Intraoral scan bodies and methods for their use

Abstract

Scan bodies are used during intraoral scans. In one configuration, the scan body includes a registration body and a bridge with the registration body having registration surfaces located above an upper level of the bridge. In another configuration, the sidewalls of the bridge include at least one concave portion that extends from the upper surface to the lower surface of the bridge. In a further configuration, the sidewalls of the bridge are straight and tapered in a narrowing taper toward an outer end. Bridges with straight sidewalls use different shapes at the outer end to present different shapes to the scanning software. Another configuration has a selectively connectable bridge that allows the user to select the size and shape of bridge to be used with a registration body. These features improve the ability of the scanning software to identify the positions of the scan bodies.

Description

INTRAORAL SCAN BODIES AND METHODS FOR THEIR USEFIELD OF THE INVENTION

[0001] The disclosure generally relates to intraoral scan bodies and methods for using scan bodies during an intraoral scan.BACKGROUND OF THE INVENTION

[0002] The successful fabrication and installation of a dental prosthetics, especially a fullarch dental prosthetics, hinges on obtaining accurate information relative to the implants (and / or intermediate abutments) including location and orientation (i.e. x, y, z coordinates) of the implants installed in the patient’s mouth (e.g. within the maxilla or mandible of a patient). Historically, this information has been obtained through physical impressions, which have been referred to as wet impressions or putty impressions. With technical advancements, data relative to the implants is now commonly obtained by scanners operating in conjunction with software to develop a digital image with x, y, z coordinate positions of the implant and / or the abutment. Several scanning techniques have been developed including the use of photogrammetry or intraoral scanners. Generally speaking, photogrammetry relies on photographic technologies while intraoral scanners rely on laser or light technologies. Those technologies that rely on photogrammetry are generally understood to provide more accurate data, although the technology is often more expensive and is limited in its overall capabilities, such as the ability to scan tissue.

[0003] For a variety of reasons, intraoral scanners are quite popular even though they can produce less accurate results. To assist in the acquisition of the image, the scanning techniques employ scan bodies, which are dental devices that are temporarily installed or mounted to the implants, which may include a direct mount to the implant or an indirect mount via an intermediary appliance such as an abutment. The scan body is scanned and its location in space is determined, which then allows the location of the implant and / or abutment to be determined based upon one or more correlations.

[0004] While popular and convenient, intraoral scanning for the purpose of locating implant locations, especially with edentulous patients seeking full-arch prosthetics, hasproblems. For example, intraoral scanners have been found to generate lower quality data when the scanner moves between various scan bodies and encounters surfaces such as tissue, bone, saliva, or blood. Another issue is that the digital model can be corrupted if the software recognizes a repeated shape such as a multiple scan bodies having the shape. The skilled person understand that intraoral scanning generally captures data by randomly moving a scanner around the mouth of a patient and the software associated with the scanner builds a digital image by accumulating the data within a process commonly known as stitching or knitting. When software cannot distinguish between multiple scan bodies, a problem sometimes referred to as ghosting occurs, which negatively impacts the success of the scan or the ultimate quality of the scan. For example, ghosting may include the superimposing of one scan body onto another scan body within the mouth.SUMMARY OF THE INVENTION

[0005] The disclosure provides scan bodies used to facilitate acquiring a scan during intraoral scans. In one configuration, the scan body includes a registration body and a bridge, with the registration body having registration surfaces located above an upper level of the bridge. In another configuration, the sidewalls of the bridge include at least one concave portion that extends from the upper surface to the lower surface of the bridge. In a further configuration, the sidewalls of the bridge are straight and tapered in a narrowing taper toward an outer end. Bridges with straight sidewalls can include different shapes at the outer end to present different overall geometry. The various geometric features improve the ability of the scan bodies to be distinguished by scanning software used in conjunction with the intraoral scanner.

[0006] The disclosure provides an array of scan bodies adapted to be directly or indirectly mounted to dental implants; the assembly comprising: a first plurality scan bodies adapted to be arranged with respect to the dental implants; each scan body having an overall geometry; each scan body of the first plurality of scan bodies being adjacent to and in close proximity with at least one other scan body of the first plurality of scan bodies, wherein the at least one other scan body is an adjacent scan body; and each scan body having a different overall geometry than its adjacent scan body.

[0007] The disclosure provides a method of installing a plurality of scan bodies directly or indirectly on dental implants prior to an intraoral scan, the method comprising the steps of: mounting scan bodies to dental implants, where the scan bodies have different overall geometries relative to each other; positioning each scan body to be in close proximity to at least one adjacent scan body; and arranging the scan bodies so that each scan body has a different overall geometry than each of its adjacent scan bodies.

[0008] A scan body for use during an intraoral scan, the scan body comprising: a registration body having a central body portion, an attachment portion extending from the central body portion, and a registration portion that defines first and second registration surfaces; the registration portion extending laterally from the central body portion; and the registration body defining a fastener opening offset from the first and second registration surfaces.

[0009] A scan body for use during an intraoral scan, the scan body comprising: a registration body having a central body portion, an attachment portion extending from the central body portion, and a registration portion that defines first and second registration surfaces; the registration portion extending laterally from the central body portion; and the registration body defining a fastener opening offset from one of the the first and second registration surfaces and extending through an edge of the other of the first and second registration surfaces.

[0010] A method of performing an intraoral scan, the method comprising: providing a patient with a plurality of implants, wherein at least two of the plurality of implants have a scan body mounted thereto to define an array of scan bodies, wherein the array of scan bodies includes adjacent scan bodies that are in close proximity with at least one other adjacent scan body, and wherein the adjacent scan bodies have distinct overall geometries; and scanning, with an intraoral scanner, the array of scan bodies.

