Methods and systems for homogeneous dental instruments

Abstract

The method and system described herein receive patient dental arch data, process that data on a server, determine vertical displacement and mandibular anterior position, and open the patient's airway to enable the patient to breathe during sleep. [Solution] A homogeneous dental instrument is formed by direct manufacturing using processed dentition data, vertical displacement, and mandibular anterior position, the dental instrument including a lower dental tray and an upper dental tray, the lower dental tray including a pair of vertical displacement occlusal pads with vertical displacement and a first pair of button protrusions, the upper dental tray including a second pair of button protrusions, the first pair of button protrusions and the second pair of button protrusions providing the mandibular anterior position when two elastic bands are attached and connected to the upper dental tray and the lower dental tray.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application is a non - provisional application of U.S. Provisional Patent Application No. 62 / 679,007, entitled "Methods and Systems for Homogeneous Dental Appliances", filed on May 31, 2018, which is hereby incorporated by reference in its entirety, and claims the benefit under 35 U.S.C. § 119(e).

Background Art

[0002] Treatments for sleep apnea and obstructive sleep apnea include surgery, airway positive pressure devices such as CPAP devices, and treatments such as dental appliances. Known dental appliances include "Elastic Mandibular Advancement Appliances" (EMA®) and related appliances. The EMA® appliance works by promoting forward fixation of the mandible to increase air flow. A problem with the EMA® appliance is the risk that button protrusions attached to elastic bands on each side of the appliance may come off the appliance. One way to attach the button protrusions on each side of the appliance is by adhesion. However, when the button protrusions are adhered, with increased use over time, there is a risk that they may come off. What is needed is a dental appliance with a low risk of button protrusions coming off.

Summary of the Invention

[0003] Embodiments of the method include receiving patient oral characteristic data on a server, processing the oral characteristic data, determining dentition data, vertical displacement, and mandibular anterior position to open the patient's airway, thereby enabling the patient to breathe during sleep, and forming a dental instrument by direct manufacturing using the dentition data, vertical displacement, and mandibular anterior position, the dental instrument including a lower dental tray and an upper dental tray, the lower dental tray including vertical displacement and a first pair of button protrusions, and the upper dental tray including a second pair of button protrusions, the first pair of button protrusions and the second pair of button protrusions providing the mandibular anterior position when two elastic bands are attached and connected to the upper and lower dental trays.

[0004] In one or more embodiments, the dental instrument is formed by three-dimensional (3D) printing of one or more of a photopolymerizable liquid thermosetting crosslinked polymer, polyurethane, methacrylate, or copolymer.

[0005] In one or more embodiments, the dental instrument is formed by three-dimensional (3D) printing of a polymerizable resin composition comprising a urethane monomer, an acid monomer, and one or more hydrophobic monomers of urethane dimethacrylate (UDMA).

[0006] In one or more embodiments, the dental instrument is milled or injection molded using one or more ethylene-propylene copolymers and polyoxymethylene copolymers.

[0007] In one or more embodiments, the dental instrument is injection molded using one or more materials selected from thermoplastic olefins, thermoplastic polyolefins, and olefin-based thermoplastic elastomers.

[0008] In one or more embodiments, receiving patient oral characteristic data includes scanning the patient's teeth with a scanner or camera and transmitting the oral characteristic data to a server.

[0009] In one or more embodiments, receiving patient oral characteristic data includes scanning the patient's oral cavity, photographing the oral cavity to determine dentition data, and transmitting the oral characteristics to a server, wherein the oral characteristic data includes one or more images of the patient's teeth and gingival line, and one or more images of the patient's soft palate.

[0010] In one or more embodiments, the method includes determining the vertical displacement as a function of the patient's soft palate shape via oral characteristic data.

[0011] In one or more embodiments, determining vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes determining a vertical displacement of 5 to 7 millimeters if there is a space of 5 to 7 millimeters between the posterior edge of the patient's soft palate and the posterior wall of the pharyngeal orifice.

[0012] In one or more embodiments, determining the vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes processing the oral characteristic data and measuring the distance between the gingival-coronal junction of the maxillary central incisors and the gingival-coronal junction of the mandibular central incisors.

[0013] In one or more embodiments, determining vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes determining if there is a 3-5 mm gap between the patient's posterior soft palate and the posterior wall of the pharyngeal orifice, if the posterior soft palate is longer than normal, and providing a vertical displacement of 8-10 mm.

[0014] In one or more embodiments, determining vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes determining if the posterior edge of the soft palate is longer than a normal soft palate and the jaw is pterygoid, if there is a space of 2 mm or less between the soft palate and the posterior wall of the pharyngeal orifice, and providing a vertical displacement of at least 11 to 14 mm.

[0015] In one or more embodiments, determining the vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes determining whether the soft palate is short, normal, or long.

[0016] In one or more embodiments, the lower dental tray includes a first vertical displacement occlusal pad on the left side and a second vertical displacement occlusal pad on the right side, wherein the height of each of the first and second vertical displacement occlusal pads is determined according to oral characteristic data, which provides soft tissue data indicating the patient's airway function.

[0017] In one or more embodiments, the vertical displacement is provided by the thickness of the lower dental tray.

[0018] Another embodiment relates to a system including a processor and a persistent computer-readable storage medium that stores instructions for operating when executing on the processor a method including receiving patient oral characteristic data, processing the oral characteristic data in a server to determine dentition data, vertical displacement, and mandibular anterior position to open the patient's airway so that the patient can breathe during sleep, and forming a dental instrument by direct manufacturing using the dentition data, vertical displacement, and mandibular anterior position, wherein the dental instrument includes a lower dental tray and an upper dental tray, each being homogeneous, the lower dental tray including a vertical displacement occlusal pad with a first pair of button projections, and the upper dental tray including a second pair of button projections, the first pair of button projections and the second pair of button projections providing mandibular anterior position when two elastic bands are attached and connected to the upper and lower dental trays.

[0019] Another embodiment involves receiving one or more patient-associated datasets on a server, determining one or more button projection positions on the server based on the datasets received from the scanner, at least the patient's dentition pattern, gingival line, soft palate shape and soft palate measurements, and, with respect to the patient's palate shape, uvular position measurements, communicating one or more button projection and vertical displacement positions on the server, including assigning a value associated with each of the one or more positions for button projection positioning, each value representing the distance between the button projection on the upper tray and the button projection on the lower tray relative to mandibular advancement, and the value data The method involves transmitting a data to one or more three-dimensional printers, milling machines, and injection molding machines; forming a dental instrument by direct manufacturing using values ​​associated with each of one or more determined positions for positioning button protrusions; the dental instrument including a lower dental tray and an upper dental tray, each of which is homogeneous; the lower dental tray including vertical displacement and a first pair of button protrusions; and the upper dental tray including a second pair of button protrusions, the first and second pairs of button protrusions providing an anterior mandibular position when two elastic bands are attached and connected to the upper and lower dental trays.

