Heated Dental Aligner Separator for One-Step Trimming
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Solution Overview
Problem
Existing jaw-spanning dental apparatuses made of polymethylmethacrylate, such as aligners or bite splints, require manual cutting and trimming with sharp edges that need smoothing, which is time-consuming and risks damage during the post-processing of thermoform films.
Innovation Solution
A hand tool with a grip, separating element, heating means, and power supply for thermally separating and refining thermoform film at its glass temperature, ensuring a single-step process without degradation, using temperature regulation and suction means to manage fumes and improve visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cutting and trimming with rotating instruments is used, then separation can be achieved, but the process is time-consuming and requires multiple steps
Solution Approach 1:
The patent combines separation and refinement operations into a single integrated step by heating the thermoform film to its glass transition temperature, allowing both cutting and edge smoothing to occur simultaneously without requiring multiple separate tools or steps
Solution Approach 2:
The invention changes the temperature parameter of the thermoform film to its glass transition temperature range, which fundamentally alters the material's mechanical properties and enables both separation and refinement to occur in one operation without degradation
2Ease of manufacture
If rotating instruments are used for cutting and trimming, then separation can be achieved, but sharp edges require additional time-consuming smoothing
Solution Approach 1:
The patent merges separation and refinement into a single operation by heating the material to its glass transition temperature, where the material becomes sufficiently soft to be separated and simultaneously smoothable in one continuous action
Solution Approach 2:
The invention exploits the glass transition phase change of the thermoform film material, where heating to the glass transition temperature transforms the material from a rigid state to a pliable state that allows both cutting and smoothing without requiring separate operations
3Productivity
If heating to high temperature is used for separation, then single-step processing is achieved, but material degradation and melting may occur
Solution Approach 1:
The patent precisely controls the temperature parameter within the glass transition temperature range of the thermoform film material, which is sufficiently high to enable single-step separation and refinement but remains below the degradation temperature to maintain material integrity
Solution Approach 2:
The invention incorporates temperature regulation means that monitor and control the heating process to maintain the separating element temperature within the optimal range, preventing both insufficient heating and excessive heating that would cause material degradation
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 tool enables a fast, smooth, and efficient separation process reducing the number of steps and minimizing damage risk by maintaining the film below its degradation temperature, while providing visual guidance and fume management.
Implementation Method 1
a heating means adapted to regulate heating of the separating element so as to increase the temperature of the thermoform film substantially to at least its glass temperature
Implementation Method 2
by heating up the thermoform film substantially to at least its glass temperature, separation and refinement can take place in a single step
Data Source
AI summary
A hand tool (1) for separating a deep-drawn jaw-spanning dental apparatus such as an aligner or a bite splint of thermoform film. The hand tool includes a grip (2) for holding; a separating element (3) for thermally separating the deep-drawn thermoform film and refining the separated deep-drawn thermoform; a heating device adapted to regulate heating of the separating element (3) so as to increase the temperature of the thermoform film substantially to at least its glass temperature; and a power supply device for supplying electric power to the heating device.