[0011] The disclosure provides an installation and method of use wherein at least adjacent installed scan bodies have different overall geometries so that an intraoral scanner, working in conjunction with associated scanning software, does not encounter adjacent scan bodies having the same geometry or does not encounter scan bodies having the samegeometry during a scanning session. In one or more embodiments, the different overall geometries may be provided by distinction in the perimeter geometry of the bridge.

[0012] In another configuration, each scan body of a group of installed scan bodies has at least an overall geometry, such as the perimeter geometry of the bridge, that is different from the overall geometry, such as the perimeter geometry of the bridge, of each of the other scan bodies in the group. The plurality of scan bodies with each scan body of the plurality having a unique overall geometry, such as a unique perimeter geometry of the bridge, provides unique shapes to the scanner to minimize the chance that any one scan body is mistaken for another scan body by the scanning software, which is building the initial digital model from the scan data. The shape of the scan body also provides the ability of arrangement such that a contiguous scan is possible from scan body to scan body with tissue, saliva, and blood being obscured so as not to disrupt accurate scanning. The difference in the perimeter geometries can be provided by the perimeter geometries of the bridges.

[0013] The disclosure provides a scan body having a registration body and a bridge. The registration body includes a central body portion, an attachment portion, and a registration portion that includes two registration surfaces which are the target of the intraoral scan procedure.

[0014] The disclosure provides some embodiments of the registration body with a fastener hole that is defined through the central body portion and attachment portion. In some configurations, the fastener hole is completely offset from both registration surfaces while in other embodiments the fastener hole is at least partially defined by one of the registration surfaces.

[0015] The disclosure provides a scan body structure that locates one of the registration surfaces at a level entirely above an upper surface of the bridge.

[0016] The disclosure provides a scan body structure that locates one of the registration surfaces at a level entirely above an upper surface of the bridge with at least a portion of the other registration surface at a level above the upper surface of the bridge.

[0017] The disclosure also provides a scan body with a bridge sidewall geometry defined by at least one concave portion that extends from the upper surface to the lower surface. In some configurations, a plurality of concave portions are separated by a projection. Theconcave portions can be various widths and depths. The projection can be pointed, rounded, or flat. In one configuration, the sidewalls are perpendicular to the upper and lower surfaces of the bridge. In other configurations, the opposed sidewalls taper toward each other from the lower surface of the bridge to the upper surface of the bridge. Different combinations of concave portions and projections are used to form a plurality of scan bodies having different geometries. The ends of the scan bodies can be rounded or flat.

[0018] The disclosure also provides a scan body with bridge sidewalls being straight and tapering toward each other toward the outer end of the bridge. Different outer ends are used to provide different geometry for these scan bodies. A rounded outer end and a straight outer end provide different geometries.

[0019] The disclosure provides a scan body system associated methods wherein the scan body includes a registration body that includes registration surfaces. Any one of a plurality of bridges are selectively connectable to the registration body. The user selects a bridge based on the size and shape needed for a particular location in the mouth. The user then connects the selected bridge to the registration body. The plurality of bridges can be manufactured and provided with the registration bodies. In another configuration, the plurality of bridges are 3D printed by the user from a selected digital file. In this configuration, a single bridge or a plurality of bridges are created on demand as needed for a particular scan. In an exemplary configuration, a plurality of bridges of varying length and perimeter combinations are provided on a carrier that allows a user to connect a registration body to a selected bridge directly from the carrier to form the scan body. This process is repeated to create a group of scan bodies.

[0020] The disclosure provides a kit that includes a plurality of scan bodies. The scan bodies have different perimeter geometries so that scan bodies can be installed without adjacent scan bodies having the same perimeter geometries. In one embodiment, sufficient unique perimeter geometries are provided so that all the scan bodies installed for a scan have different perimeter geometries. The different perimeter geometries help to distinguish one scan body from another by the scanning software. The scan bodies of the kit can have different lengths. Subgroups of scan bodies can be provided with the same length. In one configuration, a kit of nine scan bodies has two scan bodies with a first length, two scanbodies with a second length, four scan bodies with a third length, and one scan bodies with a fourth length.

[0021] The disclosure also provides a method of generating a digital model by conducting an intraoral scan with a plurality of scan bodies having unique geometries. Each of the plurality of scan bodies is in contact with at least one other scan body with the registration bodies fully exposed for scanning. In another configuration, the end of one scan body is positioned close to an adjacent scan body while not being in physical contact. One configuration of the method includes the step of associating bridge geometry with the registration body geometry.BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. l is a three-dimensional view of a first exemplary configuration of a scan body.

[0023] FIG. 2 is a three-dimensional view of two exemplary scan bodies similar to the scan body of FIG. 1 where the two have different sidewall geometries and different lengths.

[0024] FIG. 3 is a top plan view of an exemplary kit that includes a plurality of scan bodies according to the first exemplary configuration.

[0025] FIG. 4 is a bottom plan view of the scan bodies of FIG. 3.

[0026] FIG. 5 is a top plan view of a second exemplary configuration of a scan body.

[0027] FIG. 6 is a side view of FIG. 5.

[0028] FIG. 7 is an end view of FIG. 5.

[0029] FIG. 8 is a top plan view of a third exemplary configuration of a scan body.

[0030] FIG. 9 is a side view of FIG. 8.

[0031] FIG. 10 is an end view of FIG. 8.

[0032] FIG. 11 is a three-dimensional view of a fourth exemplary configuration of a scan body.