[0020] In one or more embodiments, the dental instrument is formed by three-dimensional (3D) printing of one or more photopolymerizable liquid thermosetting crosslinked polymers, polyurethanes, methacrylates, or copolymers.

[0021] In one or more embodiments, the dental instrument is milled or injection molded one or more times using one or more ethylene-propylene copolymers and polyoxymethylene copolymers.

[0022] In one or more embodiments, the dental instrument is formed by three-dimensional (3D) printing of a polymerizable resin composition comprising a urethane monomer, an acid monomer, and one or more hydrophobic monomers of urethane dimethacrylate (UDMA).

[0023] In one or more embodiments, the dental appliance is injection molded using a thermoplastic olefin, a thermoplastic polyolefin, or an olefinic thermoplastic elastomer.

[0024] In one or more embodiments, the vertical displacement is a function of the shape of the patient's soft palate.

[0025] In one or more embodiments, the vertical displacement is provided by one or more of a pair of occlusal pads on the lower dental tray or by the thickness of the lower dental tray.

[0026] In one or more embodiments, in determining the gingival line, the maxillary crown-gingiva junction and the mandibular crown-gingiva junction are identified, and the upper dental tray is formed to reach a distance of 3 millimeters below the maxillary crown-gingiva junction, and the lower dental tray is formed to reach approximately 3 millimeters below the mandibular crown-gingiva junction.

[0027] Some embodiments include a processor and a persistent computer-readable storage medium storing instructions that operate when executed on a processor that executes the methods described herein.

Brief Description of the Drawings

[0028] [Figure 1A] shows a system and network environment including a computer device according to one or more embodiments of the present disclosure.

[0029] [Figure 1B] shows a processor and a computer device according to one or more embodiments of the present disclosure.

[0030] [Figure 2] shows a network environment according to one or more embodiments of the present disclosure.

[0031] [Figure 3] This shows a milling machine according to one or more embodiments of the present disclosure.

[0032] [Figure 4] This refers to a homogeneous dental instrument including a button projection and a vertically displaced occlusal pad, manufactured by direct production according to one or more embodiments of the present disclosure.

[0033] [Figure 5] This shows an exemplary thermal injection mold for creating a homogeneous dental tray by direct manufacturing according to one or more embodiments of the present disclosure.

[0034] [Figure 6] This shows the negative portion of a thermal injection mold for a bottom dental tray according to one or more embodiments of the present disclosure.

[0035] [Figure 7] In accordance with one or more embodiments of this disclosure [Figure 6] This shows the positive portion of a thermal injection molding die for a bottom dental tray, used in conjunction with the mold.

[0036] [Figure 8] This shows the negative portion of a thermal injection mold for an upper dental tray according to one or more embodiments of the present disclosure.

[0037] [Figure 9] This is in accordance with one or more embodiments of the present disclosure. [Figure 8] This shows the positive portion of the thermal injection molding die for the upper dental tray, which is used in conjunction with the mold.

[0038] [Figure 10] This describes a process of milling a “pack” of solid material in a dental tray by direct manufacturing according to one or more embodiments of the present disclosure.

[0039] [Figure 11] This shows a dental instrument equipped with an elastic band attached according to one or more embodiments of the present disclosure.

[0040] [Figure 12] This shows the oral side of a patient with a short soft palate, according to one or more embodiments of the present disclosure.

[0041] [Figure 13] This shows the open mouth of a patient with a normal soft palate and uvula, according to one or more embodiments of this disclosure.

[0042] [Figure 14] According to one or more embodiments of this disclosure, the soft palate shows the oral side of a normal patient.

[0043] [Figure 15] This shows an open mouth position in a patient with a long soft palate and uvula, according to one or more embodiments of this disclosure.

[0044] [Figure 16] This shows the oral side of a patient with a long soft palate, according to one or more embodiments of this disclosure.

[0045] [Figure 17] This shows an open mouth position in a patient with a long soft palate and uvula, according to one or more embodiments of this disclosure.

[0046] [Figure 18] This shows a dental instrument in which a mold is positioned with the patient's teeth open, according to one or more embodiments of the present disclosure. Detailed description of the invention

[0047] In the detailed description below, reference is made to the accompanying drawings which form part of this specification. In the drawings, unless otherwise indicated, similar reference numerals are used to identify typical similar components. The exemplary embodiments described in the detailed description of the invention, the drawings, and the claims are not intended to be limiting. Embodiments not described in the detailed description may be applied and modifications not described in the detailed description may be made, without departing from the spirit or scope of the subject matter of the invention presented herein.

[0048] Referring here to Figure 1A, the drawing shows a computer device 10 connected to a computer server 30 via a network interface in an exemplary environment 100. As further described herein, the illustrated computer device 10 and computer server 30 can be implemented using computationally implemented methods, systems, and products according to various embodiments. In various embodiments, the computer device 10 and computer server 30 enable the functions of the computer device 10.

[0049] The computer device 10 shown in Figure 1A may be a tablet computer, and in other embodiments, methods, systems, and products computationally implemented according to various embodiments may be embodied in other types of computer systems having other form factors, including other types of portable computer devices such as mobile phones, laptops, smartphones, and e-readers. The computer device may include smartphones, client computers, etc., which can be considered as computer devices. As shown, the computer device 10 may include a display such as a touchscreen as input / output for the computer device 10. The computer device 10 may further include a keyboard, either as a touch input / output keyboard or an attached keyboard. As further shown, the computer device 10 may be connected to a scanner 16. In one embodiment, the scanner 16 may be a scanning camera capable of creating a 3D image of a tooth.

