Orthodontic aligner, attachment, system including appliance and attachment, and method for orthodontic appliance and attachment fabrication

Abstract

To provide an improved orthodontic aligner, attachment, system and method.SOLUTION: An orthodontic aligner includes a shell that defines a tooth cavity. The tooth cavity is configured to receive a patient's tooth and has an edge that defines an opening. An integral hook 22 extends outwardly from wall portions of the shell 12 adjacent to the tooth cavity and is spaced occlusally apart from the edge. The integral hook has a side wall that defines an interior space and includes a window. The interior space opens to the tooth cavity. The window extends through the side wall so that the interior space is accessible. The window can be sized to interfere with insertion of an elastic band. A system for orthodontic treatment includes an attachment. The integral hook is configured to receive the attachment. A method of manufacturing the orthodontic aligner includes a step for preparing a mold including a hook mold.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Application No. 29 / 866,462, filed September 13, 2022, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present invention relates generally to the field of orthodontic treatment, and more specifically to orthodontic appliances, attachments for teeth, attachments engageable with orthodontic appliances, and methods of manufacturing the orthodontic appliances and attachments. [Background technology]

[0003] Orthodontics is the practice of manipulating teeth to correct malocclusions between the teeth in the upper and lower dental arches. Treatment of malocclusions usually involves the use of orthodontic appliances that apply corrective forces to the teeth. Over time, these corrective forces force the teeth to move to their orthodontically correct positions.

[0004] One method of applying corrective forces is with orthodontic appliances called "dental aligners," or simply "aligners." Aligners are typically supplied as a series of removable appliances that gradually reposition the patient's teeth from their initial orientation to their orthodontically correct orientation. Patients being treated with aligners can insert and remove the aligners at will, and thus do not need to visit an orthodontist for archwire changes as is often necessary with orthodontic brackets. Rather, the patient only begins using the next aligner in the series according to the treatment plan when the currently worn aligner has moved the teeth to or near their final orientation for that aligner.

[0005] To manufacture the aligners, the orthodontist first obtains a computer model of the patient's dentition. This model can be generated, for example, by taking an impression of the dentition and scanning the impression into a computer. Once the computer model is obtained, the orthodontist can determine a target orientation of the teeth that will provide the corrected dentition. Multiple computer models can then be generated, each model corresponding to a sequential orientation of the dentition from an initial orientation to a target orientation. This sequential orientation from the initial orientation to the target orientation allows the patient's teeth to move according to a proposed treatment plan. The treatment plan typically includes multiple steps of movement of the teeth from the initial orientation to the target orientation. Depending on the extent of tooth movement, the treatment plan can include a series of individual aligners that are worn in a predetermined order from the initial orientation to the final orientation according to the treatment plan.

[0006] The aligners can be configured to be used in conjunction with dental attachments, called "attachments." An attachment is a solid object that bonds to one or more of the patient's teeth. The attachment is adhesively secured to the tooth and protrudes outward from the tooth. The aligner is then manufactured to fit both the attachment and the tooth. For certain tooth movements, the attachment gives the aligner more power so that the force applied to the tooth can be increased or in a different direction versus using the aligner alone. Among many other benefits, the clinician can better control and predict tooth movement. Ultimately, this configuration can reduce treatment time. When used in conjunction with aligner treatment, the attachment can allow for a more aggressive treatment plan and more pronounced and obvious correction of dental malocclusions versus aligner treatment without attachments.

[0007] Other orthodontic appliances can be used in conjunction with the aligners. For example, an elastic band can be bonded to the aligner at one end and secured at the other end to another aligner on the opposite jaw. When stretched, the elastic band exerts additional force on one or more teeth. Aligners with the aid of elastic bands can be useful in correcting underbites and overbites. Attachment of the elastic band to the aligner is usually accomplished by altering the gingival margin of the aligner to create an attachment point. For example, the gingival margin can be cut in two places and an elastic member is then looped through each of the cuts. This can be called a hook cutout. The middle portion of the aligner between the cuts is bent outward so that the elastic band fits between the aligner and the teeth / gingiva. Attaching the elastic member in this location can cause problems.

[0008] First, the increased corrective forces applied to the dental aligner by the elastic bands create stresses at the attachment points, especially at the cut locations. Shear forces at these points tend to tear the aligner at the cut edges where stress is concentrated. Even without tearing, high stresses at these locations can cause the material to deform or deteriorate prematurely. Degradation can occur through excessive bending, breaking, and / or tearing. Degradation can prevent the aligner from effectively treating the patient and may require the aligner to be replaced. Either way, degradation extends treatment time.

[0009] Second, cutting the aligner can introduce defects at or near the gingival margin, thus reducing the structural integrity of the aligner and potentially making it less effective at moving the teeth in the absence of elastic bands. Again, this can increase treatment time.

[0010] The use of hook clips is also problematic. New patients find it difficult to locate each of the cuts, even when looking in the mirror. It is difficult for patients to find the hook clip by feel, as it does not produce a noticeable tactile feature. And even after finding the hook clip, the patient must insert the elastic band while stretching the edges. This usually requires some practice and can be uncomfortable for the patient, which can lead to compliance issues.

[0011] In addition to hook clips, elastic bands can be utilized in conjunction with aligners via button clips. A button clip is essentially a hole in the side of the aligner. A button, which is a metal or plastic object, is bonded to the patient's tooth. The clip fits over the button. In this way, the button is accessible for the patient or clinician to attach the elastic band. Because the button is bonded to the surface of the tooth, there is a chance of failure to bond, usually due to accidental contact with another object. Failure to bond requires an emergency appointment where the button is reattached. Treatment may be interrupted for this reason. Summary of the Invention [Problem to be solved by the invention]

[0012] Despite overall commercial success, there is a need for improved orthodontic appliances, attachments, systems, and methods. [Means for solving the problem]

[0013] The present invention overcomes shortcomings and drawbacks in orthodontic systems including orthodontic aligners and attachments heretofore known for use in orthodontic treatment. While the present invention will be described in connection with certain embodiments, it will be understood that the present invention is not limited to these embodiments. Instead, the present invention includes all alternatives, modifications, and equivalents as may be included within the spirit and scope of the present invention. In accordance with the principles of the present invention, an orthodontic aligner for orthodontic treatment of a patient's teeth includes a shell defining at least one tooth cavity. The tooth cavity is configured to receive at least one of the patient's teeth, the tooth cavity having an edge defining an opening through which the patient's tooth is received. The shell has wall portions. An integral hook extends outwardly from one of the wall portions adjacent the tooth cavity and is spaced occlusally from the edge. The integral hook has a sidewall defining an interior space and a window. The interior space opens to the tooth cavity. The window extends through the sidewall such that the interior space is accessible through the window.