[0033] FIG. 12 is an exploded side view thereof.

[0034] FIG. 13 is an exploded rear view thereof.

[0035] FIG. 14 is an upper three-dimensional view of one portion of the scan body.

[0036] FIG. 15 is a lower three-dimensional view thereof.

[0037] FIG. 16 is a three-dimensional view of a plurality of bridges carried by a carrier.

[0038] FIG. 17 is another view thereof.

[0039] FIG. 18 is a perspective view of an array of scan bodies according to aspects of the disclosure.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0040] This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. The drawing figures are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In the description, relative terms such as "horizontal,” “vertical," “up,” "down,” "top” and “bottom” as well as derivatives thereof (e.g., "horizontally,” "downwardly,” "upwardly," etc.] should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,” "longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. When in use, the scan bodies of this disclosure are connected to the patient's mandible or the maxilla or both. The scan bodies are thus used in an upright configuration as depicted in the drawings as well as upside down. Terms concerning attachments, coupling and the like, such as "joined,” "connected," and “interconnected," refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

[0041] A first configuration of an exemplary scan body is indicated generally by the number 2 in FIGS. 1-4 and 18. A second configuration of an exemplary scan body is indicated by the number 102 in FIGS. 5-7. A third configuration of an exemplary scan body is indicated by the number 202 in FIGS. 8-10. A fourth configuration of an exemplary scan body is indicated by the number 302 in FIGS. 11-13.

[0042] According to conventional techniques, scan bodies 2, 102, 202, and 302 are attached, either directly or indirectly, to dental implants before an intraoral scan isconducted. Scan bodies 2, 102, 202, and 302 are used to help acquire data from an intraoral scan that is used by software generate a digital model that identifies locations and orientations of the dental implants. The digital model can be used to build prosthetics that fit the implants and function in the mouth of the patient. Scan bodies 2, 102, 202, and 302, which may also be referred to as scan abutments, scan guides, and scan flags, are therefore structures that, when mounted to an implant or to an intermediate device mounted to an implant (e.g. an abutment], help gather data during an intraoral scan.

[0043] In the first configuration depicted in FIGS. 1-4 and 18, scan body 2 generally includes a bridge 8 and a registration body that includes a central body portion 3, an attachment portion 4, and a registration body portion 10. Some configurations of scan body 2 lack bridge 8 as shown in FIGS. 3-4. Attachment portion 4 is the portion of scan body 2 that is placed over the exposed end of a dental implant or connected to an intermediate device mounted to the dental implant. Attachment portion 4 can be cylindrical and tapered as depicted or polygonal. Attachment portion 4 can be connected to the implant or to the intermediate device with a fastener, a snap fit, or other type of connection. When a fastener is used, a fastener hole 6 is defined through central body portion 3 and attachment portion 4 to provide access to the fastener, implant or intermediate device through the body of scan body 2. The fastener is installed and removed using fastener hole 6 in configurations that install scan body 2 with a fastener.

[0044] Bridge 8 of scan body 2, which may also be referred to as a wing 8, is extending laterally or cantilevered from central body portion 3. Bridge 8 is elongated in a direction generally perpendicular to the axis of fastener hole 6. When scan body 2 is installed within a patient's mouth (i.e. mounted on the implant], bridge 8 can be positioned (e.g. via rotation] in close proximity to another installed scan body 2. In the context of this disclosure, the term "in close proximity to" includes the condition of direct contact or direct touching. Close proximity also means that one article is spaced from another a distance that is less than the width of bridge 8 or the width of central body portion 3, or in other embodiments half the width of the bridge or body portion. It will be appreciated that by positioning the scan bodies, for example through rotation, so that the bodies are at least closely positioned to each other (they are in close proximity], the process of scanning will continuously detect thesurfaces of the scan bodies without encountering deleterious interruptions between scan bodies where blood, tissue, and / or bone would otherwise be detected by the scanner. In other words, the scan bodies should be configured, and during use, installed in a manner, that they are brought into sufficient proximity so as to minimize, or in embodiments eliminate, detection of intervening bone, tissue, and blood between the scan bodies. Such proximity is included in the meaning of close proximity in this disclosure.

[0045] Registration body portion 10 extends laterally or be cantilevered from central body portion 3 in a direction different from bridge 8 and can extend laterally or be cantilevered in a direction 180 degrees opposite bridge 8. Registration body portion 10 includes atleasttwo registration surfaces 20 and 22. Each registration surface is flatand one joins the other. Registration surfaces 20 and 22 are not parallel to one another. In this configuration, both bridge 8 and registration body portion 10 are cantilevered from central body portion at locations higher than attachment portion 4.

[0046] Registration body portion 10 is a cantilevered structure defined by a first lower surface 16 that projects away from central body portion 3, a first end surface 18, a chamfer surface 20 that, in whole or in part, functions as one registration surface 20, and a first upper surface 22 which, in whole or in part, functions as the other registration surface 22. Registration body portion 10 is also defined by sidewalls that join end surface 18 and chamfer surface 20 with central body portion 3 and attachment portion 4. A sloped curved wall 28, which may also be referred to sloped wall 28 or transition wall 28, extends between first upper surface 22 and a second upper surface 30 of bridge 8. In the exemplary configuration, fastener hole 6 extends through a portion of first upper surface 22 and a portion of sloped wall 28. Fastener hole 6 is offset from the center of first upper surface 22. Hole 6 extends through an edge of first upper surface 22. As noted above, first upper surface 22 is located higher than second upper surface 30 when scan body 2 is in the orientation depicted in the drawings with first upper surface 22 being located a level higher than attachment portion 4 and chamfer surface 20 being at a level higher than first end surface 18. At least a portion of registration surface 20 is also located at a level higher than second upper surface 30. The geometry of chamfer surface 20, first upper surface 22, and fastener hole 6 help the scanning software identify the direction of scan body 2.