[0050] Referring here to Figure 1B, the computer device 10 is further illustrated with a logic module 102, a network interface 104, a user interface 110, a processor 116, and memory 114. The logic module 102 can be implemented using circuit components such as ASICs, and the logic module 102 and other illustrated modules can be implemented using a combination of specially designed circuits, such as ASICs, and one or more processors 116 (or field-programmable gate arrays, FPGAs) that execute computer-readable instructions 152. For example, in some embodiments, at least one of the logic modules may be implemented using a specially designed circuit (such as an ASIC), and a second logic module may be implemented using a processor 116 (or other type of programmable circuit, such as an FPGA) that executes computer-readable instructions 152 (such as software or firmware). System requirements can determine the combination of software, firmware, and circuitry that satisfies the embodiments herein, and for example, the logic module can be designed to rapidly implement the methods and systems within the scope of this disclosure using the most efficient combination of software / hardware / firmware. In some embodiments, a computer-aided design / computer-aided manufacturing (CAD / CAM) program operates to form a dental instrument from scanned images by implementing the methods described herein. For example, a CAD program can create data in a three-dimensional format and transmit that data to a manufacturing device such as a 3D printer, milling machine, or injection molding machine. The methods described herein include automatically determining the positioning and vertical displacement of a button protrusion by using patient-oriented oral characteristic data and classifying the patient's sleep apnea needs according to soft tissue characteristics and dentition. Soft tissue as described herein refers to the position of the soft palate, gingival line, uvula, and hyoid bone tissue in the patient's oral cavity, etc.

[0051] In various embodiments, the memory 114 of the computer device 10 may include one or more mass storage devices, cache memories such as read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), random access memory (RAM), flash memory, synchronous random access memory (SRAM), dynamic random access memory (DRAM), and / or other types of storage devices. In various embodiments, one or more applications 160 stored in the memory 114 may include, for example, an operating system 162, a browser 163, and a word processing application, or an imaging application, a scanning application, and one or more communication applications 166.

[0052] The computer device 10 may also include an access restriction module 106. The access restriction module 106 of the computer device 10 can be configured to restrict access through the computer device 10 or to prevent the computer device 10 from performing one or more actions. The computer device 10 may also include an instrument generation module 108 coupled to the access restriction module 106 via a bus.

[0053] Referring to Figure 2, the device generation module 108 can be configured to determine that the first user 20 is an authorized user who is permitted to attempt to operate the computer device 10. The device generation module 108 can also be configured to determine an authorized user based on network received data while the computer device 10 is connected to the network connection 50. If the device generation module 108 is present in a cloud computing configuration or on the computer server 30, the device generation module 108 can be configured to determine network-based authentication of the first user upon initial login to the network 50 or cloud computing login to the computer server 30.

[0054] The instrument generation module 108 can be configured to receive input from the scanner 16. In some embodiments, the instrument generation module 108 is coupled to a milling machine, a 3D printer, or an injection molding machine. The instrument generation module 108 can receive CAD / CAM data or other oral characteristic data and / or dentition data to enable the creation of dental instruments according to one or more embodiments described herein.

[0055] A computer server 30 connected to the computer device 10 in Figures 1A and 1B via network 50 can establish and / or determine vertical displacement and mandibular anterior position for the treatment of sleep apnea. For example, a scanner 16 and / or a patient's dental impression can be used and examined to determine the adjustments necessary for the treatment of sleep apnea. The upper and lower trays, including the button protrusions, can be fabricated from a mold. For example, patients with malocclusion and sleep apnea will require assessment using the scanner 16 or other methods. Each patient may require different positions for both horizontal and vertical displacement for the treatment of sleep apnea, depending on the scanned teeth, soft tissues, and patient feedback. Vertical displacement may be achieved using a lower occlusal pad or the thickness of a lower dental tray. In embodiments, the vertical displacement is part of a dental instrument made from a mold, milling machine, or 3D printed.

[0056] In one embodiment, the mold allows for the pouring of thermoplastic material or an FDA-approved material such as nylon to form upper and lower trays that fit snugly to the upper and lower teeth but are removable, so that the lower tray creates an anterior mandibular position relative to the upper tray, and allows for the anterior mandibular position of the lower tray relative to the upper tray, if elastic material is removablely attached to the anterior and posterior sides of the upper and lower trays, respectively. Button protrusions on the lower and upper dental trays are adjusted so that elastic bands can be attached to the respective trays. In one embodiment, the button protrusions are milled from a “pack” of dental instrument trays, which is included as part of the mold for injection molding, or are manufactured directly during 3D printing.

[0057] One embodiment includes determining the dimensions and elasticity of one or more removable elastic bands adapted to connect the upper and lower trays via protrusions on each of the upper and lower trays such that the elastic band creates an anterior mandibular position of the lower tray with respect to the upper tray.

[0058] An elastic band can include multiple pairs of elastic bands, each pair of which may have different lengths and / or elasticity.

[0059] In one embodiment, the dental device is configured to be worn during sleep. Referring here to Figure 3, the dental device may include upper and lower trays manufactured using three-dimensional (3D) technology, such as 3D printing or 3D data acquisition via scanning, which can be sent to a milling machine 300, as shown in Figure 3. The resulting dental device is shown in Figure 4.

[0060] Referring here to Figure 4, a dental instrument 400 is shown which includes an upper tray 410, a lower tray 420, an upper button projection 450, a lower button projection 460, and an occlusal pad 470. Unlike other dental instruments that include button projections and a lower occlusal pad, the embodiments described herein include an occlusal pad that is not integrated with the lower button projection but is manufactured directly as part of the dental tray. As used herein, direct manufacturing means homogeneously forming the dental instrument in which different components, such as patient-appropriate button projections and vertically displaced occlusal pads, are manufactured simultaneously with the dental tray itself and incorporated into a mold, milled material, or printed by a 3D printer.

[0061] Suitable materials for 3D printers are resin-based materials and materials described in U.S. Patent No. 9,682,018, "Denture Tooth and Material," dated June 20, 2017, which is incorporated herein by reference in its entirety. As will be apparent to those skilled in the art, materials suitable for dental instruments must be FDA approved. Furthermore, suitable materials for resins are described in "Polymer Properties of Resins Composed of UDMA and Methacrylates With the Carboxyl Group" by Tanaka J, Hashimoto T, Stansbury JW, Antonucci JM, and Suzuki K (Dental Material Journal, 2001 10:206-215), which is incorporated herein by reference in its entirety.

[0062] As used herein, three-dimensional printing includes, but is not limited to, stereolithography (SLA), micro-stereolithography (pSLA), OLP projection, 2PP (two-photon polymerization), continuous liquid interface fabrication, and material jetting. In embodiments, three-dimensional printing includes layer-by-layer printing by continuous layers formed of discrete layers. For example, a surface having a construction plate immersed in a tank of water containing a polymer / resin component may be exposed to light at a wavelength and intensity that activates a photopolymerization initiator that causes photopolymerization. As will be apparent to those skilled in the art, there are other methods of three-dimensional printing, such as continuous liquid interface fabrication in which dental trays are constructed from a tank of photopolymerizable resin. Continuous liquid interface fabrication is described in U.S. Patent Publications 2015 / 0097315, 2015 / 0097316, and 2015 / 0102532, the respective disclosures of which are incorporated herein by reference in their entirety.