[0014] In one embodiment, the side walls of the integral hook include a mesial wall, a distal wall, an occlusal wall, and a gingival wall, and the window extends along at least any two walls, or extends along any three walls.

[0015] In one embodiment, the window opens in one of an occlusal, gingival, mesial, or distal direction when the orthodontic aligner is placed on the patient's teeth. In some variations, the window is wedge-shaped.

[0016] In one embodiment, at least a portion of the window is sized to prevent insertion of an elastic band.

[0017] In one embodiment, the window includes a through wall that traverses the outer and inner surfaces of the sidewall of the integral hook. The through wall has opposing portions that define a first width at the opening of the window, and the through wall has opposing portions that define a second width near an end of the opposing portions of the through wall. The first width is greater than the second width. In some variations, the first width is greater than a diameter of the elastic band, such that the opening is configured to receive the elastic band. In some variations, the second width is less than a diameter of the elastic band, such that there is an interference fit between the elastic band and the window at the second width.

[0018] In one embodiment, the sidewall has a generally dome-like configuration.

[0019] In one aspect of the invention, there is a system for orthodontic treatment. In one embodiment, the system includes an embodiment of an orthodontic aligner and an attachment configured to be secured to a patient's tooth. An integral hook of the orthodontic aligner is configured to receive the attachment when the orthodontic aligner is placed on at least one of the patient's teeth. The attachment is accessible through a window. In some variations, the attachment does not fill the interior space of the integral hook. For example, in one embodiment, the attachment fills 75% or less of the interior space of the integral hook. As a further example, in one embodiment, the attachment fills more than 35% of the interior space of the integral hook.

[0020] In one embodiment, the attachment does not fill the interior space of the integral hook such that the unfilled portion of the interior space between the attachment and the sidewall of the integral hook is accessible through the window.

[0021] In one embodiment, the window includes a through wall traversing the exterior and interior surfaces of the side wall, the through wall having opposing portions defining a first width at the window opening and a second width near an end of the opposing portions of the through wall. In some variations, the first width is greater than the second width. In other variations, the first width is less than the second width.

[0022] In one embodiment, when an orthodontic aligner is placed on a patient's teeth, the depth of the window from the opening to the end of the opposing portion of the through wall is greater than the distance measured from the opening to the surface of the attachment.

[0023] In one embodiment, the system further includes an elastic band. The elastic band is insertable into the window so that it contacts the attachment. After insertion, the elastic band is held in place within the window by the integral hook. In some variations, when the elastic band contacts the attachment, the elastic band and / or the integral hook are elastically deformed.

[0024] In one embodiment, the integral hook grips the elastic band when the elastic band is in contact with the attachment.

[0025] In one aspect of the invention, there is a method of manufacturing one or more embodiments of an orthodontic aligner. The method includes providing a mold including one or more protrusions on one or more configurations of a patient's teeth and a hook mold extending outwardly from the one or more protrusions. The method further includes deforming a workpiece over the mold including the hook mold to create a deformation region of the workpiece including a preformed hook, and removing a portion of the preformed hook to form a window.

[0026] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the detailed description given below, serve to explain various aspects of the invention. [Brief description of the drawings]

[0027] [Figure 1] FIG. 2 is a perspective view of a system according to an embodiment of the present invention with an aligner in position relative to a corresponding jaw including an attachment. [Diagram 2]FIG. 2 is a perspective view of the aligner of FIG. 1 in position for orthodontic treatment of the jaw shown in FIG. [Diagram 3] FIG. 3 is a perspective view of a system including the aligner and attachment shown in FIG. 2, illustrating an elastic band engaged with a temporary anchor device according to one embodiment of the present invention. [Figure 4] FIG. 2 is an enlarged perspective view of the aligner shown in FIG. 1. [Diagram 5] FIG. 5 is an enlarged view of the aligner shown in FIG. [Figure 6] FIG. 6 is a close-up view of the integral hook shown in the aligner of FIG. [Figure 7A] FIG. 7 is a cross-sectional view of one embodiment of an integral hook taken along section line 7-7 of FIG. [Figure 7B] 11A-11C are cross-sectional views of alternative embodiments of integral hooks in accordance with embodiments of the present invention. [Figure 7C] 11A-11C are cross-sectional views of alternative embodiments of integral hooks in accordance with embodiments of the present invention. [Figure 7D] 11A-11C are cross-sectional views of alternative embodiments of integral hooks in accordance with embodiments of the present invention. [Figure 8] FIG. 2 is an enlarged perspective view of the attachment of FIG. 1 according to one embodiment of the present invention. [Figure 9] FIG. 9 is a top left perspective view of the attachment of FIG. 8. [Figure 10] FIG. 9 is a bottom right perspective view of the attachment of FIG. 8. [Figure 11] FIG. 4 is an expanded perspective view of the exemplary system of FIG. 3 in accordance with one embodiment of the present invention. [Figure 12] 12 is a close-up perspective view of the attachment and integral hook arrangement of FIG. 11 without the elastic band shown in FIG. 11 in accordance with one embodiment of the present invention. [Figure 13] FIG. 13 is an elevational view of the attachment and integral hook of FIG. 12. [Figure 14] 14 is a cross-sectional view of the attachment and integral hook taken along section line 14-14 of FIG. 11 showing the elastic band engaged with the attachment. [Figure 14A]FIG. 12 is a side elevational view of the attachment and integral hook of FIG. 11 showing the elastic band engaged with the integral hook. [Figure 15] 2 illustrates a perspective view of one method of manufacturing the aligner of FIG. 1 showing a dental mold and a formed workpiece. [Figure 16] FIG. 16 is an enlarged view of the tooth mold of FIG. 15 showing a hook mold according to one embodiment of the present invention. [Figure 17] FIG. 17 is a perspective view of the hook mold of FIG. 16. [Figure 18] FIG. 17 is a side elevational view of the hook mold of FIG. [Figure 19] FIG. 17 is a schematic side elevational view of a worksheet formed on the hook mold of FIG. 16. [Figure 20] FIG. 20 is a side elevational view of the integral hook after forming a window in the modified worksheet of FIG. 19. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] An embodiment of the present invention is directed to an orthodontic treatment system that includes one or more orthodontic appliances. An exemplary system includes one or more dental aligners and / or attachments for use with the dental aligners. In one embodiment, the dental aligner includes an integral hook formed adjacent to a surface of the patient's teeth and spaced occlusally from the gingival margin of the aligner. Thus, one advantage of the integral hook is that the aligner maintains its structural strength during use, since there is no modification of the gingival margin of the aligner. The exemplary integral hook can receive an elastic band. An exemplary embodiment can include an attachment configured to be secured to a tooth. The attachment and the integral hook can be configured to cooperate with each other during orthodontic treatment. This cooperation can facilitate additional or different forces on a selected tooth or teeth. Additionally, the attachment can be directly externally accessible through a window in the integral hook. As an example, a portion of the elastic band can be inserted into the window to directly contact one or both of the attachment and the integral hook. The other end of the elastic band can be connected, for example, to an aligner on the opposite jaw, thus facilitating an inter-arch or up-down configuration to pull the patient's jaw forward or backward depending on the desired treatment. This configuration is advantageous because the force generated by the elastic band can be transmitted by the attachment alone or by a combination of the attachment and aligner. In some variations, the system can include an elastic band that extends from a first integral hook of an aligner worn on the patient's jaw to a second integral hook on the same aligner, or to a button attached to a tooth in the same jaw on which the aligner is worn. In some variations, the system can include an elastic band that extends from a first integral hook of an aligner worn on the patient's jaw to a second integral hook on a second aligner worn on the opposite jaw, or to a button attached to a tooth in the opposite jaw.