[0047] In an alternative configuration, at least one of registration surfaces 20 and 22 is provided with a unique feature that is identifiable by the scanner software. The feature can be a shape or number printed on or provided inset into or raised on one of surfaces 20 and 22, a sidewall irregularity, or a different diameter or curvature of one or both of surfaces 20 and 22.

[0048] Bridge 8 is further defined by a second lower surface 32 which is connected by sidewalls 24 and 26 to second upper surface 30. Second upper surface 30 and second lower surface 32 are generally flat. A second end surface or end wall 34 can be flat or rounded. First lower surface 16, second lower surface 32, and both sidewalls 24 and 26 smoothly transition with central body portion 3 and attachment portion 4.

[0049] The portions of sidewalls 24 and 26 extending from central body portion 3 to second end surface 34 define unique geometries that allows one individual scan body 2 to be distinguished from other scan bodies 2 that are in use during a scan. At least adjacent scan bodies 2 have different geometries. In the exemplary configuration, these portions of sidewalls 24 and 26 are perpendicular to second upper surface 30 and second lower surface 32. In other configurations, opposed portions of sidewalls 24 and 26 can be angled toward each other such that the width of second upper surface 30 is smaller than the width of second lower surface 32 at the position of the opposed sidewall portions.

[0050] As generally explained above, the geometry of the bridges of the scan bodies, which may be referred to as bridge geometry, may provide the scan body with an overall geometry that, relative to other scan bodies within a group, is distinguishable from the overall geometry of the other scan bodies within a group. One aspect of the bridge geometry that may provide a distinguishing characteristic is the sidewall geometry, which relates to the shape of the bridge sidewall [e.g. sidewall 24 and / or sidewall 26], Another aspect of the bridge geometry that may provide a distinguishing characteristic is the geometry of the end wall of the bridge, which may also be referred to as the geometry of the second end surface (e.g. end surface 34 or end wall 34). Yet another aspect of the geometry of the bridge that may provide a distinguishing characteristic is the geometry of the top perimeter of the bridge, which may be referred to as top perimeter geometry or simply perimeter geometry. As used within this disclosure, geometry refers to shape and merely the dimension of length.Accordingly, as understood herein, two scan bodies that have the same overall shape but different sizes (e.g. one may be longer than the other], are not deemed to be geometrically distinct.

[0051] In some of the exemplary configurations, sidewalls 24 and 26 are defined by at least one concave portion or divot 40 or at least one projection 42. As shown in FIGS. 2 and 3, different numbers and / or shapes of concave portions 40 and projections 42 are used to provide different sidewall geometries of the respective bridges. As also shown in FIG. 3, the different numbers and shapes of concave portion 40 and projections 42 also provide different perimeter geometries of the respective bridges. Concave portions 40 can have different depths, different curvatures, and different spans to provide different geometries. A concave portion 40 can be bounded by two projections 42 or single projection 42. Projections 42 can have different curvatures (e.g. they can be more rounded or more pointed] and have different heights.

[0052] Another bridge geometry configuration uses straight sidewalls with different end wall geometries is shown in FIG. 18, wherein scan body 2 include respective bridges that have straight sidewalls (one set of sidewalls is parallel and the other set converges toward each other] with different end wall configurations (one with three walls and one with a single straight wall] . Curved end walls can also be used. In one or more embodiments, when in use, a plurality of different scan bodies 2 are arranged within a patient’s mouth (e.g. mounted to implants abutments] in an array, which may also be referred to as a configuration or assembly (an example depicted in FIG. 18] that approximates the prosthetic being designed for the patient. As indicated above, the selected scan bodies 2 are chosen and installed to be in close proximity (e.g. to touch or be closely spaced] to each other when connected to the implants. For example, bridge 8 from one scan body 2 touches a registration body portion 10 of another scan body 2. Bridges 8 thus visually link one scan body 2 to another to help the scanner gather continuous data.

[0053] In the exemplary configuration depicted in the drawings, at least the upwardly- facing registration surfaces 20 and 22 of the registration body portions 10 on all of the scan bodies 2 used for a scan have the same geometry. This geometry is used by scanning softwareto identify the digital x, y, z coordinate position of the implant and / or the abutment, necessary to design a prosthesis that will attach to the implant or abutment.

[0054] Aspects of this disclosure therefore provide a kit of scan bodies that have a plurality of overall geometries. For example, the scan bodies of the kit may include bridges with multiple different geometries such as different perimeter geometries. An example of a kit 50 is depicted in FIGS. 3 and 4. The perimeter geometry of the bridges is defined by a top plan view of each scan body 2. As shown, the perimeter geometries of the respective bridges of the scan bodies are different in the depicted plurality of scan bodies 2. Each has a unique shape (i.e. overall geometry]. According to embodiments of the invention, these different overall geometries facilitate scanning because the scanner and associated software used during an intraoral scan can distinguish the scan bodies based upon the differences in overall geometries, which thereby minimizes errors in scanning related to an inability of the software to distinguish between the various scan bodies (i.e. ghosting). In certain aspects, a kit includes a plurality of scan bodies where each scan body has a unique overall geometry. In other aspects, a kit includes a plurality of scan bodies with a plurality of overall geometries, but the kit may include multiples of one or more of the scan bodies within the kit.