[0063] In some embodiments, the dental instrument can be formed by injection molding. For example, two molds, such as mold 500 shown in Figure 5, can be used for upper and lower dental trays.

[0064] Referring to Figure 6, a portion of the mold showing the negative type of the bottom dental tray 600 is shown. Specifically, mold 600 includes negative type teeth 640, negative type button protrusions such as 610, and negative type occlusal pads such as 620. Referring to Figure 7, the positive type 700 of the bottom dental tray is shown. Positive type 700 includes button protrusions such as 710, occlusal pads 720, and teeth 740.

[0065] Referring to Figure 8, a type similar to that in Figure 6 is shown, representing a negative type of upper dental tray. As shown, the negative type 800 includes button protrusions 810, 812 and negative teeth 840. Referring to Figure 9, a positive type 900 of the upper dental tray is shown, which includes button protrusions 910, 912 and teeth 940.

[0066] Referring here to Figure 10, a milling process 1000 including a solid material, or “pack” 1010, is shown, milled for a top dental tray made from an FDA-approved material. In one or more embodiments, the material to be milled may be an ethylene-propylene copolymer or a polyoxymethylene copolymer. In other embodiments, the material may be a thermoplastic olefin, a thermoplastic polyolefin, or an olefin-based thermoplastic elastomer. As will be apparent to those skilled in the art, different materials can be used to create the “pack” for milling.

[0067] During the process, the button projection 1010 is milled as shown in 1020. Next, the upper dental tray of the dental instrument is milled from the pack as shown in 1030. The lower dental tray can be milled in a similar process. Thus, the dental instrument can be milled to become part of a single homogeneous dental tray by directly manufacturing the button projection and / or occlusal pad of the lower dental tray, independently of post-gluing or post-bonding the button projection and occlusal pad.

[0068] Therefore, as described above, upper and lower dental trays for dental instruments can be manufactured directly using milling, injection molding, and / or 3D technology. Suitable materials for injection molding of dental instruments include thermoplastic materials and thermoplastic elastomers. In one or more embodiments, these may be ethylene-propylene copolymers or polyoxymethylene copolymers. In other embodiments, the material may be a thermoplastic olefin, a thermoplastic polyolefin, or an olefin-based thermoplastic elastomer. Suitable materials for 3D printing technology include thermosetting polymers such as photopolymerizable liquid materials. In one or more embodiments, suitable materials for 3D printing include crosslinked polymers such as polyurethane, methacrylate, or copolymers. In some embodiments, the 3D printing material may include nylon material.

[0069] In one or more embodiments, the material used for milling and / or injection molding is a ethylene-propylene copolymer having the following properties as shown in Table 1, which can be provided by Myerson Tooth, Inc., including VisiClear® and DuraFlex®.

[0070] TIFF2026076377000002.tif105149

[0071] In another embodiment, the milling or injection molding material can be provided by DuraCetal®, a polyoxymethylene copolymer having the following properties as shown in Table 2, and is also available from Myerson Tooth, Inc. TIFF2026076377000003.tif103139TIFF2026076377000004.tif45131

[0072] Referring now to Figure 11, the dental instrument 1100 is shown together with an upper dental tray 1102 and a lower dental tray 1104, which have elastic bands connecting both sides of the dental instrument. As shown in the figure, on the left side of the dental instrument, there is an elastic band 1108 connecting the buttons 1110 and 1120 of the button projection.

[0073] Dental instruments obtained by injection molding, milling, or 3D printing conveniently do not require the addition of any parts other than the elastic band shown in Figure 11, because the dental instrument is manufactured directly so that the button protrusions and mandibular occlusal pads are homogeneously included via a mold, milled pack, or 3D printer, without the need to add them later. Dental trays prior to direct manufacturing disclosed herein required the addition of different parts such as button protrusions and occlusal pads using adhesives or by thermoforming (without milling) methods.

[0074] In direct manufacturing, the positioning of the button protrusion and occlusal pad is required during the manufacturing of the entire dental instrument; therefore, measurements to determine the position of the button protrusion and occlusal pad for each patient are determined before creating a homogeneous dental tray. Referring again to Figure A, the scanner / camera 16 determines the proper position of the button protrusion and occlusal pad, including determining the necessary oral characteristic data, which may include dentition data and soft palate data in one embodiment.

[0075] In one or more embodiments, the method includes determining the amount of the vertical component of a dental instrument, or the height of the occlusal pad, as a function of the soft palate shape. In other embodiments, the vertical displacement is determined by the patient's soft tissue, such as the hyoid bone shape. In one or more embodiments, a scanner and / or camera, such as scanner / camera 16, detects the soft palate shape. The data is collected as oral characteristic data and provided to a processor that operates to classify the oral characteristics in order to manufacture instruments uniformly.

[0076] In one or more embodiments, the soft palate is classified into three types: short, normal, and long. Therefore, in one or more embodiments, the method includes determining whether the posterior edge of the soft palate is short. For example, if there is a space of about 5 to 7 millimeters between the posterior edge of the soft palate and the posterior wall of the pharyngeal orifice, the soft palate is determined to be short, and dental instruments require a vertical displacement of about 5 to 7 millimeters. In some embodiments, in determining the vertical displacement, a scanner can measure the distance from the gingival-coronal junction of the maxillary central incisor to the gingival-coronal junction of the mandibular central incisor. If this distance is, for example, 20 mm and a vertical displacement of 7 mm is desired, in some embodiments the vertical displacement can be determined so that the occlusion has a vertical displacement of 7 mm.

[0077] In some embodiments, the method includes determining whether the posterior edge of the soft palate is longer than that of a normal soft palate. If the soft palate is longer and there appears to be a 3-4 mm space between the posterior edge of the soft palate and the posterior wall of the pharyngeal orifice, in some embodiments, a dental instrument can be made that provides a vertical displacement of 8-10 mm so that the soft palate does not obstruct the orbit when the patient is in a supine position.

[0078] In cases of pterygoid jaw, where the soft palate is very long and there is only 2 mm or less of space between the soft palate and the pharyngeal opening, the instrument will require a vertical displacement of 11-14 mm.

[0079] In one or more embodiments, the scanner determines whether the soft palate is short, long, or normal, and determines the position of the uvula relative to the palate. Figures 12 to 17 show possible examples of scanning a patient's soft palate.