[0029] For these and other purposes, and with reference to Figures 1, 2, and 3, in one exemplary embodiment of the present invention, a dental aligner 10 includes a hollow shell 12 configured to encase one or more crowns of a patient's teeth. The shell 12 can be one or more layers of resilient material and is formed with a number of cavities 14 that collectively define a rim 16. Each cavity 14 is shaped to receive a particular one of the patient's teeth 18. The rim 16 defines an opening 20 in the shell 12. As shown in Figure 1, the cavities 14 receive respective ones of the patient's teeth 18 through the openings 20.

[0030] In the depicted, non-limiting exemplary embodiment, the aligner 10 includes an integral hook 22 in the shell 12. The integral hook 22 has an outer wall 28 that forms a tooth cavity 24 of the aligner 10 to facilitate orthodontic treatment according to an orthodontic treatment plan. The outer wall 28 can define an interior space 52 (FIG. 7A) of the integral hook 22. The interior space 52 can be sized to receive an attachment 26 bonded to a tooth of the jaw on which the aligner 10 is worn. With continued reference to FIG. 1, the integral hook 22 can receive an attachment 26 shown on a tooth 30. When the aligner 10 is placed on the patient's teeth as shown in FIGS. 2 and 3, the attachment 26 can be received within the integral hook 22. In one embodiment, the aligner 10 in conjunction with the attachment 26 forms a system 32 for orthodontic treatment, which can be utilized with an elastic band 34 or other elastic member, an example of which is shown in FIG. 3. As described herein, the elastic band 34 can pass through a window 50 (FIG. 7A) located on the outer wall 28 of the integral hook 22 to reach the attachment 26 that seats within the interior space 52 of the integral hook 22. As shown in FIG. 1, the outer wall 28 can have a dome-like or rounded rectangular shape that helps spread the elastic band 34 over the attachment 26. The window 50 and the dome-like shape of the outer wall 28 assist the patient in seating the elastic band 34 onto the attachment 26. In some configurations, the integral hook 22 can help the patient seat the elastic band 34 onto the attachment 26 without requiring the patient to see the integral hook 22.

[0031] 2 and 3, during orthodontic treatment, the dental aligner 10 can be selectively positioned over the patient's teeth 18. The integral hooks 22 receive the attachments 26. Due at least in part to slight differences in one or more positions of the cavity 14 relative to the positions of the corresponding teeth, the shell 12 can fit closely over the teeth 18. This misalignment can be intentional according to a treatment plan developed for the patient. As a result of these misalignments, the aligner 10 can elastically deform while being positioned over the patient's teeth 18. This elastic deformation can be observable as a measurable amount of volumetric or localized distortion in the shell 12. The distortion of the shell 12 creates pressure against the teeth as the shell 12 attempts to return to an unstrained condition or a reduced-strain configuration. Forced contact with the aligner 10 can move the patient's teeth toward a predetermined position according to the patient's treatment plan. In this regard, the integral hooks 22 can be misaligned with the attachments, such that the hooks 22 can be forcefully engaged with the attachments 26 in response to the intended movement of the teeth 30.

[0032] 3, the system 32 can further include an elastic band 34, which in this exemplary embodiment is shown engaged with the integral hook 22 and a temporary anchoring device (TAD) 36. In this example, the TAD 36 provides a fixed anchor point to which the elastic band 34 is connected. Although not shown, the elastic band 34 can be attached to the patient's opposing jaw in a top-down configuration designed to move one or both jaws in a predetermined direction.

[0033] In one embodiment of the present invention, a set of aligners (not shown) may include one or more dental aligners 10. Each of the aligners in the set may be slightly different so that each provides a slightly different movement of the teeth during orthodontic treatment. Each aligner 10 may include one or more of the integral hooks 22 that cooperate with corresponding attachments 26. The location of the one or more integral hooks 22 and the attachments 26 may vary from aligner 10 to aligner 10. In other words, a set of aligners may correspond to a set of attachments, with the number and location of the attachments varying in each of the aligners in the set. During treatment, attachments may be removed from one tooth and new attachments may be added to other teeth. Individual dental aligners are utilized in a predetermined sequence to complete the orthodontic treatment. Thus, each aligner 10 in the set of aligners may move one or more teeth by a prescribed amount. Cumulatively, these individual amounts may result in a complete treatment of the patient's malocclusion.

[0034] 4 and 5, to fit against the patient's teeth, the shell 12 has wall portions configured to fit against exposed surfaces of the patient's teeth. By way of example, the wall portions may be defined by an occlusal portion 40, a labial portion 42, and a lingual portion 44. These portions 40, 42, 44 are shown relative to the cavity 24. The edge 16 defines the gingival portion of the shell 12. The portions 40, 42, and 44 of each cavity 14 generally fit against a corresponding portion of a respective one of the patient's teeth, with the edge 16 corresponding to the gingival margin for the particular tooth 18. The shell 12 may also include a distal portion 46 that surrounds the cavity that receives the rearmost molar tooth.

[0035] As shown in Figures 4 and 5, the integral hook 22 can be formed in the lip-facing portion 42 of the shell 12. For clarity, the integral hook 22 is described within the context of the depicted, non-limiting exemplary embodiment, which has a vertically oriented integral hook 22 with a window 50 that opens into the bite-facing surface of the integral hook 22. However, the integral hook 22 of the present disclosure need not be limited to the depicted configuration and can be configured in other ways. For example, the integral hook 22 can be rotated about an axis perpendicular to the sidewall through which the integral hook 22 extends. Additionally or alternatively, the window 50 can be rotated relative to the integral hook 22 about that same axis. Furthermore, the window 50 need not have a converging wedge shape as depicted, but can have a straight shape or a diverging wedge shape (see, e.g., Figures 7A-7D).

