Hybrid Indirect Bonding Tray with Segmented Release Modules
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Solution Overview
Problem
Existing indirect bonding tray systems in orthodontics face challenges such as inaccurate bracket placement, inadequate space for excess adhesive, and bonding failures, particularly due to protrusions like integral hooks, which complicate the removal process.
Innovation Solution
The development of a hybrid indirect bonding tray that incorporates patient-specific digital models of orthodontic shells and modules, allowing for precise positioning and securement of brackets using a singular, integrated tray and shell combination, with features like recesses, retention features, and access lumens for easy removal, and customizable design for varying bracket types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If protrusions such as integral hooks are added to brackets for banding, then the brackets can be securely attached to teeth, but tray removal becomes difficult and bonding failures occur
Solution Approach 1:
The bonding tray is divided into multiple segments or sections, each designed to interact with specific bracket features. The tray includes release features that engage with protrusions on brackets during placement but disengage during removal, allowing secure attachment initially and easy removal later without bonding failures.
Solution Approach 2:
The bonding tray incorporates dynamic release features that change their interaction with bracket protrusions based on the operational phase. During placement, the features engage with hooks for secure attachment; during removal, the same features are designed to disengage or deform, allowing easy tray removal without causing bonding failures between brackets and teeth.
2Productivity
If indirect bonding trays are used to position multiple brackets simultaneously, then productivity increases, but manufacturing precision decreases leading to inaccurate bracket placement
Solution Approach 1:
Different regions of the bonding tray are designed with locally optimized features for specific bracket types and tooth positions. Each section of the tray has customized geometry, material properties, or engagement features tailored to the local requirements, ensuring high precision placement even when handling multiple brackets simultaneously across different areas of the dentition.
Solution Approach 2:
The bonding tray is pre-configured with brackets positioned in their exact target locations before patient treatment. Digital planning software determines precise bracket positions, and the tray is fabricated accordingly with features that guide bracket placement. This preliminary positioning action ensures that when the tray is applied, brackets are automatically placed with high accuracy without requiring manual adjustment during the procedure.
3Device complexity
If traditional bonding trays are used, then the process is simple, but inadequate space exists for clearing excess adhesive
Solution Approach 1:
The bonding tray design incorporates three-dimensional features such as recesses, channels, or elevated edges that create additional spatial dimensions for excess adhesive management. These features provide designated areas where excess adhesive can be redirected or contained, effectively increasing the available space for adhesive clearance without significantly complicating the overall tray structure or design.
Data Source
AI summary
Optimized indirect bonding tray systems are described where an hybrid IDB tray apparatus may generally comprise an orthodontic shell configured to conform to a dentition of a patient and one or more modules incorporated along the orthodontic shell and where each of the one or more modules defines a recess configured to removably retain a bracket. Each recess may open along the orthodontic shell to position the bracket against a surface of a crown.