[0055] Scan bodies 2 within a kit can have different lengths or subgroups of scan bodies 2 can be provided with the same length. In the exemplary configuration of FIGS. 3 and 4, kit 50 of nine scan bodies 2 has two scan bodies 2 with a first length, two scan bodies 2 with a second length, four scan bodies 2 with a third length, and one scan bodies 2 with a fourth length. Other groupings of scan body lengths can be used to form different kits. Additionally, multiples of the same scan bodies 2 can be included in the same kit 50.

[0056] In the second configuration depicted in FIGS. 5-7, scan body 102 generally includes a central body portion 3 and a hollow attachment portion 4 that are similar to the first configuration. Scan body 102 also includes bridge 8 that is cantilevered from central body portion 3.

[0057] Scan body 102 further includes a registration body portion 110 that extends laterally or is cantilevered from central body portion 3 in a direction different from bridge 8 and can extend laterally or be cantilevered in a direction 180 degrees opposite bridge 8. Both bridge 8 and registration body portion 110 extend laterally or are cantilevered fromcentral body portion 3 at locations higher than attachment portion 4. When in use, a plurality of different scan bodies 102 are selected with body configurations that approximate the prosthetic being designed for the patient. As described earlier, the selected scan bodies 102 are chosen to touch each other when connected to the implants.

[0058] In the exemplary configuration depicted in the drawings, at least the upwardly- facing surfaces 120 and 122 of the registration body portions 110 on all of the scan bodies 2 used for a scan have the same geometry. Whether in whole or in part, surfaces 120 and 122 function as the registration surfaces for scan body 102. This surface, or the associated geometry, is used by the scanning software, optionally in conjunction with stored data relative to the characteristics of the particular scan bodies, to identify the digital x, y, z coordinate position of the implant and / or the abutment, necessary to design a prosthesis that will attach to the implant or abutment.

[0059] As best shown in FIG. 6, registration body portion 110 may include a laterally- extending or cantilevered structure defined by a first lower surface 116 that projects away from central body portion 3, a first end surface 118, a chamfer surface 120 that, in whole or in part, functions as one of the registration surfaces 120, and a first upper surface 122 which, in whole or in part, functions as the other registration surface 122. Registration body portion 110 may also be defined by sidewalls that join end surface 118 and chamfer surface 120 with central body portion 3 and attachment portion 4. A sloped curved wall 128, which may also be referred to as sloped wall 128 or transition wall 128, extends between first upper surface 122 and a second upper surface 30 of bridge 8. Fastener hole 6 extends through a portion of second upper surface 30 and a portion of sloped curved wall 128. In this configuration, fastener hole 6 is thus entirely offset from first upper surface 120 of registration body portion 110 in the second configuration of scan body 102. First upper surface 122 is located higher than second upper surface 30 when scan body 2 is in the orientation depicted in the drawings with first upper surface 122 being higher than attachment portion 4 and chamfer surface 120 being higher than first end surface 118. At least a portion of chamfer surface 120 is also located higher than second upper surface 30. The geometry of chamfer surface 120 and first upper surface 122 help the scanning software identify the orientation of scan body 102.

[0060] In an alternative configuration, at least one of registration surfaces 120 and 122 is provided with a unique feature that is identifiable by the scanner software. The feature can be a shape or number printed on or provided inset into or raised on one of surfaces 120 and 122, a sidewall irregularity, or a different diameter or curvature of one or both of surfaces 120 and 122.

[0061] Bridge 8 of the second configuration is similar to scan body 2 with the same numbers used to identify similar structures. Second end surface 34 can be flat or rounded. First lower surface 16, second lower surface 32, and both sidewalls 24 and 26 smoothly transition with central body portion 3 and attachment portion 4. The portions of sidewalls 24 and 26 extending from central body portion 3 to second end surface 34 define unique geometries that allows one individual scan body 102 to be distinguished from other scan bodies 102 that are in use during a scan. In the exemplary configuration, these portions of sidewalls 24 and 26 are perpendicular to second upper surface 30 and second lower surface 32. In other configurations, these portions of sidewalls 24 and 26 can be angled such as when the width of second upper surface 30 is smaller than the width of second lower surface 32.

[0062] As with previous configurations, the geometry of the bridges of the scan bodies, which may be referred to as bridge geometry, may provide the scan body with an overall geometry that, relative to other scan bodies within a group, is distinguishable from the overall geometry of the other scan bodies within a group. One aspect of the bridge geometry that may provide a distinguishing characteristic is the sidewall geometry, which relates to the shape of the bridge sidewall (e.g. sidewall 24 and / or sidewall 26). Another aspect of the bridge geometry that may provide a distinguishing characteristic is the geometry of the end wall of the bridge, which may also be referred to as the geometry of the second end surface (e.g. end surface 34 or end wall 34). Yet another aspect of the geometry of the bridge that may provide a distinguishing characteristic is the geometry of the top perimeter of the bridge, which may be referred to as top perimeter geometry or simply perimeter geometry. As used within this disclosure, geometry refers to shape and merely the dimension of length. Accordingly, as understood herein, two scan bodies that have the same overall shape but different sizes (e.g. one may be longer than the other), are not deemed to be geometrically distinct.

[0063] In the exemplary configuration, sidewalls 24 and 26 are defined by at least one concave portion or divot 40 or at least one projection 42. Similar to that depicted in FIGS. 2- 4, different numbers and / or shapes of concave portions 40 and projections 42 are used to provide different sidewall geometries of the respective bridges. As also shown in FIG. 3, the different numbers and shapes of concave portion 40 and projections 42 also provide different perimeter geometries of the respective bridges. Concave portions 40 can have different depths, different curvatures, and different spans to provide different geometries. A concave portion 40 can be bounded by two projections 42 or single projection 42. Projections 42 can have different curvatures (e.g. they can be more rounded or more pointed] and have different heights.

