Dental Sensor Overmoulding for Ergonomics and Shock Protection
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Solution Overview
Problem
Current dental intraoral sensors are uncomfortable due to sharp corners and hard materials, difficult to differentiate from competitors, and lack ergonomic design, while also requiring additional protection against shocks and electromagnetic interference.
Innovation Solution
An intraoral dental radiological image sensor with a casing made of hard plastic and overmolded flexible plastic material, providing a smooth rubber consistency on corners and internal support areas, reducing roughness and enhancing ergonomics, while maintaining mechanical resistance and shock protection without additional foams or electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the casing is made of hard plastic material for mechanical resistance, then the structural strength is improved, but the comfort and ergonomics deteriorate due to sharp angles and hard surface
Solution Approach 1:
The patent applies different material properties to different regions of the casing. The hard plastic material is used for the main body to provide mechanical resistance, while flexible plastic material is applied locally to corners and edges to provide comfort. This local differentiation resolves the contradiction by having each region possess the quality appropriate for its function.
Solution Approach 2:
The casing combines hard plastic material and flexible plastic material in a composite structure. The hard material provides structural strength while the flexible material provides comfort. This composite approach allows both requirements to be satisfied simultaneously in different parts of the same component.
2Reliability
If additional protective sheets (foam, elastomer, aluminum foil, lead foil) are added for shock protection, then the reliability is improved, but the device complexity and bulk increase
Solution Approach 1:
The protective function is merged with the casing structure itself. The flexible plastic material is integrated into the casing as an inherent component rather than being added as a separate protective layer. This merging eliminates the need for additional protective sheets while maintaining shock protection functionality.
Solution Approach 2:
The composite structure of hard and flexible plastic materials provides both structural integrity and shock absorption in a single integrated component, eliminating the need for multiple separate protective layers.
3Volume of moving object
If the casing is made thin for size reasons, then the compactness is improved, but the transparency increases causing unwanted images from ambient light
Solution Approach 1:
The flexible plastic material is applied locally to specific areas of the casing, particularly corners and edges, rather than covering the entire surface. This local application provides the necessary properties without making the entire casing thick, thus maintaining compactness while addressing light interference in critical areas.
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 solution results in a more comfortable, visually appealing, and distinctive sensor that is solid and well-protected against shocks, with reduced bulk and potential for reduced electromagnetic interference, allowing for easier handling and positioning.
Implementation Method 1
overmouldings in one flexible plastic material with a smooth rubber consistency
Implementation Method 2
the parts molded in flexible material inside the housing being connected to parts in flexible material outside the housing by bridges formed in openings in the hard material parts
Data Source
Figure 1~5
Figure 6~7
AI summary
The invention relates to an intra-oral dental radiology sensor. The sensor includes an electronic image-acquisition module and a housing (30) moulded from a hard plastic material (32) locally provided with overmouldings (34) of a more flexible plastic material having a more flexible gum consistence and covering the hard plastic material on areas located outside the housing and corresponding to protruding angular portions of the hard plastic material, and on areas located inside the housing at locations against which the electronic module may bear. The flexible plastic material (34) is preferably a copolymer of the SEBS type (Styrene-Ethylene-Butylene-Styrene) while the hard plastic material (32) is preferably a polyamide. The patient's comfort is improved and the module is better protected against shocks without increasing the overall dimensions thereof.