Cast Metallic Palatal Portion for Orthodontic Retainer

Solution Overview

Problem

Conventional orthodontic retainers with plastic or acrylic palatal portions are bulky, uncomfortable for patients, and prone to breakage, requiring frequent repairs or replacements.

Innovation Solution

A cast orthodontic retainer system featuring a thin palatal portion made from a metallic material, such as a cobalt-chromium-molybdenum alloy, utilizing the lost wax technique for casting, allowing for a thickness of less than 0.30 millimeters and improved durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If plastic or acrylic material is used for the palatal portion, then the retainer can be manufactured easily, but the palatal portion becomes bulky and uncomfortable for patients

Engineering Contradiction:

Improveease of manufactureVSAvoidcomfort

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent changes the material parameter from plastic/acrylic to metallic material, which fundamentally alters the thickness and comfort characteristics. The metallic material allows for thinner construction while maintaining strength, directly resolving the contradiction between ease of manufacture and patient comfort.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite structure combining metallic material for the palatal portion with traditional orthodontic wire components. This composite approach leverages the superior strength-to-weight ratio of metals to achieve thinner, more comfortable retainers while maintaining manufacturing feasibility through established casting techniques.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If plastic or acrylic material is used for the palatal portion, then the retainer can be manufactured easily, but the material breaks easily requiring costly repairs or replacement

Engineering Contradiction:

Improveease of manufactureVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the material parameter from plastic/acrylic to metallic material, which fundamentally alters the thickness and comfort characteristics. The metallic material allows for thinner construction while maintaining strength, directly resolving the contradiction between ease of manufacture and patient comfort.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite structure combining metallic material for the palatal portion with traditional orthodontic wire components. This composite approach leverages the superior strength-to-weight ratio of metals to achieve thinner, more comfortable retainers while maintaining manufacturing feasibility through established casting techniques.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If metallic material is used for the palatal portion, then the palatal portion can be made thinner and more comfortable, but the manufacturing process becomes more complex

Engineering Contradiction:

ImprovecomfortVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent changes the material parameter from plastic/acrylic to metallic material, which fundamentally alters the thickness and comfort characteristics. The metallic material allows for thinner construction while maintaining strength, directly resolving the contradiction between ease of manufacture and patient comfort.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces complex plastic molding processes with metallic casting techniques. While casting has its own complexity, it enables thinner, stronger constructions that plastic cannot achieve, and the process can be integrated into existing orthodontic laboratory workflows through established methodologies.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 metallic palatal portion provides enhanced comfort and structural strength, reducing the likelihood of breakage and minimizing the need for costly repairs or replacements, while maintaining the necessary structural integrity for orthodontic retention.

Implementation Method 1

The palatal portion of the orthodontic retainer is preferably cast from the metallic material utilizing the 'lost wax' technique of casting.

Methodology Applied

Scientific EffectLost wax technique:

Data Source

PatentUSRE47917E1Cast orthodontic retainer system

Publication Date: 2020.03.31 DEAN ULTRATHIN RETAINER CO

AI summary

A cast orthodontic retainer system for reducing discomfort and improving durability. The cast orthodontic retainer system generally includes a palatal portion for positioning against the palate of a patient's mouth and a retention portion for extending across an anterior portion of the patient's teeth. The palatal portion of the present invention is fabricated of a cast metallic material, thus allowing for the palatal portion to be substantially thinner than the palatal portions of retainers in the prior art. In a preferred embodiment, the palatal portion of the present invention will be fabricated of a combination of cobalt, chromium and molybdenum (generally marketed under the trademark VITALLIUM). The palatal portion of the orthodontic retainer is preferably cast from the metallic material utilizing the “lost wax” technique of casting.