[0080] Referring to Figures 12 and 13, we see a lateral view of the patient's head 1200 and a view of the patient with their mouth open 1300. Figure 12 shows a short palate 1210. Figure 13 shows the same short palate 1310 from a frontal perspective view.

[0081] Figure 14 shows a lateral view of the patient 1400 and a normal palate 1410. Figure 15 shows an anterior perspective view of the patient with their mouth open 1500 and a normal palate 1510.

[0082] Figure 16 shows a lateral view of the patient 1600 and the elongated palate 1610. Figure 17 shows a frontal perspective view of the patient with the mouth open 1700 and the elongated palate 1710.

[0083] Determining whether the palate is short, normal, or long can be done by a dental specialist through examination, or, according to the embodiment, via a scanner / camera that collects data about the patient.

[0084] The position and size of the occlusal pads of the lower dental tray are determined as a function of the patient's palatal length. Furthermore, in some embodiments, the maxillary button projections of the upper dental tray are positioned on the incisal edges of the space between the left and right canines and the first premolars.

[0085] The position of the mandibular button protrusion can be determined by assessing the patient's range of motion. In some embodiments, the scanner detects the maximum range of motion by measuring the anterior-posterior extension of the mandible. For example, if the patient's mandible advances only 5-7 mm, the button is positioned 23 mm away from the patient's teeth. If the patient has a potential advance of 7-10 mm, the button is positioned 25 mm away, and if the patient has a potential advance of 10-17 mm, the button is positioned 27 mm away.

[0086] In one or more embodiments, the method includes determining the button position of the mandibular arch by centering a patient model and positioning the center of the mandibular button 23, 25, or 27 mm from the center of the maxillary button.

[0087] As mentioned above, the scanner / camera captures an image / scan of the patient's mouth to determine dental arch data and soft tissue data such as soft palate data, and a computer system coupled to the scanner or processor built into the scanner / camera determines the position of the aforementioned button protrusions and occlusal pads.

[0088] Referring now to Figure 18, a diagram of a dental instrument according to an embodiment of this specification is shown. More specifically, the dental instrument 1800 includes an upper dental tray 1802, a lower dental tray 1804, four button projections 1810, 1820 positioned on the upper dental tray 1802, and button projections 1830, 1849 positioned on the lower dental tray. The lower dental tray 1804 including vertical displacement occlusal pads 1850 and 1860 is also shown. In one embodiment, the dental instrument has elastic bands 1870 and 1880 positioned on both sides thereof, connecting the upper dental tray 1802 to the lower dental tray 1804.

[0089] Furthermore, Model 1890, illustrated in Figure 18, also includes the patient's teeth. This model can be created by scanning the patient and 3D printing it, or by creating a dental impression of the patient.

[0090] In one or more embodiments, the dental arch data includes gingival line data to enable the patient to hold dental instruments. More specifically, dental instruments can be held more securely if the dental tray is designed to fit the gingival line. Thus, in some embodiments, the method includes determining a distance of 3 millimeters below the coronal-gingival junction of the upper dental tray, unless there is a protruding axial inclination of the incisors. For patients with protruding axial inclination of the incisors, the upper dental tray is formed to reach one-third to one-half of the anterior teeth. The lower dental tray is formed to reach 3 millimeters below the coronal-gingival junction, unless the patient's mandibular incisors also have a protruding axial inclination. For patients with protruding axial inclination of the mandibular incisors, the lower dental tray is formed to reach above the coronal-gingival region of the anterior incisors. The gingival line data is provided when forming the dental tray using a 3D model, either before milling or before using a mold.

[0091] As described above, the dental instrument shown in Figure 18 is formed in one or more embodiments by a method that includes receiving patient oral characteristic data, processing the oral characteristic data in a server to determine dentition data, vertical displacement, and mandibular anterior position to open the patient's airway so that the patient can breathe during sleep, and forming the dental instrument by direct manufacturing using the dentition data, vertical displacement, and mandibular anterior position, the dental instrument including a lower dental tray and an upper dental tray, each of which is homogeneous, the lower dental tray including a vertical displacement occlusal pad with vertical displacement and a first pair of button protrusions, and the upper dental tray including a second pair of button protrusions, the first pair of button protrusions and the second pair of button protrusions providing mandibular anterior position when two elastic bands are attached and connected to the upper and lower dental trays.

[0092] In one or more embodiments, the dental instrument is formed by three-dimensional (3D) printing of one or more of a photopolymerizable liquid thermosetting crosslinked polymer, polyurethane, methacrylate, or copolymer.

[0093] In one or more embodiments, the dental instrument is formed by three-dimensional (3D) printing of a polymerizable resin composition comprising a urethane monomer, an acid monomer, and one or more hydrophobic monomers of urethane dimethacrylate (UDMA).

[0094] In one or more embodiments, the dental instrument is milled or injection molded using one or more ethylene-propylene copolymers and polyoxymethylene copolymers.

[0095] In one or more embodiments, the dental instrument is injection molded using a thermoplastic olefin, thermoplastic polyolefin, or olefin-based thermoplastic elastomer.

[0096] In one or more embodiments, receiving patient oral characteristic data includes scanning the patient's teeth with a scanner or camera and transmitting the oral characteristic data to a server.

[0097] In one or more embodiments, receiving patient oral characteristic data includes scanning the patient's oral cavity, photographing the oral cavity to determine dentition data, and transmitting the oral characteristics to a server, wherein the oral characteristic data includes one or more images of the patient's teeth and gingival line, and one or more images of the patient's soft palate.

[0098] In one or more embodiments, the method includes determining the vertical displacement as a function of the patient's soft palate shape via oral characteristic data.

[0099] In one or more embodiments, determining vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes determining a vertical displacement of 5 to 7 millimeters if there is a space of 5 to 7 millimeters between the posterior edge of the patient's soft palate and the posterior wall of the pharyngeal orifice.

[0100] In one or more embodiments, determining vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes processing the oral characteristic data and measuring the distance from the gingival-coronal junction of the maxillary central incisor to the gingival-coronal junction of the mandibular central incisor.

[0101] In one or more embodiments, determining vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes determining if there is a 3-5 mm gap between the patient's posterior soft palate and the posterior wall of the pharyngeal orifice, if the posterior soft palate is longer than normal, and providing a vertical displacement of 8-10 mm.

[0102] In one or more embodiments, determining vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes determining if the posterior edge of the soft palate is longer than a normal soft palate and the jaw is pterygoid, if there is a space of 2 mm or less between the soft palate and the posterior wall of the pharyngeal orifice, and providing a vertical displacement of at least 11 to 14 mm.

