the dental appliance comprises a polymeric sheet composition comprising at least one layer having a thickness between about 0.2 mm and 0.5 mm and an elastic modulus between about 150,000 psi and 300,000 psi.

11. The method of claim 10, wherein the polymeric sheet composition comprises a copolyester.

12. The method of claim 11, wherein the polymeric sheet composition comprises a copolyester having an elastic modulus of about 150,000 psi - 300,000 psi; 160,000 psi - 290,000 psi; 170,000 psi - 280,000 psi; 160,000 psi - 270,000 psi; 170,000 psi - 260,000 psi; 180,000 psi - 250,000 psi; 190,000 psi - 230,000 psi; 195,000 psi - 225,000 psi; 200,000 psi - 220,000 psi; 205,000 psi - 220,000 psi; or 215,000 psi - 220,000 psi.

13. The method of claim 11, wherein the polymeric sheet composition comprises a copolyester having an elastic modulus of about 180,000 psi - 220,000 psi; 185,000 psi - 215,000 psi; 190,000 psi - 210,000 psi; or 195,000 psi - 205,000 psi.

14. The method of any one of claims 10-13, wherein, the dental appliance comprises a trim line extending between about -1 mm and 4.0 mm above an apex of a gum line of a tooth.

15. The method of any one of claims 10-13, wherein, the dental appliance comprises a trim line extending between about 0 mm and 2.0 mm above an apex of a gum line of a tooth.

16. The method of any one of claims 10-15, wherein the polymeric sheet composition comprises a copolyester having a thickness of about 0.25 mm - 0.45 mm, 0.3 mm - 0.4 mm, 0.35 mm - 0.4 mm, or 0.34 mm - 0.42 mm.

17. The method of any one of claims 10-15, wherein the polymeric sheet composition has a pull-off force with a cured dental composite material of less than 22 N.

18. The method of any one of claims 10-15, wherein the polymeric sheet composition has a pull-off force with a cured dental composite material of 5 N - 22 N, 5 N - 20 N, 5 N - 15 N, 5 N - 10 N, 1 N - 10 N, 2 N - 10 N, 3 N - 10 N, or 4 N - 10 N.

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