Orthodontic Aligner with Lingual Protrusions for Open Bite

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Solution Overview

Problem

Anterior open bite malocclusion is challenging to treat with invisible aligner trays due to the tongue's strong muscle force that intrudes the incisors, making it difficult to close the bite effectively.

Innovation Solution

The orthodontic device features a plastic aligner tray with lingual-facing protrusions, such as star-shaped, cone-shaped, or diamond-shaped designs, which irritate the tongue, preventing it from thrusting against the incisors and causing intrusion. Additionally, a flexible clear corrugated aligner material is used to provide flexibility and accurately form the protrusions around the dental model.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If standard flat clear Essix material is used for invisible aligner trays, then the aligner can be manufactured with simple vacuum-forming process, but the material is too stiff and wears out in force to move teeth effectively

Engineering Contradiction:

Improvevacuum-forming processVSAvoidflexibility to move teeth

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent changes the physical parameters of the Essix material by introducing longitudinal and transverse corrugations (ridges and grooves) that modify the material's mechanical properties. These corrugations reduce the material's stiffness while maintaining its flexibility and ability to conform to tooth structures, enabling effective tooth movement without compromising manufacturing simplicity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure within the Essix material itself by incorporating multiple layers of corrugations (longitudinal and transverse) that work together to provide optimized mechanical properties. This internal composite architecture allows the single-material aligner to achieve both ease of manufacture and sufficient flexibility for tooth movement.

Inventive Principle:

Principle #40Composite materials

2Productivity

If invisible aligner trays are used to treat anterior open bite, then teeth can be aligned gradually, but the tongue's strong muscle force intrudes the incisors making bite closure difficult

Engineering Contradiction:

Improvegradual tooth alignmentVSAvoidtongue intrusion force

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality changes by adding protrusions at specific locations on the aligner tray, particularly in the anterior region where tongue intrusion occurs. These localized protrusions create targeted irritation to the tongue, preventing intrusion at the critical area while maintaining the overall gradual alignment function of the aligner.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent converts the harmful tongue intrusion force into a beneficial effect by using protrusions to intentionally irritate the tongue. This irritation causes the tongue to retract, transforming the potential harmful intrusion force into a beneficial retraction force that aids in closing the anterior open bite.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Object-affected harmful factors

If protrusions are added to aligner trays to prevent tongue thrusting, then bite closure can be facilitated, but the manufacturing complexity increases

Engineering Contradiction:

Improvetongue thrusting preventionVSAvoidaligner structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent segments the protrusion formation process into distinct stages: first forming the basic aligner tray structure, then adding separate protrusion elements. This segmentation allows the protrusions to be added as discrete features rather than requiring complete redesign of the entire aligner manufacturing process, thus managing complexity while achieving tongue thrusting prevention.

Inventive Principle:

Principle #1Segmentation

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 use of lingual-facing protrusions in the aligner trays effectively prevents tongue thrusting, allowing the incisors to extrude and facilitating bite closure, while the flexible corrugated material ensures accurate formation of protrusions, enhancing treatment efficacy.

Implementation Method 1

heated to soften it

Methodology Applied

Scientific EffectThermal softening: Heating

Implementation Method 2

vacuumed down over the dental model with a 'suck-down' method

Methodology Applied

Scientific EffectVacuum forming: Vacuum

Data Source

PatentUS12213859B2Clear plastic aligner with configurable protrusions for anterior or open bite treatment and mattress plastic material for invisible aligners

Publication Date: 2025.02.04 SPARTAN ORTHODONTICS INC

AI summary

Protrusions or holes with jagged edges formed on the lingual side of invisible aligner trays are provided. The protrusions or holes include two components and serve to irritate the tongue causing it to retract away from the incisors thus eliminating intruding force otherwise exerted by the tongue. A clear corrugated material is provided which is suited for making the aligner trays having the protrusions which otherwise would be difficult with standard thick material used. The lingual side protrusions are added by computer to the impressions taken from a patient's teeth such that the protrusions are formed on the dental model used to make the aligner trays.