[0064] Another bridge geometry configuration uses straight sidewalls with different end wall geometries is shown in FIG. 18, wherein scan body 2 include respective bridges that have straight sidewalls (one set of sidewalls is parallel and the other set converges toward each other] with different end wall configurations (one with three walls and one with a single straight wall]. Curved end walls can also be used.

[0065] A third configuration of scan body 202 shown in FIGS. 8-10 does not include bridge 8. The third configuration provides the unique registration body portion 110 geometry with central body portion 3 and attachment portion 4. Registration body portion 110 has the same geometry as the second configuration of scan body 102.

[0066] The scan bodies of the foregoing configurations may be fabricated using known techniques including, but not limited to, casting and 3D printing. In one or more embodiments, the scan bodies can be fabricated from various metals or metal alloys including, but not limited to, aluminum, zirconium, and stainless steel. In other embodiments, the scan bodies can be fabricated from various polymeric materials.

[0067] A fourth configuration of the scan body is indicated by the number 302 in the exemplary configuration depicted in FIGS. 11-13. The fourth configuration uses elements from the first and second configurations and the same reference numbers are used to identify these elements. Scan body 302 uses a configuration of bridge 8 that is selectively attachable to a central body portion 3. This configuration allows a user to build custom scan bodies 302.The user selects bridge 8 from a plurality of available bridges 8 and attaches it to central body portions 3 to form scan body 302.

[0068] When bridge 8 is connected to central body portion 3 as depicted in FIG. 11, the overall shape of scan body 302 is essentially the same as the shape of scan body 102. The features that connect bridge 8 to central body portion 3 are internal to scan body 302 when the two are connected. In the exemplary configuration, central body portion 3 has an outer surface in the configuration of a tapered cylinder with the inner end surface of bridge that engages this surface complementing it so that the two parts appear and function as a single part when connected. Bridge 8 and central body portion 3 are joined with a permanent or nonpermanent connector. The connector is one of or a combination of mechanical fasteners, an interlocking arrangement of elements, an adhesive, fusing, and a weld. The mechanical fasteners include bolts and nuts, screws, rivets, clips and clamps, pins and cotter pins, adhesives, interlocking joints that are designed to fit together securely without the need for additional fasteners. The interlocking arrangement can use friction and / or the elasticity of materials to create a resilient force with these being used alone or in combination with mechanical detents or other connectors described above. In the exemplary configuration of FIGS. 11-15, the connector for scan body 302 includes a projection 304 that is received in a recess 306 defined by bridge 8. Projection 304 can be held with friction, an adhesive, a detent that projects from either part, a mechanical fastener, or a combination of these. The two elements can be made from different materials such that bridge 8 will slightly stretch and resiliently hold itself on projection 304 when projection 304 is fully seated in recess 306. For example, projection 304 can be a metal and bridge 8 can be a polymer.

[0069] In one configuration, the end user is supplied with a plurality of central body portions 3 with projections 304 and a plurality of different bridges 8. The user can then build a kit of scan bodies 302 by selecting desired bridges 8 and connecting them to central body portions 3.

[0070] In another configuration, bridges 8 are 3D printed from a selected digital file. The user then connects the printed bridges to central body portions 3 that are otherwise supplied or are also printed. When printed, bridges 8 can be formed on a common carrier 310 for the user to select as desired. The plurality of bridges 8 are printed on a common carrier 301with each positioned with recess 306 facing up or outwardly so that a central body portion 3 can be attached to a selected bridge 8 while bridge 8 is still connected to carrier 301. The user then bends or twists the connected combination to separate bridge 8 from carrier 310.

[0071] It should therefore be appreciated that the scan bodies disclosed herein are useful in facilitating the acquisition of data during oral scanning. It should also be appreciated that the scan bodies and assemblies disclosed herein can be used in a manner that minimizes or eliminates problems associated with scanning and / or stitching or knitting via associated software when intervening tissue, bone and blook is encountered between adjacent scan bodies and / or when data processing is frustrated by an inability to distinguish between similarly shaped scan bodies (i.e. ghosting). It will further be appreciated that the scan bodies and assemblies are advantageously useful in performing intraoral scans where scan bodies are mounted (directly or indirectly) to multiple implants installed with the mouth (e.g. within the maxilla or mandible) of a patient. Use of scan bodies and associated methods disclosed herein is particularly useful for performing intraoral scans on edentulous patients seeking full-arch dental prosthetics.

[0072] Aspects of the invention therefore provide a method of performing an intraoral scan using the scan bodies and assemblies disclosed herein. This may include the step of selecting a group of scan bodies (e.g. scan bodies 2 from set 50), where each scan body of those selected has a unique overall geometry (e.g. distinct sidewall geometry or and / or unique perimeter geometry) relative to the other scan selected scan bodies (i.e. within the group). These scan bodies are attached to the dental implants, directly or indirectly, within the patient’s mouth and arranged so as to be in close proximity or touching adjacent scan bodies.

