Elastomer Composite Orthodontic Aligner for Continuous Force Application
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Solution Overview
Problem
Current clear aligners require numerous trays and lengthy treatment times due to intermittent force application, leading to material waste, costly doctor visits, and inefficient tooth movement, as they can only achieve small incremental tooth movements and may cause posterior teeth intrusion.
Innovation Solution
An orthodontic appliance formed with a combination of an elastic material and reinforcing fibers, such as polyester or polyethylene, which allows for continuous force application and increased elasticity, enabling larger incremental movements and reducing treatment duration by using 3D printing and casting techniques to create a custom-fitting appliance with tooth sockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If clear aligners are used to move teeth incrementally, then teeth can be moved to desired position, but treatment time becomes lengthy (about 2 years) and multiple trays are required
Solution Approach 1:
The patent changes the material parameter from conventional plastic to elastomer composite material, which fundamentally alters the force application characteristics. This material parameter change enables continuous force application instead of intermittent force, thereby reducing treatment time while maintaining tooth position accuracy
Solution Approach 2:
The patent uses an elastomer composite material containing reinforcing fibers (such as polyester or polyethylene fibers) that provides both the elasticity needed for continuous force application and the strength required for durable appliances. This composite material enables larger incremental movements while maintaining control, reducing the number of trays needed
2Manufacturing precision
If clear aligners are used to achieve small incremental movements, then teeth can be moved precisely, but material waste increases due to multiple trays required
Solution Approach 1:
By changing the material properties to elastomer composite, the patent enables each appliance to be used for longer periods with continuous force application, reducing the total number of appliances needed and thereby reducing material waste while maintaining alignment precision
3Ease of manufacture
If plastic aligners are used with uniform thickness, then manufacturing is simplified, but posterior teeth may become embedded inside jaw bone (intrusion movement)
Solution Approach 1:
The elastomer composite material allows for variable thickness design where different regions of the appliance can have different thicknesses to apply appropriate forces to different tooth regions. This enables precise control over force application to prevent unwanted intrusion of posterior teeth while maintaining manufacturing feasibility
4Speed
If clear aligners apply large initial force, then teeth can be moved quickly initially, but force dissipates quickly and treatment becomes inefficient
Solution Approach 1:
The patent changes the material from plastic to elastomer composite, which fundamentally changes the force-time characteristics. The elastomer material provides continuous force application over extended periods rather than large initial force that dissipates quickly, creating a more favorable force profile for efficient tooth movement
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 appliance provides a more efficient and comfortable tooth movement by applying continuous force, reducing treatment time and material waste, while minimizing the risk of posterior teeth intrusion and improving the overall effectiveness of orthodontic alignment.
Implementation Method 1
the elastic material being in an amount that imparts to the appliance elastic properties such that the appliance exerts a continuous aligning force on a tooth or teeth
Implementation Method 2
3D printing a cast-able appliance using a cast-able material
Data Source
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Figure 3
Figure 4A~4D
AI summary
Provided herein is an orthodontic aligning appliance for moving tooth or teeth of a patient and methods of making and using the same. The orthodontic aligning appliance is formed of a material ("appliance forming material") having an elastic material in an amount that imparts to the aligner elastic properties such that the appliance exerts a continuous aligning force on a tooth or teeth, the elastic material is a material other than polyester, and the elastic material accounts for all or substantially all the elastic properties of the appliance.