Automated Aligner Shell Removal Using Pressure Differential
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual removal of aligners from molds is prone to damage and deformation, especially for complex molds, leading to production bottlenecks and quality issues, which existing automation methods fail to address effectively.
Innovation Solution
An automated shell removal device utilizing a pressure differential between the upper and lower surfaces of the untrimmed aligner, combined with a platform and pads to prevent damage, facilitates the secure attachment of the mold to a platform and controlled separation of the aligner from the mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual removal of aligner from mold is performed, then flexibility in handling complex molds is maintained, but aligner damage and deformation occur
Solution Approach 1:
The patent replaces manual mechanical removal with an automated pneumatic system. A blowout tool delivers controlled air pressure through a nozzle to separate the aligner from the mold, eliminating hand tools and manual manipulation that cause damage. The pneumatic mechanism provides consistent, damage-free removal force.
Solution Approach 2:
The invention employs pneumatic pressure to achieve aligner removal. Compressed air is delivered through a blowout tool with a nozzle positioned at the aligner-mold interface. The pneumatic force expands the aligner material slightly, creating separation from the mold without mechanical scraping or forcing that causes damage.
2Productivity
If automated removal methods are implemented, then production speed increases, but existing methods fail to address complex mold structures
Solution Approach 1:
The blowout tool and nozzle system is designed to be adaptable to different mold configurations. The nozzle can be positioned at various locations along the aligner-mold interface, and the air pressure can be adjusted dynamically based on the specific mold geometry and aligner complexity, enabling automated removal of complex cases.
Solution Approach 2:
The pneumatic force is applied locally at the critical separation interface between the aligner and mold, rather than applying force throughout the entire structure. The nozzle targets specific areas where separation is needed, allowing the system to handle complex geometries by focusing pressure where the aligner needs to be released.
3Manufacturing precision
If manual removal is used, then alignment precision can be maintained, but time consumption creates production bottlenecks
Solution Approach 1:
The pneumatic system performs the removal action automatically without requiring skilled manual intervention. The blowout tool is positioned and activated to deliver air pressure that self-effectively separates the aligner from the mold, eliminating the time-consuming manual manipulation while maintaining precision through controlled pneumatic force delivery.
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
This method increases production speed, reduces aligner inaccuracies and damage, enhances aligner quality, and streamlines the production process by minimizing manual intervention.
Implementation Method 1
A pressure differential between an upper surface of the untrimmed aligner and a lower surface of the untrimmed aligner is caused
Data Source
AI summary
A shell removal device includes a platform configured to secure a mold. An untrimmed shell is formed over the mold. The shell removal device further includes a drive mechanism configured to move the platform away from the untrimmed shell responsive to sensor data indicative that the untrimmed shell has begun to separate from the mold.