[0073] As discussed above, when adjacent scan bodies are in close proximity, which includes touching, the scanning of tissue, blood, or bone between the adjacent scan bodies is minimized or eliminated, which improves the overall quality of the scan. For example, the close proximity provides continuity for the scanner and / or software. In one embodiment, one scan body is in close proximity to another scan body (e.g. an adjacent scan body) when the spacing between the two scan bodies is less than the width of the bridge. In another embodiment, one scan body is in close proximity to another when the spacing between thetwo scan bodies is less than half of the minimum width of the bridge. In one or more embodiments, one scan body is in close proximity with another scan body when the acquisition of a digital image of bone, blood, or tissue between scan bodies does not interfere with accurate acquisition of the scan bodies.

[0074] In order the ensure that the installed scan bodies are placed within close proximity of another scan body, the scan bodies can be seleted according to their size to ensure thatthe the size of neighboring scan bodies, as primarily determinted by the size (e.g. length) and / or shape fo the bridge is sufficient to extend into at least close proximity with an adjacent scan body. Also, the manner in which the scan bodies are mount and / or adjusted after mounting can be used to ensure close proximity. It wll be appreciate that the scan bodies can be rotated, generally parallel to the maxilla or mandible, so that the bridge can extend in a direction toward an adjacent scan body to thereby place the scan bodies within close proximity to each other (or to touh each other).

[0075] In other embodiments, the group of scan bodies selected may include two or more scan bodies having the same or similar geometries, and the method may therefore include the step of arranging each scan body to be in close proximity to at least one adjacent scan body and positioning the scan bodies so that each scan body has a different perimeter geometry than each of its adjacent scan bodies.

[0076] In one or more embodiments, the methods of the invention employ intraoral scanners, which may also be referred to as IOS scanners, of a type common in the field of dental imaging. As the skilled person appreciates, these scanners operate on technology that is capable of aquiring images of the scan bodies, as well as other materials within the mouth include teeth, bone, tissue and blood. Commercially available intraoral scanners that can be used include, but are not limited to, those available from Trios Intraoral Scanners and marketed as 3Shape, those available from Carestream Dental and marketed as CS 3700, CS 3800, and CS 3900, those available from Meditand marketed as i Series, and those available from Shining 3D and marketed as AoralScan.

[0077] During acquisition of the image (i.e. during scanning), a scanner is moved, optionally randomly, through the mouth to capture data and create a digital image. These skilled in the art appreciate that this is accomplished by stitching or knitting the datatogether to form the digital image. It will also be appreciated that among the data aquired and converted into a digital image is the location of the respective registry surfaces of the various scan bodies. During subsquent processing of the information, the digital image of these registry surfaces (e.g. surfaces 20, 22) are matched or otherwise correlated with stored digital images of the scan body (or portion thereof including the registry surfaces) in order to accruatly determine the location of the implants and / or abutments attached to the implants. In one or more aspects, this correlation is accomplished with human intervention where a technician matches the registry surfaces of the acquired image and the corresponding registry surface of the stored digital image file (i.e. preexisiting digital image file of the scan body or poriton thereof). In other aspects, correlation between the registry surfaces of the aquired image the registry surfaces of the storeed file is accomplished using artifical intellegence.

[0078] Various modifications and alterations that do not depart from the scope and spirit of this invention will become apparent to those skilled in the art. This invention is not to be duly limited to the illustrative embodiments set forth herein.

Claims

CLAIMSWhat is claimed is:

1. An array of scan bodies adapted to be directly or indirectly mounted to dental implants; the assembly comprising: a] a first plurality scan bodies adapted to be arranged with respect to the dental implants; each scan body having an overall geometry; b] each scan body of the first plurality of scan bodies being adjacent to and in close proximity with at least one other scan body of the first plurality of scan bodies, wherein the at least one other scan body is an adjacent scan body; and c] each scan body having a different overall geometry than its adjacent scan body.

2. The array of claim 1, wherein each of a second plurality of the first plurality of scan bodies includes a bridge with a bridge geometry; the bridge geometries being unique.

3. The array of any of the preceding claims, wherein each scan body of the first plurality of scan bodies has a unique overall geometry.

4. The array of any of the preceding claims, wherein each of a subset of the first plurality of scan bodies includes a registration body and a bridge extending from the registration body; each bridge having an upper surface, a lower surface, an end wall extending between the upper and lower surfaces, first and second sidewalls extending between the upper and lower surfaces; and the bridge having a sidewall geometry and an end wall geometry.

5. The array of any of the preceding claims, wherein the sidewall geometry of the bridge provides the different overall geometries to adjacent scan bodies.

6. The array of any of the preceding claims, wherein each of the first and second sidewalls defines at least one concave indentation.

7. The array of any of the preceding claims, wherein each of the first and second sidewalls defines at least two concave indentations separated by a projection.

8. The array of any of the preceding claims, wherein the registration body includes a central body portion, an attachment portion extending from the central body portion, and a registration portion that defines first and second registration surfaces; and the registration portion extending laterally from the central body portion;9. The array of any of the preceding claims, where the bridge extends laterally from its central body portion in a direction different than the registration portion.

10. The array of any of the preceding claims, where the bridge extends laterally from its central body portion in a direction 180 degrees opposite than the registration portion.

11. The array of any of the preceding claims, wherein one of the registration surfaces is located at a level higher than the upper surface of the bridge.

12. The array of any of the preceding claims, wherein at least a portion of the other of the registration surfaces is located at a level higher than the upper surface of the bridge.

13. The array of any of the preceding claims, wherein the registration body defines a fastener opening offset from the first and second registration surfaces.

14. The array of any of the preceding claims, wherein the registration body defines a fastener opening that is offset from one of the registration surfaces while passing through an edge of the other registration surface.

