Orthodontic Aligner Flexible Zones for Continuous Force Delivery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional orthodontic aligners lack flexibility, leading to intermittent force delivery and inadequate engagement of teeth, especially when teeth are not well-aligned, which can result in deviations from the intended treatment plan and require frequent revisions.
Innovation Solution
The development of an orthodontic appliance with a thin elastomeric shell featuring flexible zones created by 3D printing patterns of voids, folds, or reduced thickness, allowing for enhanced flexibility and improved tooth engagement and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional orthodontic aligners are used, then the appliance structure is simple and easy to manufacture, but the appliance lacks flexibility leading to intermittent force delivery and inadequate tooth engagement
Solution Approach 1:
The patent applies this principle by incorporating flexible zones within the aligner body that allow the appliance to deform and adapt to tooth movements. These flexible zones enable continuous force delivery while maintaining engagement with misaligned teeth, resolving the contradiction between appliance simplicity and flexibility.
Solution Approach 2:
The patent implements local quality by creating specific flexible zones at predetermined locations within the aligner rather than making the entire appliance flexible. This allows targeted flexibility where needed while maintaining structural integrity and simplicity in other areas, thereby improving adaptability without excessive complexity.
2Reliability
If conventional rigid aligners are used, then manufacturing is straightforward, but force delivery is intermittent and tooth engagement is inadequate
Solution Approach 1:
By integrating flexible zones into the aligner structure, the patent ensures reliable and continuous tooth engagement while maintaining a manufacturing process that is essentially identical to conventional aligner fabrication. The flexible zones are incorporated during the same molding process, so ease of manufacture is preserved.
Solution Approach 2:
The patent applies dynamics by designing the aligner to transition from a static rigid structure to a dynamic flexible structure that can adapt during tooth movement. The flexible zones allow the appliance to deform elastically and return to its original shape, providing continuous force delivery and reliable engagement throughout the treatment process.
3Duration of action of moving object
If flexible zones are added to the aligner, then continuous force delivery is achieved, but the appliance structure becomes more complex
Solution Approach 1:
The flexible zones are implemented as integrated portions of the aligner body rather than separate components. This allows continuous force delivery through elastic deformation while avoiding the complexity of assembling multiple parts. The flexible zones are created within the same manufacturing process, minimizing structural complexity.
Solution Approach 2:
The patent segments the aligner into rigid portions and flexible zones, allowing each to perform its specific function. The rigid portions maintain structural integrity and overall shape, while the flexible zones provide continuous force delivery through localized deformation. This segmentation enables force continuity without requiring complex overall restructuring.
4Manufacturing precision
If rigid aligners are used, then manufacturing precision is easier to achieve, but frequent treatment plan revisions are needed due to inadequate tooth engagement
Solution Approach 1:
The flexible zones allow the aligner to dynamically adapt to actual tooth positions during treatment, maintaining engagement even when teeth are not perfectly aligned with the appliance. This reduces the need for treatment plan revisions while the overall manufacturing precision of the aligner remains high, as the flexible zones are precisely positioned during fabrication.
Solution Approach 2:
The flexible zones provide a tolerance buffer that accommodates minor manufacturing variations and tooth position deviations without requiring costly rework or treatment plan changes. This maintains manufacturing precision standards while improving treatment efficiency by preventing engagement failures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The appliance provides continuous, gentle forces for effective tooth movement, maintaining precise engagement and alignment, reducing the need for frequent treatment plan revisions and ensuring consistent progress towards the desired tooth positions.
Implementation Method 1
a flexible pattern in the shell to create zones of enhanced flexibility
Implementation Method 2
3D printing a pattern of voids, folds, or areas of reduced thickness in the shell of the appliance
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Tooth-positioning appliances and apparatuses, components, methods, and techniques for producing and using tooth-positioning appliances are provided. An example tooth-positioning appliance for adjusting the position of teeth of a patient includes a tooth-clasping arrangement shaped to secure the orthodontic appliance to at least one tooth and a flexible arrangement connected to the tooth-clasping arrangement. The flexible arrangement is less rigid than the tooth-clasping arrangement.