[0036] This exemplary integral hook 22 extends labially (outwardly) relative to the labial portion 42 of the shell 12. This creates a cavity or open space between the shell 12 and the corresponding tooth surface in the absence of the attachment 26. This cavity or open space is referred to herein as an "internal space 52" and is shown in Figures 7A-7D and described below. As described herein, the integral hook 22 includes a window 50 that extends through the thickness of the shell 12. As an example, as shown in Figure 3, the window 50 can receive an elastic band 34. It will be understood that the window 50 can receive other orthodontic devices, such as telescoping or fixed length arms often utilized in Herbst style appliances. In some variations, the system 32 can include multiple integral hooks 22, each of which can be formed of any single or combination of portions 42, 44, and 46, and embodiments of the present invention are not limited to a single integral hook 22 on the labial portion 42 as shown. For example, the integral hook 22 may be formed on the tongue portion 44 of the shell 12 and thus extend outwardly, away from the tongue portion 44 in the tongue direction.

[0037] As shown in Figures 5, 6, 7A, 7B, 7C, and 7D, the integral hook 22 is integral with the shell 12 and has an outer wall 28 that defines a dome-like configuration relative to the labial portion 42 of the shell 12. The outer wall 28 defines an interior space 52 (as labeled in each of Figures 7A-7D). In this exemplary embodiment, the interior space 52 is disposed labially relative to the corresponding tooth 18 (see, for example, Figure 3), and the interior space 52 is accessible through a window 50 disposed in the outer wall 28. Thus, the cavity 24 of the shell 12 receives the tooth 30, and the interior space 52 of the integral hook 22 receives the attachment 26. Without the attachment 26, the interior space 52 would be an empty space adjacent the tooth 30 (i.e., an empty dome). Typically, the integral hook 22 protrudes from the labial portion 42 of the shell 12. Although having any configuration sufficient to facilitate orthodontic treatment, this exemplary embodiment is defined by a labial wall 54, a mesial wall 56, a distal wall 58, an occlusal wall 60, and a gingival wall 62. These walls 54, 56, 58, 60, and 62 are integral with the shell 12 and define the interior space 52. The terms labial, mesial, distal, occlusal, and gingival are used in the description of the drawings, but are only referenced to distinguish one direction from the other and are not limiting. For example, an integral hook on the lingual side of the aligner would have a similar description, but could include a lingual wall rather than a labial wall. Furthermore, the term "wall" in any of the labial, mesial, distal, occlusal, and gingival walls is not limited to a flat surface, i.e., a plane that faces or is oriented in a particular direction. For example, any single or all of the walls can be curved (i.e., have no flat areas) and / or multi-faceted (i.e., have many planes). Also, although integral hook 22 is shown generally oriented perpendicularly to portion 42 of shell 12, integral hook 22 can be rotated to other orientations to orient the wall or wall portion in a particular direction. As a specific example, the integral hook can be rotated 45° from that shown so that the window opens in a mesio-occlusal or distal-occlusal direction.These orientations would result in the wall or portions thereof facing labial (or lingual), mesial, distal, occlusal, and gingival directions.

[0038] In the illustrated exemplary embodiment, the window 50 is defined by a through-thickness surface or wall 64 that intersects or connects with the outer surface 70 and inner surface 78 of the integral hook 22. In the example shown in FIG. 7A, the opposing through-wall portions 64a, 64b of the wall 64 follow a mouth-shaped configuration with the maximum distance between the opposing lingual and labial portions 64a, 64b of the through-wall 64 at the occlusal wall 60. The mouth-shaped configuration is concave relative to the labial portion 42. This maximum distance defines the width of the opening 68 for the window 50 at the occlusal wall 60. Around the periphery of the integral hook 22, the through-wall 64 extends across the occlusal wall 60 from the mesial wall 56 to the distal wall 58. In essence, the through-wall 64 is on three of the four sides of the integral hook 22. The through-wall 64 extends around each of the mesial and distal walls 56, 58 towards the gingival wall 62 to the most gingival end 66. The distance between the opposing lingual through wall portion 64a and labial through wall portion 64b decreases gradually along each wall 56, 58, respectively, toward each of the ends 66 of the through wall 64. In this example, one or both of the mesial wall 56 and distal wall 58 have ends 66. The ends 66 represent the furthest distance that the window 50 extends along the mesial wall 56 and along the distal wall 58. At each end 66, the lingual wall portion 64a and the labial wall portion 64b meet or merge. Although the ends 66 on each wall 56, 58 appear to be symmetrically disposed, embodiments of the present invention are not limited to this configuration. The narrowing distance between the portions 64a, 64b creates a wedge shape. As shown, the opposing portions 64a, 64b of the through wall 64 may be non-planar, and in this example, have an arcuate shape.

[0039] The through wall 64 defines the dimensions of the window 50. For example, the depth D1 of the window 50 is determined by the end 66 of the wall 64 where the opposing portions 64a, 64b meet. The depth D1 is the perpendicular distance from a plane at the opening 68 to a plane at the end 66. In FIG. 7A, these planes are perpendicular to the page at each of these locations. The depth D1 of the window 50 may depend on the dimensions of the attachment 26, which will be described below. The depth D1 of the window 50 in FIG. 7A is approximately half the height H1 between the general occlusal and gingival sides of the integral hook 22 about the base point at the labial portion 42 of the protrusion P1 between the general labial and lingual sides of the integral hook 22.

[0040] In this exemplary configuration, the aperture 68 may be widest at the occlusally facing wall 60, and thus the window 50 is open in the occlusal direction. Furthermore, the distance between the opposing portions 64a, 64b determines a width W1 at the occlusally facing wall 60 at the aperture 68. The distance between the opposing portions 64a, 64b decreases to a width W2 at or near the end 66 (e.g., within 2 mm to 3.5 mm). In some configurations, the width W1 may be greater than the width W2. Thus, the window 50 narrows in the gingival direction. That is, the window 50 may narrow in the direction away from the aperture 68. In the depicted embodiment, the ratio of the width W1 to the width W2 is about 2:1. In some configurations, the ratio of W1:W2 may be 0.5:1, 1:1, 4:1, or a ratio having a value between any of the aforementioned values. The dimensions of the widths W1 and W2 may depend on the dimensions of the elastic band 34, as described with reference to FIGS. 14 and 14A. Although not shown, the window 50 can extend across any two or three of the walls 54, 56, 58, 60, and 62 and thus can be open in any single direction, mesial, distal, or gingival, to receive the elastic band 34.