15. The array of any of the preceding claims, wherein the first and second registration surfaces are flat.

16. The array of any of the preceding claims, wherein the first registration surface is parallel to the upper surface of the bridge and the second registration surface is not parallel to the first registration surface.

17. The array of any of the preceding claims, wherein the first registration surface is joined with the second registration surface.

18. The array of any of the preceding claims, wherein the second registration surface slopes downwardly with respect to the first registration surface.

19. The array of any of the preceding claims, wherein the bridge is provided separate from the registration body and selectively attachable to the registration body.

20. The array of any of the preceding claims, wherein each scan body includes: a registration body having a central body portion, an attachment portion extending from the central body portion, and a registration portion that defines first and second registration surfaces.

21. The array of any of the preceding claims, wherein the registration portion extends laterally from the central body portion; the registration body defining a fastener opening offset from the first and second registration surfaces.

22. The array of any of the preceding claims, wherein the registration body defines a fastener opening that is offset from one of the registration surfaces while passing through an edge of the other registration surface.

23. The array of any of the preceding claims, wherein the first and second registration surfaces are flat.

24. The array of any of the preceding claims, wherein the second registration surface is not parallel to the first registration surface.

25. The array of any of the preceding claims, wherein the first registration surface is joined with the second registration surface.

26. The array of any of the preceding claims, wherein the second registration surface slopes downwardly with respect to the first registration surface.

27. A method of installing a plurality of scan bodies directly or indirectly on dental implants prior to an intraoral scan, the method comprising the steps of: a] mounting scan bodies to dental implants, where the scan bodies have different overall geometries relative to each other; b] positioning each scan body to be in close proximity to at least one adjacent scan body; and c] arranging the scan bodies so that each scan body has a different overall geometry than each of its adjacent scan bodies.

28. The method of installing of any of the preceding claims, wherein each scan body includes a registration body and a bridge extending laterally from the registration body and further comprising the step of positioning the bridge of a scan body in close proximity with the registration body of an adjacent scan body.

29. A scan body for use during an intraoral scan, the scan body comprising: a) a registration body having a central body portion, an attachment portion extending from the central body portion, and a registration portion that defines firstand second registration surfaces; b] the registration portion extending laterally from the central body portion; andc] the registration body defining a fastener opening offset from the first and second registration surfaces.

30. The scan body of any of the preceding claims, wherein the first and second registration surfaces are flat and the fastener opening is substantially perpendicular to the first registration surface.

31. The scan body of any of the preceding claims, wherein the second registration surface is not parallel to the first registration surface.

32. The scan body of any of the preceding claims, wherein the first registration surface is joined with the second registration surface.

33. The scan body of any of the preceding claims, wherein the second registration surface slopes downwardly with respect to the first registration surface.

34. The scan body of any of the preceding claims, further comprising a bridge extending from the central body portion in a direction different from the registration portion; the bridge having an upper surface, a lower surface, an end wall extending between the upper and lower surfaces, first and second sidewalls extending between the upper and lower surfaces; and the bridge having a sidewall geometry and an end wall geometry.

35. The scan body of any of the preceding claims, wherein the first registration surface is located at a level higher than the upper surface of the bridge.

36. The scan body of any of the preceding claims, wherein each of the sidewalls defines at least one concave indentation.

37. The scan body of any of the preceding claims, wherein the sidewalls define at least two concave indentations separated by a projection.

38. The scan body of any of the preceding claims, wherein the bridge is provided separate from the registration body and selectively attachable to the registration body.

39. A scan body for use during an intraoral scan, the scan body comprising: a) a registration body having a central body portion, an attachment portion extending from the central body portion, and a registration portion that defines first and second registration surfaces; b) the registration portion extending laterally from the central body portion; and c) the registration body defining a fastener opening offset from one of the the first and second registration surfaces and extending through an edge of the other of the first and second registration surfaces.

40. The scan body of any of the preceding claims, wherein the first and second registration surfaces are flat and the fastener opening is substantially perpendicular to the first registration surface.

41. The scan body of any of the preceding claims, wherein the second registration surface is not parallel to the first registration surface.

42. The scan body of any of the preceding claims, wherein the first registration surface is joined with the second registration surface.

43. The scan body of any of the preceding claims, wherein the second registration surface slopes downwardly with respect to the first registration surface.

44. The scan body of any of the preceding claims, further comprising a bridge extending from the central body portion in a direction different from the registration portion; the bridge having an upper surface, a lower surface, an end wall extending between the upper and lower surfaces, first and second sidewalls extending between the upperand lower surfaces; and the bridge having a sidewall geometry and an end wall geometry.

45. The scan body of any of the preceding claims, wherein the first registration surface is located at a level higher than the upper surface of the bridge.

46. The scan body of any of the preceding claims, wherein each of the sidewalls defines at least one concave indentation.

47. The scan body of any of the preceding claims, wherein the sidewalls define at least two concave indentations separated by a projection.

48. The scan body of any of the preceding claims, wherein the bridge is provided separate from the registration body and selectively attachable to the registration body.

49. A method of performing an intraoral scan, the method comprising: a) providing a patient with a plurality of implants, wherein at least two of the plurality of implants have a scan body mounted thereto to define an array of scan bodies, wherein the array of scan bodies includes adjacent scan bodies that are in close proximity with at least one other adjacent scan body, and wherein the adjacent scan bodies have distinct overall geometries; and b] scanning, with an intraoral scanner, the array of scan bodies.

50. The method of any of the preceding claims, further comprising the step of providing a subset of the scan bodies including a bridge having a bridge geometry, wherein each scan body of the subset including a distinct bridge geometry relative to the other scan bodies within the subset.

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