Batch Thermoformer for Dental Aligners
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Solution Overview
Problem
Current thermoforming technologies for dental aligners lack control over temperature set points for each aligner and require complex, costly processes that do not allow for simultaneous production of multiple aligners, leading to inefficiencies and reduced accuracy in aligner adaptation to dental models.
Innovation Solution
A vacuum-based thermoforming system with independently controlled heating elements and a movable heater cap, allowing for precise temperature control and simultaneous production of multiple aligners by creating a vacuum seal between a polymer sheet and dental models, enabling more accurate and efficient aligner formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If individual aligners are thermoformed sequentially using positive pressure, then each aligner can be formed, but production speed is slow and cannot produce batches simultaneously
Solution Approach 1:
The patent combines multiple thermoforming stations into a single system where multiple dental models are positioned simultaneously on one platform. Each station has its own vacuum cup and heating element, allowing parallel processing of multiple aligners without requiring separate sequential machines, thus increasing productivity while maintaining manageable complexity
Solution Approach 2:
The thermoforming system is divided into multiple independent stations, each capable of forming one aligner simultaneously. Each station includes dedicated vacuum cups, heating elements, and control mechanisms, allowing independent operation and simultaneous production of multiple aligners without interference
2Adaptability or versatility
If a continuous mode operation is used, then production can proceed without stopping, but the operator cannot produce a single aligner or adjust production quantity flexibly
Solution Approach 1:
The system allows dynamic selection of the number of aligners to produce by simply loading or unloading dental models from specific stations. The operator can activate only the required number of stations, enabling flexible production quantities from one to multiple aligners while maintaining efficient batch processing capability when needed
3Manufacturing precision
If positive pressure is used for thermoforming, then the polymer can be forced onto the model, but bubbles form and accuracy is reduced
Solution Approach 1:
The patent inverts the traditional positive pressure approach by using negative pressure (vacuum) to draw the softened polymer onto the dental model. This vacuum application eliminates bubble formation by pulling air and vapor away from the polymer-model interface, ensuring accurate adaptation and high manufacturing precision
4Adaptability or versatility
If the temperature set point is adjusted, then the heating can be optimized, but all aligners receive the same temperature without individual control
Solution Approach 1:
Each thermoforming station is equipped with its own independently controllable heating element and temperature sensor. This allows different temperature set points for different stations, enabling optimization for various polymer types or thicknesses at each location while maintaining precise local control for high manufacturing accuracy
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 solution enables faster production of aligners with improved accuracy and reduced costs, allowing for better adaptation to dental models and increased control over the thermoforming process, resulting in enhanced performance and patient outcomes.
Implementation Method 1
A vacuum source is provided to apply a vacuum to the cups below the polymer sheet wherein the pressure contained in said cups is lower than atmospheric pressure whereby at least a portion of the polymer sheet is drawn into each of the cups and drawn over the dental models to form an aligner over each of the dental models
Implementation Method 2
A heater cap that is movable in proximity to the cups is provided to heat the polymer sheet to be formed onto the dental models
Data Source
AI summary
The present invention is directed to a system for thermoforming a batch of dental appliances simultaneously. An embodiment of the invention includes a vacuum plate having an upper surface and a plurality of cups for receiving dental models. A polymer sheet extends over the upper surface of the vacuum plate and over the cups. A heater cap that is movable in proximity to the cups is provided to heat the polymer sheet to be formed onto the dental models. The vacuum plate is configured to create a vacuum seal between an upper edge of the cups and the polymer sheet. A vacuum source is provided to apply a vacuum to the cups below the polymer sheet wherein the pressure contained in said cups is lower than atmospheric pressure whereby at least a portion of the polymer sheet is drawn into each of the cups and drawn over the dental models to form an aligner over each of the dental models. The invention includes the process of drawing a vacuum in a series of steps, or phases, to the cups below the polymer sheet to form the polymer effectively around the dental model.