[0041] Alternative or additional non-limiting embodiments are depicted in Figures 7B, 7C, and 7D, with like reference numbers referring to like features throughout the figures. In the example shown in Figure 7B, the opposing through-wall portions 64a, 64b of the wall 64 follow a mouth-shaped configuration, with the maximum distance between the opposing lingual and labial portions 64a, 64b of the through-wall 64 at the occlusal wall 60. The mouth-shaped configuration is convex with respect to the labial portion 42, and thus is generally the opposite orientation to that shown in Figure 7A. In the example shown in Figure 7C, the opposing through-wall portions 64a, 64b follow a rectangular configuration, with the opposing lingual and labial portions 64a, 64b being generally parallel, and the end 66 being perpendicular to the parallel opposing portions 64a and 64b. The width between the opposing lingual and labial portions 64a, 64b is constant from the opening 68 to the end 66, with W1 being equal to W2. 7D, the opposing through-wall portions 64a, 64b follow an irregular polygonal configuration in which the opposing lingual and labial portions 64a, 64b are not parallel and the end 66 is not perpendicular to the opposing portions 64a and 64b. The width between the opposing lingual and labial portions 64a, 64b increases from the opening 68 to the end 66, with W1 being less than W2.

[0042] With reference to one exemplary embodiment shown in Figures 8, 9, and 10, the attachment 26 can be attached or formed on the lip-facing surface of the patient's tooth 30 at the lingual side 72 of the attachment 26. Although not shown, attachment to the tooth 30 can be accomplished during the formation of the attachment 26 to the tooth surface. In this regard, and although not shown in the figures, the attachment 26 can be formed and placed on the patient's tooth, such as the tooth 30 in Figures 1 and 8, while the patient is in the clinician's office. A template aligner (TA) can be utilized for this dual purpose. The TA is similar to the aligner 10, but is usually more flexible, and includes a cavity where the attachment 26 is to be bonded to the tooth 30. The cavity is a negative replica of the attachment 26, i.e., the cavity is the size and shape of the attachment 26 in the desired orientation on the patient's tooth. The clinician can fill the cavity with a composition and then place the TA on the patient's tooth. In this manner, the attachments 26 can be formed and attached in the correct locations to the patient's teeth 30. Once the composition has set or hardened, the TA is peeled off the patient's teeth, leaving the attachments 26 bonded in the correct locations. The TA can be fabricated or printed in a similar manner as the aligners 10, described below.

[0043] Alternatively, separately formed attachments 26 can be adhesively attached to the patient's teeth with, for example, Transbond XT (available from 3M), Transbond PLUS (available from 3M), Go-To Adhesive (available from Reliance), Grenggloo & Blugloo (available from Ormco) in a layer between the lingual side 72 and the surface of the teeth 30. As shown generally with reference to Figures 2 and 3, when the patient places the aligner 10 on his or her jaw, the integral hooks 22 receive the attachments 26.

[0044] It is recognized that, like the integral hook 22, the attachment 26 may be oriented differently than shown for the non-limiting exemplary embodiment of Figures 8, 9, and 10. Nevertheless, for clarity, the features of the attachment 26 will now be described with reference to Figures 8, 9, and 10, where the attachment 26 has a mesial side 74, a distal side 76, an occlusal side 80, and a gingival side 82. The sides 74, 76, 80, and 82 face outwardly and may each cooperate with one or more of the walls 56, 58, 60, 62 of the integral hook 22. During treatment, cooperation between the sides 74, 76, 80, and 82 of the attachment 26 and the walls 56, 58, 60, and 62 of the integral hook 22 may produce orthodontic treating forces against the tooth 30 and one or more surrounding teeth 18 according to a treatment plan. 9 and 10, sides 74, 76, 80, and 82 produce a claw-like or hook-like shape with occlusal side 80 having a concave arc and gingival side 82 having a convex arc. Sides 80 and 82 intersect mesial side 74 and distal side 76, respectively, with rounded tips 84 that are generally parallel or at a slight intersecting angle to one another.

[0045] In the exemplary embodiment shown in Figure 8, the attachment 26 is oriented with the concave side 80 facing in the occlusal direction. The tip 84 thus points in a generally labial-occlusal direction. The shape and orientation of the attachment 26 on the tooth 30 is not limited to the embodiment shown. For example, depending on the forces required for treatment, the attachment 26 can be oriented with the concave side 80 facing in any single direction: gingival (180° from that shown in Figure 8), mesial, or distal.

[0046] The fit of the attachment 26 (without the elastic band 34) within the integral hook 22 is shown in Figures 12, 13, and 14, where the attachment 26 is received in the interior space 52 of the integral hook 22. In some variations, the attachment 26 does not fill all of the interior space 52. In other words, in some configurations, the volume of the attachment 26 is less than the volume of the interior space 52. In some embodiments, the attachment 26 occupies all or almost all of the interior space 52. With reference to the non-limiting exemplary embodiment depicted in Figure 14, the relative fill volume of the attachment 26 can be from 25% to 75%, and as a further example, from 45% to 75%. To this end, one or more of the sides 74, 76, 80, and 82 may not be in direct contact with the corresponding walls 56, 58, 60, and 62 of the integral hook 22, thereby leaving a portion of the interior space 52 unfilled. That is, there are gaps between one or more sides 74 , 76 , 80 , and 82 of the attachment 26 and the corresponding walls 56 , 58 , 60 , and 62 of the integral hook 22 .

[0047] An example of this volumetric relationship is shown in Figures 13 and 14. In one embodiment, the mesial side 74 and distal side 76 of the attachment 26 can be in direct contact with the corresponding walls 56 and 58 of the integral hook 22. Thus, there is little, if any, relative movement between the aligner 10 and the attachment 26 in the mesial / distal direction. The gingival side 82 of the attachment 26 can conform to the gingival wall 62. A protrusion P2 between the labial and lingual sides of the attachment 26 can fill the interior space 52 in the labial-lingual direction. Thus, a gap may exist primarily between the occlusal side 80 of the attachment 26 and the occlusal wall 60 of the integral hook 22.

[0048] 13 and 14, the window 50 is in the occlusally facing wall 60, and the gap or unfilled portion 86 of the interior space 52 between the attachment 26 and the integral hook 22 is an occlusally facing portion of the interior space 52, so that the unfilled portion 86 is open to the window 50. In one embodiment, this results in the occlusal side 80 of the attachment 26 being exposed at the window 50. Stated another way, the depth D1 (FIG. 13) of the window 50 from the opening 68 in the occlusally facing wall 60 to the end 66 along the mesial wall 56 is greater than the depth D2 from the opening 68 in the occlusally facing wall 60 to the occlusal side 80 of the attachment 26. Thus, when viewed in the direction of the mesial wall 56, the attachment 26 has an exposed occlusal intergingival portion 90. The exposed portion 90 extends occlusally relative to the end 66 and toward the opening 68. A portion 92 of the occlusal side 80 is thus exposed at the window 50.

