LED Tray Light Distribution for Dental Impression Curing
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Solution Overview
Problem
Conventional light curing impression systems are inefficient in curing impression material due to inadequate light distribution, particularly in external and extra-oral areas, leading to prolonged curing times and discomfort for patients, and existing solutions are bulky, costly, and difficult to sterilize.
Innovation Solution
A light curing impression system featuring a reusable LED tray with a flexible printed circuit board and hermetically sealed LEDs that can be autoclaved, combined with a rechargeable activation module and a light pipe for efficient light dispersion, allowing for rapid curing of impression material in under 30 seconds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional curing lamps are used to cure impression material, then the light can reach all regions in the mouth, but the curing time is prolonged and light cannot reach external areas of the tray
Solution Approach 1:
The curing light source is segmented into multiple LED elements distributed throughout the tray structure, including internal walls and external surfaces. This segmentation allows light to be delivered simultaneously to multiple regions including internal tray areas, external tray areas, and extra-oral regions, eliminating the time delay of sequential curing and ensuring complete curing of all impression material regions.
Solution Approach 2:
The light delivery system transitions from a single external light source to a three-dimensional distributed LED array embedded within and on the tray. LEDs are positioned on internal walls, external surfaces, and strategic locations to provide omnidirectional light distribution, ensuring that light reaches all impression material surfaces from multiple angles and dimensions simultaneously.
2Productivity
If light sources are embedded in the tray to improve light distribution, then curing efficiency improves, but the device becomes bulky and expensive to manufacture
Solution Approach 1:
The tray structure serves multiple functions: it contains the impression material, provides structural support, and acts as the light delivery system through embedded LEDs. The LEDs are integrated into the tray walls and surfaces, eliminating the need for separate light delivery devices and reducing overall system complexity while maintaining high curing efficiency.
Solution Approach 2:
The tray design uses standard manufacturing techniques to replicate the LED embedding pattern across different tray sizes and configurations. The LED array pattern is copied and adapted to various tray geometries, allowing efficient light distribution without requiring complex custom designs for each application scenario.
3Ease of operation
If the tray contains electronic components for light emission, then curing control improves, but sterilization becomes difficult
Solution Approach 1:
The system is segmented into a disposable tray portion containing embedded LEDs and a reusable electronic control portion. The tray with LEDs can be sterilized independently without the sensitive electronics, while the control unit remains external. This segmentation allows the tray to undergo autoclaving or other sterilization processes while the electronics are protected and reused across multiple patients.
Solution Approach 2:
The electronic control components are extracted from the tray structure and placed in a separate reusable unit. Only the simple LED embedding and basic circuitry remain in the disposable tray, which can be sterilized. The complex electronics are removed to the external control unit, enabling easy sterilization of the tray while maintaining precise curing control through the external electronics.
4Loss of time
If high intensity light is used to reduce curing time, then curing speed improves, but heat generation increases causing patient discomfort
Solution Approach 1:
The light delivery is segmented into multiple low-power LED elements distributed throughout the tray rather than a single high-power source. Each LED operates at low intensity, generating minimal heat, but collectively they provide sufficient total light output to cure the impression material quickly. The distributed arrangement prevents localized overheating and patient discomfort.
Solution Approach 2:
The curing process uses periodic or pulsed light activation rather than continuous high-intensity illumination. The LEDs are activated in sequences or pulses, providing sufficient cumulative energy for curing while allowing thermal dissipation between pulses. This periodic action maintains curing speed while controlling heat generation and patient comfort.
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 system enables rapid and efficient curing of impression material in all areas, including external and extra-oral regions, reduces patient discomfort, and allows for easy sterilization and cost-effective production.
Implementation Method 1
A light curing impression system featuring a reusable LED tray with a flexible printed circuit board and hermetically sealed LEDs
Implementation Method 2
rapid curing of impression material in under 30 seconds
Implementation Method 3
combined with a rechargeable activation module and a light pipe for efficient light dispersion
Data Source
AI summary
A light curing impression system comprising a light emitting tray that precisely distributes an optimal amount of curing light energy to internal, external and extra oral portions of the dental arch to cure impression material. The light curing impression system generally includes an LED light source, a light emitting impression tray, an activation module and impression material.