[0103] In one or more embodiments, determining the vertical displacement as a function of the patient's soft palate shape via oral characteristic data includes determining whether the soft palate is short, normal, or long.

[0104] In one or more embodiments, the lower dental tray includes a first vertical displacement occlusal pad on the left side and a second vertical displacement occlusal pad on the right side, wherein the height of each of the first and second vertical displacement occlusal pads is determined according to oral characteristic data, which provides soft tissue data indicating the patient's airway function.

[0105] In one or more embodiments, the vertical displacement is provided by the thickness of the lower dental tray.

[0106] Another embodiment relates to a system including a processor and a persistent computer-readable storage medium that stores instructions for operating when executing on the processor a method including receiving patient oral characteristic data, processing the oral characteristic data in a server to determine dentition data, vertical displacement, and mandibular anterior position to open the patient's airway so that the patient can breathe during sleep, and forming a dental instrument by direct manufacturing using the dentition data, vertical displacement, and mandibular anterior position, wherein the dental instrument includes a lower dental tray and an upper dental tray, each being homogeneous, the lower dental tray including vertical displacement and a first pair of button protrusions, and the upper dental tray including a second pair of button protrusions, the first pair of button protrusions and the second pair of button protrusions providing mandibular anterior position when two elastic bands are attached and connected to the upper and lower dental trays.

[0107] Another embodiment involves receiving one or more patient-associated datasets on a server, determining one or more button projection positions on the server based on the datasets received from the scanner, at least the patient's dentition pattern, gingival line measurements, soft palate measurements from the soft palate shape, and uvular position measurements relative to the patient's palate shape, communicating one or more button projection and vertical displacement positions on the server, and assigning a value to each of the one or more positions for button projection positioning, where each value represents the distance between the upper tray button projection and the lower tray button projection relative to mandibular advancement. The method involves transmitting value data to one or more three-dimensional printers, milling machines, and injection molding machines; forming a dental instrument by direct manufacturing using values ​​associated with each of one or more determined positions for positioning button protrusions; the dental instrument including a lower dental tray and an upper dental tray, each of which is homogeneous; the lower dental tray including vertical displacement and a first pair of button protrusions; and the upper dental tray including a second pair of button protrusions, the first and second pairs of button protrusions providing anterior mandibular position when two elastic bands are attached and connected to the upper and lower dental trays.

[0108] In one or more embodiments, the dental instrument is formed by three-dimensional (3D) printing of one or more photopolymerizable liquid thermosetting crosslinked polymers, polyurethanes, methacrylates, or copolymers.

[0109] In one or more embodiments, the dental instrument is milled or injection molded one or more times using one or more ethylene-propylene copolymers and polyoxymethylene copolymers.

[0110] In one or more embodiments, the dental instrument is formed by three-dimensional (3D) printing of a polymerizable resin composition comprising a urethane monomer, an acid monomer, and one or more hydrophobic monomers of urethane dimethacrylate (UDMA).

[0111] In one or more embodiments, the dental instrument is injection molded using a thermoplastic olefin, thermoplastic polyolefin, or olefin-based thermoplastic elastomer.

[0112] In one or more embodiments, the vertical displacement is a function of the patient's soft palate shape.

[0113] In one or more embodiments, vertical displacement is provided by one or more of the pair of occlusal pads on the lower dental tray, or by the thickness of the lower dental tray.

[0114] In one or more embodiments, the gingival line determination identifies the maxillary crown-gingival junction and the mandibular crown-gingival junction, the upper dental tray is formed to reach a distance of 3 millimeters below the maxillary crown-gingival junction, and the lower dental tray is formed to reach approximately 3 millimeters below the mandibular crown-gingival junction.

[0115] Another embodiment includes a processor and a persistent computer-readable storage medium that stores instructions for operating when performing a method on the processor that includes receiving one or more patient-associated datasets in a server, and includes determining one or more button projection positions in the server based on the datasets received from the scanner, at least the patient's dentition pattern, palatal measurements from the soft palate shape, and uvular position measurements relative to the patient's palate shape, communicating one or more button projection and vertical displacement positions in the server, and assigning a value to each of the one or more positions for positioning the button projection, each value relating to the button projection of the upper tray relative to mandibular advancement The system includes a method for representing the distance to the button protrusions on the lower tray, transmitting value data to one or more 3D printers, milling machines, and injection molding machines, forming a dental instrument by direct manufacturing using values ​​associated with each of the one or more positions determined for positioning the button protrusions, and the dental instrument including a lower dental tray and an upper dental tray, each of which is homogeneous, with the lower dental tray including vertical displacement and a first pair of button protrusions, and the upper dental tray including a second pair of button protrusions, the first and second pairs of button protrusions providing anterior mandibular position when two elastic bands are attached and connected to the upper and lower dental trays.

[0116] Those skilled in the art will recognize that prior art has advanced to the point where there is little difference left between hardware and software implementations in terms of system aspects. Typically, the use of hardware or software (though not always, in certain situations the choice between hardware and software can be important) is a design choice representing a cost-effectiveness trade-off. Those skilled in the art will understand that there are various means (such as hardware, software, and firmware of one or more machines or products) by which the processes, systems, and other technologies described herein can be implemented, and that the preferred means differs depending on the context in which the processes, systems, and other technologies are deployed. For example, if the implementer determines that speed and accuracy are paramount, they may primarily choose hardware and / or firmware means. Or, if flexibility is paramount, they may primarily choose software implementations implemented on one or more machines or products. Or, as yet another method, they may choose several combinations of hardware, software, and firmware of one or more machines or products. Accordingly, there are several possible means by which the processes, apparatus, and other technologies described in this specification can be carried out, and no means is inherently superior to the others, in that any means to be used is a choice that depends on the circumstances in which the means are deployed and the specific concerns of the implementer (e.g., speed, flexibility, or predictability), which may vary. A person skilled in the art will recognize that optical embodiments of implementation generally use optically oriented hardware, software, and / or firmware in one or more machines or products.