[0049] The cooperation between the integral hook 22 and attachment 26 and the elastic band 34 is shown in Figures 11, 14, and 14A. In this exemplary embodiment of the system 32, the attachment 26 does not fill all of the interior space 52, and the elastic band 34 is received within the window 50 and contacts the attachment 26 on the concave side 80. This configuration is achieved by the relative fit of the attachment 26 in the interior space 52 of the integral hook 22 and the dimensions of the window 50, as discussed above.

[0050] 14 and 14A, the elastic band 34 is shown inserted through the window 50 and in contact with the exposed portion 92 of the occlusal side 80 of the attachment 26. In this exemplary embodiment, the relative dimensions of the window 50 between the opposing through-wall portions 64 and the diameter of the elastic band 34 create an interference fit between the band 34 and the integral hook 22 before the elastic band 34 seats against the exposed portion 92 of the occlusal side 80 of the attachment 26. In alternative configurations, the dimensions of the window 50 may prevent the elastic band 34 from seating on the exposed portion 92, or the dimensions of the window 50 may not prevent contact between the elastic band 34 and the exposed portion 92.

[0051] In this exemplary embodiment, the elastic band 34 contacts the integral hook 22 and the exposed portion 92 at the opposing wall portions 64a, 64b, respectively. The relative dimensions may thus include a width W1 at the opening of the window 50 that is greater than the cross-sectional dimension of the elastic band 34. As a result, during insertion of the elastic band 34 into the window 50, the elastic band 34 may thus be inserted into the window 50 without force. However, the lateral dimension of the window 50 (i.e., between the opposing through wall portions 64) narrows in a direction toward the end 66 to a width W2. At some point near where the elastic band 34 contacts the exposed portion 92 of the occlusal side 80, the width dimension between the opposing through wall portions 64a, 64b, as at width W3 in FIG. 14A, is equal to the unstretched cross-sectional dimension of the elastic band 34. Further insertion of the elastic band 34 against the occlusal side 80 of the attachment 26 toward the seating position requires a force to overcome the interference fit between the elastic band 34 and the integral hook 22.

[0052] At the point of insertion where the dimension of the window 50 is equal to the dimension of the elastic band 34, such as at W3 in FIG. 14A, the band 34 can stretch in the direction of arrow 96, i.e., straight away from the opening of the window 50. The stretching force overcomes the interference between the integral hook 22 and the elastic band 34, so that the band 34 seats against the exposed portion 92 of the attachment 26. When the elastic band 34 seats against the exposed portion 92 of the attachment 26, the elastic band 34 may not contact either of the ends 66. Without being limited by theory, during stretching, the cross-sectional dimension of the elastic band 34 can decrease to a dimension that allows the elastic band 34 to slide between the opposing through-wall portions 64a, 64b and contact the exposed portion 92. Once seated, the elastic band 34 can remain deformed in the absence of the force 96. As an example of deformation of the elastic band 34 in its position, the elastic band 34 is shown deformed from a circular cross-section to an elliptical cross-section in FIG. 14A once seated against the exposed portion 92. There may be localized deformation between the elastic band 34 and the integral hook 22 in the area of ​​contact between the two in the seated position. As an example, the width dimension of the window 50 may increase as the elastic band 34 is forced further into the window 50. Thus, after the elastic band 34 is seated, when the force in the direction of the arrow 96 is removed from the band 34, the band 34 and / or the integral hook 22 may remain partially elastically deformed. This is shown diagrammatically in FIG. 14A. If a rigid orthodontic appliance is inserted into the window, the elastic deformation of the integral hook 22 may be the only deformation that is noticeable. For example, if a metal ring (not shown) is inserted into the window 50, the integral hook 22 may deform, which may hold the ring in position within the window 50 and against the attachment 26. In either case, the remaining elastic deformation can create a gripping force on the elastic band 34 / metal ring that resists unintentional removal of the elastic band 34 / ring from the window 50. Once the elastic band 34 is in the seated position, it can be held in place by the elastic deformation of the band 34 and / or the integral hook 22. The elastic band 34 can only be removed by a force applied in the direction opposite from arrow 96.However, in an alternative configuration, the window 50 can be sized larger than the cross-sectional area of ​​the unstressed elastic band 34 so that the elastic band 34 does not deform the outer wall 28 of the integral hook 22 when the elastic band 34 is seated on the attachment 26.

[0053] 3, 14, and 14A, during treatment when the elastic band 34 applies a force, a large portion of the force from the elastic band 34 can be transferred to the attachment 26 and thus to the teeth 30. As an example, due to the seating position of the elastic band 34 on the attachment 26, at least 70% of the force from the elastic band 34 is transferred to the teeth 30. A small amount of the force from the elastic band 34 can be transferred to the integral hook 22. In particular, the force from the elastic band 34 can be transferred indirectly through the attachment 26 to the integral hook 22 via one or more of the cooperating walls 56, 58, and 62 of the integral hook 22 and one or more of the corresponding sides 74, 76, and 82 of the attachment 26. As an example, at most 30% of the force from the elastic band 34 can be transferred indirectly through the attachment 26 to the integral hook 22. Advantageously, the attachment 26 helps to stabilize the integral hook 22 so that the force from the elastic band 34 indirectly does not displace the aligner 10. In other words, it is possible to apply force to the aligner 10 via the attachment 26 rather than all of the force applied from the elastic band 34 being transmitted by the aligner 10 alone.

[0054] 15-20, according to one aspect of the present invention, an aligner 10 is manufactured. To that end, a clinician may decide to design integral hooks 22 on multiple separate cavities 14, in the shell 12 adjacent to any single cavity 14, or multiple integral hooks 22 adjacent to a single cavity of any single one of the aligners 10 that form part of the orthodontic treatment planning process. As described herein, a clinician may be a person who is not the patient and may be trained to design aligners to implement the orthodontic treatment plan as provided by the clinician. The clinician may thus be the designer, or may instead be the patient's doctor or another person reporting to the doctor. References herein to clinicians and / or doctors are not limiting to embodiments of the present invention.

[0055] With reference to FIGS. 15-20, as an example, a clinician may design an integral hook 22 for one or more cavities 14 of an aligner 10 during one portion of an orthodontic treatment, and then add a different integral hook 22 to one or more different cavities 14 of a different aligner 10 during another portion of the orthodontic treatment. These modifications are made during the design of the treatment plan and before the aligner is manufactured. Additionally, although one integral hook 22 is described and illustrated with respect to one aligner 10 (see, for example, FIGS. 1 and 15), multiple integral hooks 22 may be formed on a single aligner or on multiple aligners according to any single orthodontic treatment plan. In this manner, a clinician may develop a treatment plan utilizing an aligner 10 having multiple integral hooks 22 that change orientation and location from aligner to aligner during treatment. Embodiments of the present invention are not limited to a single aligner with a single structure as shown in the drawings.

