Orthodontic Aligner Integral Hook Design for Elastic Band Attachment

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Solution Overview

Problem

Existing orthodontic aligners face issues with stress concentration and structural integrity due to the use of hook cutouts and button attachments, leading to potential failure and prolonged treatment time, as well as patient compliance challenges with locating and inserting elastic bands.

Innovation Solution

An orthodontic aligner with an integral hook that receives an elastic band through a window, providing structural strength and allowing for direct access to the attachment, reducing stress concentration and improving patient compliance by eliminating the need for gingival edge modifications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If hook cutouts are used to attach elastic bands to aligners, then elastic bands can be attached to apply corrective forces, but stress concentration occurs at the cut locations causing potential aligner failure

Engineering Contradiction:

Improveelastic band attachmentVSAvoidaligner structural integrity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent merges the elastic band attachment function directly into the aligner structure by forming integral hooks as part of the aligner body itself, rather than using separate cutout attachments. This integration eliminates the stress concentration issues at cut locations while maintaining the ability to attach and secure elastic bands for applying corrective forces to teeth.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a reinforced hook structure that copies the attachment function of cutouts but with enhanced structural properties. The integral hook is designed with sufficient material thickness and structural support to prevent the stress concentration and tearing problems that occur with traditional cutout methods, while still allowing elastic band attachment.

Inventive Principle:

Principle #26Copying

2Ease of operation

If gingival edge modifications are made to create hook cutouts, then elastic bands can be attached, but the aligner material may deform or fail prematurely

Engineering Contradiction:

Improveelastic band attachmentVSAvoidaligner durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integral hook design incorporates sufficient material thickness and structural reinforcement beforehand to cushion against the stresses imposed by elastic band attachment. This prevents the material deformation and premature failure that occur with traditional thin-walled cutout structures, ensuring the aligner maintains its durability throughout treatment.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Force

If button attachments are used on teeth, then attachments can be secured to provide leverage for tooth movement, but bond failures may occur requiring emergency appointments

Engineering Contradiction:

Improvecorrective force applicationVSAvoidattachment bond stability

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The patent extracts the attachment from the tooth surface and relocates it to the aligner structure itself through integral hooks. This eliminates the need for bonded button attachments on teeth, removing the source of bond failures that require emergency appointments, while still providing the necessary leverage points for applying corrective forces during orthodontic treatment.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of operation

If multiple components are used for elastic band attachment (cutouts, hooks, buttons), then attachment functionality is achieved, but device complexity increases

Engineering Contradiction:

Improveelastic band attachmentVSAvoidaligner structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integral hook structure serves multiple functions: it provides structural reinforcement, creates an attachment point for elastic bands, and maintains aligner integrity. This multi-functionality reduces the need for separate components like cutouts or buttons, simplifying the overall device while achieving the same attachment functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20240081953A1Orthodontic appliances, attachments, systems including appliances and attachments, and methods for orthodontic appliance and attachment fabrication

Publication Date: 2024.03.14 ORMCO CORP (SPARK ALIGNER DIVISION)

AI summary

An orthodontic aligner includes a shell that defines a tooth cavity. The tooth cavity is configured to receive a patient's tooth and has an edge that defines an opening. An integral hook extends outwardly from wall portions of the shell adjacent the tooth cavity and is spaced occlusally apart from the edge. The integral hook has a side wall that defines an interior space and includes a window. The interior space opens to the tooth cavity. The window extends through the side wall so that the interior space is accessible. The window can be sized to interfere with insertion of an elastic band. A system for orthodontic treatment includes an attachment. The integral hook is configured to receive the attachment. The attachment is accessible through the window. The attachment may not fill the interior space. A method of manufacturing the orthodontic aligner includes preparing a mold including a hook mold.