[0117] In the detailed description above, various embodiments of apparatus and / or processes have been illustrated using block diagrams, flowcharts, and / or examples. Those skilled in the art will understand that, insofar as such block diagrams, flowcharts, and / or examples include one or more functions and / or operations, such block diagrams, flowcharts, and / or examples can be implemented individually and / or collectively by a wide range of hardware, software, firmware, or virtually a combination thereof. In one embodiment, some parts of the subject matter described herein may be implemented via application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), digital signal processors (DSPs), or other integrated formats. However, some aspects of the embodiments disclosed herein are equally implementable in whole or in part within an integrated circuit as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more processors (e.g., as one or more programs running on one or more microprocessors), as firmware, or substantially any combination thereof, and those skilled in the art will understand that designing circuits and / or writing code relating to software or firmware is well within the scope of those skilled in the art in light of this disclosure. Furthermore, those skilled in the art will understand that the mechanisms of the subject matter described herein can be distributed as various forms of program products, and that the exemplary embodiments of the subject matter described herein are applicable regardless of the particular type of signal-holding medium used to actually carry out the distribution. Examples of signal-retaining media include, but are not limited to, recordable media such as floppy disks®, hard disk drives, compact discs (CDs), digital video discs (DVDs), digital tapes, and computer memory, as well as communication media such as digital and / or analog communication media (e.g., fiber optic cables, waveguides, wired communication links, wireless communication links).

[0118] Those skilled in the art will recognize that, in a general sense, the various embodiments described herein can be implemented individually and / or collectively by a wide range of hardware, software, firmware, or any combination thereof. Accordingly, as used herein, “electrical circuit” includes, but is not limited to, an electrical circuit having at least one individual electrical circuit, an electrical circuit having at least one integrated circuit, an electrical circuit having at least one application-specific integrated circuit, an electrical circuit forming a general-purpose computer device configured by a computer program (e.g., a general-purpose computer configured by a computer program that performs at least partially the processes and / or devices described herein, or a microprocessor configured by a computer program that performs at least partially the processes and / or devices described herein), an electrical circuit forming a memory device (e.g., random access memory), and / or an electronic circuit forming a communication device (e.g., a modem, communication switch, or optical-electrical device). Those skilled in the art will recognize that the subject matter described herein can be implemented in analog or digital form or any combination thereof.

[0119] Those skilled in the art will recognize that it is common in the art to describe apparatus and / or processes using the methods described herein and then integrate such described apparatus and / or processes into a data processing system using engineering methods. That is, at least some of the apparatus and / or processes described herein can be integrated into a data processing system through a reasonable amount of experimentation. Those skilled in the art will understand that a typical data processing system generally includes one or more of the following: a system unit housing, a video display device, memory such as volatile and non-volatile memory, a processor such as a microprocessor and a digital signal processor, a computing entity such as an operating system, drivers, a graphical user interface, and an application program, one or more interacting devices such as a touchpad or a screen, and / or a control system including feedback loops and control motors (e.g., feedback for position detection and / or velocity detection, control motors for component movement and / or quantity adjustment). A typical data processing system can be implemented using suitable commercially available components, such as those commonly found in data computing / communication systems and / or network computing / communication systems.

[0120] While specific aspects of the subject matter described herein have been illustrated and explained, it will be apparent to those skilled in the art that, based on the teachings herein, changes and modifications can be made without departing from the subject matter described herein and its broader aspects, and therefore all such changes and modifications that fall within the true spirit and scope of the subject matter described herein are included in the appended claims. Furthermore, it should be understood that the present invention is defined by the appended claims. The following is the invention as originally described in the application. <Claim 1> The method consists of the following steps. After receiving the patient's oral characteristics data, The server processes the oral characteristic data to determine the dentition data, vertical displacement, and mandibular anterior position, and opens the patient's airway to allow breathing during sleep. A method for forming a dental instrument by direct manufacturing using the dentition data, vertical displacement, and mandibular anterior position, wherein the dental instrument includes a lower dental tray and an upper dental tray, the upper and lower dental trays being homogeneous, the lower dental tray including vertical displacement and a first pair of button protrusions, and the upper dental tray including a second pair of button protrusions, the first pair of button protrusions and the second pair of button protrusions providing the mandibular anterior position when two elastic bands are attached and connected to the upper dental tray and the lower dental tray. The method according to claim 1, wherein the dental instrument is formed by three-dimensional (3D) printing of one or more of a photopolymerizable liquid thermosetting crosslinked polymer, polyurethane, methacrylate, or copolymer. <Claim 3> The method according to claim 1, wherein the dental instrument is formed by three-dimensional (3D) printing of a polymerizable resin composition comprising a urethane monomer, an acid monomer, and one or more hydrophobic monomers of urethane dimethacrylate (UDMA). <Claim 4> The method according to claim 1, wherein the dental instrument is milled or injection molded from one or more ethylene-propylene copolymers and polyoxymethylene copolymers. <Claim 5> The method according to claim 1, wherein the dental instrument is injection molded using a thermoplastic olefin, thermoplastic polyolefin, or olefin-based thermoplastic elastomer. <Claim 6> The method according to claim 1, wherein receiving the patient's oral characteristic data includes scanning the patient's teeth with a scanner or camera and transmitting the oral characteristic data to a server. <Claim 7> Receiving patient oral characteristic data involves scanning the patient's mouth, This includes taking photographs of the oral cavity and determining the dental arch data, and the oral characteristic data includes one or more images of the patient's teeth and gingival line, and one or more images of the patient's soft palate. The method according to claim 1, comprising transmitting the oral characteristics to a server. <Claim 8> moreover, The method according to claim 7, comprising determining the vertical displacement as a function of the soft palate shape of the patient via the oral characteristic data. <Claim 9> Determining the vertical displacement as a function of the soft palate shape of the patient via the oral characteristic data means that, The method according to claim 8, wherein, in the case of the soft palate of the patient, there is a space of 5 to 7 millimeters between the posterior edge of the soft palate and the posterior wall of the pharyngeal orifice, the method comprising determining a vertical displacement of 5 to 7 millimeters. <Claim 10> Determining the vertical displacement as a function of the soft palate shape of the patient via the oral characteristic data means that, The method according to claim 8, further comprising processing the oral characteristic data and measuring the distance from the gingival-coronal junction of the maxillary central incisor to the gingival-coronal junction of the mandibular central incisor. <Claim 11> Determining the vertical displacement as a function of the soft palate shape of the patient via the oral characteristic data means that, To determine whether the posterior edge of the soft palate is longer than a normal soft palate in which there is a 3-5 mm space between the posterior edge of the soft palate and the posterior wall of the pharyngeal orifice of the patient, The method according to claim 8, comprising providing the vertical displacement of 8 to 10 millimeters. <Claim 12> Determining the vertical displacement as a function of the soft palate shape of the patient via the oral characteristic data means that, The method according to claim 8, comprising determining whether the posterior edge of the soft palate is longer than a normal soft palate and has a pterygoid jaw, and whether there is a space of 2 millimeters or less between the soft palate and the posterior wall of the pharyngeal orifice, and providing the vertical displacement to be at least 11 to 14 millimeters. <Claim 13> Determining the vertical displacement as a function of the soft palate shape of the patient via the oral characteristic data means that, The method according to claim 8, comprising determining whether the soft palate is short, normal, or long. <Claim 14> The method according to claim 1, wherein the lower dental tray includes a first vertical displacement occlusal pad on the left side and a second vertical displacement occlusal pad on the right side, the height of each of the first and second vertical displacement occlusal pads is determined according to the oral characteristic data, and the oral characteristic data provides soft tissue data indicating the patient's airway function. <Claim 15> The method according to claim 1, wherein the vertical displacement is provided by the thickness of the lower dental tray. <Claim 16> A system comprising a processor and a persistent computer-readable storage medium for storing instructions that would operate when executed on the processor performing the method described in claim 1. <Claim 17> A method consisting of the following steps. The server receives one or more datasets associated with a patient, Based on the dataset received from the scanner, the server determines one or more positions for positioning the button protrusion, and the received dataset includes at least the patient's dental arch pattern, palatal measurements of the soft palate shape, and measurements of the uvula position and gingival line relative to the patient's soft palate shape. One or more positions are communicated to the server for positioning the button protrusion and vertical displacement, and the communication includes: A value is assigned to each of the one or more positions for positioning the button protrusion, with each value representing the distance between the upper tray button protrusion and the lower tray button protrusion with respect to mandibular advancement. The aforementioned value data is transmitted to one or more of the 3D printer, milling machine, and injection molding machine. A dental instrument is formed by direct manufacturing using the values ​​associated with each of one or more positions for positioning button protrusions, the dental instrument comprising a lower dental tray and an upper dental tray, the upper and lower dental trays being homogeneous, the lower dental tray comprising vertical displacement and a first pair of button protrusions, and the upper dental tray comprising a second pair of button protrusions, the first pair of button protrusions and the second pair of button protrusions providing the mandibular anterior position when two elastic bands are attached and connected to the upper dental tray and the lower dental tray. <Claim 18> The method according to claim 17, wherein the dental instrument is formed by three-dimensional (3D) printing of one or more of a photopolymerizable liquid thermosetting crosslinked polymer, polyurethane, methacrylate, or copolymer. <Claim 19> The method according to claim 17, wherein the dental instrument is milled or injection molded using one or more ethylene-propylene copolymers and polyoxymethylene copolymers. <Claim 20> The method according to claim 17, wherein the dental instrument is formed by three-dimensional (3D) printing of a polymerizable resin composition comprising a urethane monomer, an acid monomer, and 17 or more hydrophobic monomers of urethane dimethacrylate (UDMA). <Claim 21> The method according to claim 17, wherein the dental instrument is injection molded using a thermoplastic olefin, thermoplastic polyolefin, or olefin-based thermoplastic elastomer. <Claim 22> The method according to claim 17, wherein the vertical displacement is a function of the shape of the patient's soft palate. <Claim 23> The method according to claim 17, wherein the vertical displacement is provided by one or more of the pair of occlusal pads on the lower dental tray, or by the thickness of the lower dental tray. <Claim 24> The method according to claim 17, wherein the determination of the gingival line identifies the maxillary crown-gingival junction and the mandibular crown-gingival junction, the upper dental tray is formed to reach a distance of 3 millimeters below the maxillary crown-gingival junction, and the lower dental tray is formed to reach approximately 3 millimeters below the mandibular crown-gingival junction. <Claim 25> A system comprising a processor and a persistent computer-readable storage medium for storing instructions that would operate when executed on the processor performing the method according to claim 17.