[0056] To that end, according to one aspect of the present invention, a clinician can selectively place and configure one or more integral hooks 22 on one or more aligners during orthodontic treatment planning. As described below, a clinician can create a virtual model of the integral hooks before having the aligners manufactured. The computer model is used to manufacture a mold from which an aligner having one or more integral hooks can be formed. The computer model is based on the patient's initial dentition. By way of example, an orthodontist can take an impression of the patient's dentition using a suitable impression material. A three-dimensional scanning device can then be used to scan the impression into a computer to generate a three-dimensional computer model of the patient's initial dentition. A three-dimensional scanning device can be used to obtain the computer model by directly scanning the patient's dentition.

[0057] The computer model of the initial dentition may be used by the orthodontist as a starting point for generating a target dentition model and one or more intermediate dentition models. The target dentition model may represent the desired arrangement of the patient's teeth at the conclusion of orthodontic treatment. Thus, during the orthodontic treatment planning process, a series of computer models are generated that provide sequential steps from the initial dentition to one or more intermediate dentition models and ending with the target dentition. Once the computer dentition models are generated, one or more molds 200 may be manufactured from the virtual models using additive manufacturing (e.g., 3-D manufacturing techniques), CNC machining, a combination thereof, or any other suitable method.

[0058] With reference to FIG. 15, once the molds 200 are manufactured, an aligner is formed from each of the molds. Following the manufacture of the molds, the workpiece 100 is deformed on the mold 200. Although not shown, the mold 200 may be one of a series of molds, each of which is created based on a corresponding computer model of the patient's dentition, each of which captures the target orientation of the patient's teeth during orthodontic treatment. The mold 200 may include a base 202 supporting a number of projections 204 in the form of model teeth extending from a model gum 206 (i.e., gingiva) and defining a gingival margin 210. In this manner, each model tooth 204 may have an orientation that produces a corresponding cavity 14 in the dental aligner 10, with the gingival margin 210 ideally providing a definitive boundary for the location of the edge 16 of the aligner 10. According to one exemplary embodiment, the mold 200 includes a hook mold 212 on the model teeth 214, as shown in FIG. 15 and FIG. 16. The hook mold 212 is spaced occlusally from the gingival margin 210 .

[0059] Although not shown, this forming process deforms the workpiece 100 such that each of the model teeth 204 creates a corresponding cavity 14 in the aligner 10. The deformation region 102 includes the integral hook 22 and is established by features of the mold 200, including the hook mold 212 on the model tooth 214. The hook mold 212 is configured to form at least a portion of the integral hook 22 during deformation of the workpiece 100. In this manner, the hook 22 is integrated into the workpiece 100 as it deforms and at a location away from the patient's gingival margin 210. In other words, the integral hook 22 is not an additional structural component that is bonded to the shell 12 after formation.

[0060] 16, in one embodiment, the molded molar 214 defines an occlusal surface 224, a labial surface 226, and a lingual surface 228 against which the occlusal portion 40, the labial portion 42, and the lingual portion 44 (shown in FIG. 1) of the cavity 24 conform during deformation of the workpiece 100. As shown, the hook mold 212 projects labially from the labial surface 226 of the molded molar 214. The hook mold 212 has a labial side 230, a mesial side 232, a distal side 234, an occlusal side 236, and a gingival side 240. The sides 230, 232, 234, 236, and 240 collectively form the walls 54, 56, 58, 60, and 62 of the integral hook 22 during deformation. That is, during deformation, the shell 12 is heated and deforms onto and around the surface of the molar tooth 214, thus conforming to one or more portions of the sides 230, 232, 234, 236, and 240. However, in the illustrated embodiment, the window 50 (shown, for example, in FIG. 12) of the integral hook 22 is not formed. At that point, a preformed hook 242 is formed around the mold hook 212 in the deformation region 102. As shown, the preformed hook 242 (FIG. 15) is a protrusion having a dome-like configuration that projects outwardly relative to the shell 12 forming the cavity 14. The preformed hook 242 lacks the window 50.

[0061] With regard to the exemplary features of the mold hook 212, the integral hook 22 is designed to receive the attachment 26 shown in FIG. 1, for example, although the attachment 26 and the hook mold 212 are not identical in shape or size according to one embodiment. With reference to FIGS. 16 and 17, the hook mold 212 extends outwardly from the labial surface 226 of the model tooth 214. In this exemplary embodiment, the main body portion 244 of the hook mold 212 is generally shaped similarly to the corresponding side of the attachment 26. For example, the sides 232, 234, 240, and 230 of the main body portion 244 generally replicate the location and orientation of the sides 74, 76, 82, and 84 of the attachment 26 shown in FIGS. 9 and 10. Thus, the side 232 positions the wall 56 of the integral hook 22 in the deformation region 102 during the formation of the workpiece 100. Similarly, side 234 locates wall 58 of integral hook 22 and side 240 locates side 62 at deformation region 102. The remainder of integral hook 22, i.e., bite-facing wall 60, is formed by bite side 236 of hook mold 212.

[0062] 17 and 18, a mold fin portion 246 extends away from the main body portion 244. In this exemplary embodiment, the mold fin portion 246 extends in an occlusal direction. In that respect, the mold fin portion 246 defines the occlusal side 236 of the hook mold 212. The mold fin portion 246 is narrower than the main body portion 244 and is generally centered relative to the main body portion 244 such that the hook mold 212 is symmetrical along a plane that divides the mold fin portion 246 along the labial-lingual direction. By way of example, the mold fin portion 246 may be between 5% and 25% of the overall width of the main body portion 244. A chamfer 250 extends from the mold fin portion 246 to the side 232. Although not shown, a similar chamfer extends between the mold fin portion 246 and the distal side 234. The chamfer 250 is arcuate and slightly angled, so that it can face outward in the mesio-occlusal and distal-occlusal directions. The chamfer 250 facilitates removal of the deformation area from the hook mold 212 after formation. In some variations, the chamfer 250 can form an index mark on the workpiece, for example, to indicate where the workpiece should be cut to form the window 50. In some configurations, the mold fin portion 246 includes a U-shaped relief area or protrusion 254.

[0063] During deformation of the workpiece 100, the molded fin portion 246 forms the occlusally facing wall 60 of the integral hook 22, and the embossed areas or protrusions 254 form the cut pattern 256 (shown in phantom). In particular, the molded fin portion 246 forms all or part of the non-filled portion 86 defined between the attachment 26 and the integral hook 22 when the attachment 26 is inserted into the hook 22. Advantageously, during deformation, the molded fin portion 246 controls defect formation on the occlusally facing wall 60 of the integral hook 22. For example, the molded fin portion 246 reduces or eliminates web formation at the transition of the deformation region 102 between the lip-facing portion 42 and the occlusally facing wall 60. For this reason, the location of the occlusally facing wall 60 and the embossed areas 254 are more consistent with respect to size, shape, and orientation.

[0064] During removal of the deformation region 102 from the mold 200 as shown in FIG. 15, the hook mold 212 is removed from the preformed hook 242. The hook mold 212 can detach from the mold 200 during removal. The preformed hook 242 is shown in FIG. 19 following molding on the hook mold 212. As shown, after formation, the preformed hook 242 lacks a window. Thus, following mold removal, the window 50 is cut from the preformed hook 242 along the cut pattern 256. In one embodiment, the window 50 is cut according to the cut pattern 256 transferred from the raised / relief region 254. By way of example, the window 50 can be cut by hand with a punch tool or by machining.

[0065] Although the present invention has been illustrated by the description of various embodiments, and these embodiments have been described in some detail, it is not the intention of the inventors to restrict or in any way limit the scope of the appended claims to such details. Accordingly, additional advantages and modifications will readily occur to those skilled in the art. The various features of the present invention can be used alone or in any combination, depending on the needs and preferences of the user. [Explanation of symbols]

[0066] 10 Dental Aligners 12. Shell 14 Cavity 16. Edge 18 teeth 20 aperture 22 Integrated hook 24 Cavity 26 Attachment 28 Exterior Wall 30 teeth 32 System 34 Elastic Band 36 Temporary anchor devices 40 Occlusal area 42 Lip-facing part 44 Tongue-facing part 46 Distal part 50 Windows 52 Interior Space 54 Lip Wall 56 Mesial wall 58 Distal wall 60 Occlusal wall 62 Gingival wall 64 Wall penetration 64a Lingual part 64b labial part 66 End 68 Aperture 70 Outer surface 72 Lingual 74 Mesial side 76 Distal 78 Inner surface 80 Occlusal side 82 Gingival 84 Tip 86 Unfilled part 90 Exposed part 92 Exposed part 96 Arrow 100 work pieces 102 Deformation Area 200 Mold 202 Base 204 Model Tooth 206 Model Gums 210 Gingival Margin 212 Hook mold 214 Mold molar 224 Occlusal surface 226 Lip-Facing Surface 228 Tongue-facing surface 230 labial side 232 Mesial side 234 Distal 236 Occlusal side 240 Gingival 242 Preformed Hooks 244 Main body part 246 Mold fin part 250 Chamfer 254 Relief area 256 cutting patterns

Claims

1. A system for orthodontic treatment, Orthodontic aligners for the treatment of a patient's teeth, A shell comprising: at least one tooth cavity configured to receive at least one of the patient's teeth; and a rim defining an opening in which the at least one tooth cavity receives the at least one of the patient's teeth. Includes, The shell has wall portions, and an integrated hook extends outward from one of the wall portions adjacent to the at least one tooth cavity and is spaced apart from the edge in the occlusal direction. The integrated hook has a side wall defining an internal space and a window, the internal space opening to the at least one tooth cavity, and the window extending through the side wall so that the internal space is accessible through the window. Orthodontic aligners, An attachment configured to be fixed to the patient's teeth, Includes, The integrated hook is configured to receive the attachment when the orthodontic aligner is placed on at least one of the patient's teeth, and the attachment is accessible through the window. system.

2. The system according to claim 1, wherein the side wall of the integrated hook includes a mesial wall, a distal wall, an occlusal wall, and a gingival wall, and the window extends along at least two arbitrary walls.

3. The system according to claim 1, wherein the side wall of the integrated hook includes a mesial wall, a distal wall, an occlusal wall, and a gingival wall, and the window extends along any three walls.

4. The system according to claim 1, wherein the window is open in one of the occlusal direction, gingival direction, mesial direction, or distal direction when the orthodontic aligner is positioned on the patient's teeth.

5. The system according to claim 1, wherein the window is wedge-shaped.

6. The system according to claim 1, wherein at least a portion of the window is sized to prevent the insertion of an elastic band.

7. The system according to claim 1, wherein the window includes a through wall that crosses the outer and inner surfaces of the side wall of the integrated hook, the through wall having opposing portions, the opposing portions defining a first width at the opening of the window and a second width near the end of the opposing portions of the through wall, the first width being greater than the second width.

8. The system according to claim 7, wherein the first width is greater than the diameter of the elastic band, and the opening is configured to receive the elastic band.

9. The system according to claim 8, wherein the second width is less than the diameter of the elastic band, and there is an interference fit between the elastic band and the window at the second width.

10. The system according to claim 1, wherein the side wall has a substantially dome-like structure.

11. The system according to claim 1, wherein the attachment does not fill the internal space of the integrated hook.

12. The system according to claim 1, wherein the attachment occupies 75% or less of the internal space of the integrated hook.

13. The system according to claim 12, wherein the attachment fills more than 35% of the internal space of the integrated hook.

14. The system according to claim 1, wherein the attachment does not fill the internal space of the integrated hook so that the unfilled portion of the internal space between the attachment and the side wall of the integrated hook is accessible through the window.

15. The system according to claim 14, wherein the window includes a through wall that crosses the outer and inner surfaces of the side wall, the through wall having opposing portions, the opposing portions defining a first width at the opening of the window and a second width near the ends of the opposing portions of the through wall, the first width being greater than the second width.

16. The system according to claim 14, wherein the window includes a through wall that crosses the outer and inner surfaces of the side wall, the through wall having opposing portions, the opposing portions defining a first width at the opening of the window and a second width near the end of the opposing portions of the through wall, the first width being less than the second width.

17. The system according to claim 15, wherein, when the orthodontic aligner is placed on the patient's teeth, the depth of the window from the opening to the end of the opposing portion of the through wall is greater than the distance measured from the opening to the surface of the attachment.

18. The aforementioned system further includes an elastic band, The elastic band is insertable into the window so as to contact the attachment, and after insertion, the elastic band is held in place within the window by the integrated hook. The system according to claim 1.

19. The system according to claim 18, wherein the elastic band and / or the integrated hook are elastically deformed when the elastic band is in contact with the attachment.

20. The system according to claim 18, wherein the integrated hook grips the elastic band when the elastic band is in contact with the attachment.

21. A step of preparing a mold including one or more protrusions on one or more components of the patient's teeth, and a hook mold extending outward from the one or more protrusions, The steps include: deforming a workpiece on the mold including the hook mold to create a deformed region of the workpiece including a pre-formed hook; The step of removing a portion of the pre-formed hook to form the window, A method for manufacturing the system described in claim 1, including the above.

Images