Claims

1. The steps include: the server receiving one or more datasets associated with a patient, A step in which a server determines one or more positions for positioning a button protrusion based on a dataset received from a scanner, wherein the received dataset includes at least the patient's dentition pattern and gingival line, The server communicates one or more positions and vertical displacements for positioning the button protrusion, wherein the communication step is: A step of assigning a value associated with each of one or more positions for positioning the button protrusion, wherein each value represents the distance between the upper tray button protrusion and the lower tray button protrusion with respect to mandibular advancement, The steps include transmitting the aforementioned value to one or more of the 3D printer, milling machine, and injection molding machine, A step of forming a dental instrument by direct manufacturing using the values ​​associated with each of one or more positions for positioning the button protrusions, wherein the dental instrument includes a lower dental tray and an upper dental tray, each of the lower dental tray and the upper dental tray being homogeneous, the lower dental tray including the vertical displacement and a first pair of the button protrusions, and the upper dental tray including a second pair of the button protrusions, the first pair and the second pair of the button protrusions providing an anterior mandibular position when two elastic bands are attached to connect the upper dental tray and the lower dental tray, A method having.

2. The method according to claim 1, wherein the dental instrument is formed by three-dimensional (3D) printing of one or more of a photopolymerizable liquid thermosetting crosslinked polymer, polyurethane, methacrylate, and copolymer.

3. The method according to claim 1, wherein the dental instrument is formed by one or more milling processes and injection molding processes using one or more ethylene-propylene copolymers and polyoxymethylene copolymers.

4. The method according to claim 1, wherein the dental instrument is formed by three-dimensional (3D) printing of a polymerizable resin composition comprising a urethane monomer, an acid monomer, and one or more hydrophobic monomers of urethane dimethacrylate (UDMA).

5. The method according to claim 1, wherein the dental instrument is injection molded using a thermoplastic olefin, thermoplastic polyolefin, or olefin-based thermoplastic elastomer.

6. The method according to claim 1, wherein the vertical displacement is a function of the shape of the patient's soft palate.

7. The method according to claim 1, wherein the vertical displacement is provided by one or more of the pair of occlusal pads on the lower dental tray, or by the thickness of the lower dental tray.

8. The method according to claim 1, wherein the determination of the gingival line identifies the maxillary crown-gingival junction and the mandibular crown-gingival junction, the upper dental tray is formed to reach a distance of approximately 3 millimeters below the maxillary crown-gingival junction, and the lower dental tray is formed to reach approximately 3 millimeters below the mandibular crown-gingival junction.

9. A system comprising a processor and a non-temporary computer-readable storage medium that stores instructions for performing the method according to claim 1 when executed by the processor.

10. The method according to claim 1, wherein the received dataset includes palatal measurements of the soft palate shape of the patient and uvular position measurements relating to the soft palate shape of the patient.

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