Mandibular Advancement Device with Fixed Fins for Sleep Apnea
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Solution Overview
Problem
Existing mandibular advancement devices face challenges with manual fabrication methods leading to inconsistent and precise adjustments, higher residual monomer levels, decreased durability, and reduced patient comfort due to size limitations and complex designs.
Innovation Solution
Digitally designed and milled mandibular advancement devices comprising upper and lower splints with fixed fins, allowing for accurate titration without adjustment screws or straps, using CAD processes and materials like PEEK, which provide comfort and durability while minimizing residual monomers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual artisanal fabrication methods are used, then devices can be custom designed for each patient, but manufacturing precision and consistency are limited
Solution Approach 1:
The patent replaces manual artisanal fabrication with automated digital design and manufacturing systems. CAD software enables precise digital modeling of patient-specific anatomy, while automated milling machines fabricate devices with consistent precision. This substitution eliminates human skill variability while maintaining custom design capability through digital patient-specific modeling.
Solution Approach 2:
The invention changes the manufacturing parameters from manual processes to automated digital processes. By using CAD/CAM technology, the system achieves controlled precision through digital parameters rather than artisanal skill, enabling reproducible accuracy in fin positioning and device geometry while maintaining adaptability to individual patient needs.
2Adaptability or versatility
If adjustment screw mechanisms are used, then mandible advancement can be adjusted, but device complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-setting the fin positions during the digital design and manufacturing phase. Multiple fins are fabricated at predetermined positions that correspond to different mandible advancement settings. This eliminates the need for adjustment mechanisms during use, as the desired setting is already established in the device structure itself.
Solution Approach 2:
The invention segments the adjustment function into multiple fixed fin positions rather than using a continuous adjustment mechanism. Each fin position represents a discrete advancement setting, allowing the device to provide adjustable functionality through segmented, pre-determined positions rather than complex mechanical adjustment systems.
3Ease of manufacture
If layered monomer fabrication is used, then devices can be built up to required shapes, but residual monomer levels increase
Solution Approach 1:
The patent replaces chemical layering processes with automated mechanical milling. Instead of building up device geometry through multiple layers of monomer that require curing, the system mills the complete device from a single block of cured material using CAD-guided automated milling machines. This eliminates residual monomer contamination while maintaining fabrication flexibility through digital design control.
Solution Approach 2:
The invention uses a single-block milling approach that creates devices without the need for layered construction. By milling from pre-cured material blocks, the process eliminates the chemical residues associated with incremental monomer layering and curing, producing cleaner devices with no harmful residual monomers.
4Adaptability or versatility
If multiple components and straps are used, then adjustment flexibility is provided, but durability and reliability decrease
Solution Approach 1:
The patent merges multiple adjustment components into a unified fin structure. Instead of using separate straps and screws for adjustment, the invention integrates multiple fin elements directly into the device body, each fin representing a different advancement setting. This consolidation eliminates the need for separate adjustment components, improving durability and reliability while maintaining adjustment flexibility.
Solution Approach 2:
The invention applies preliminary action by pre-establishing all adjustment settings during the manufacturing phase through multiple fixed fin positions. This eliminates the need for ongoing mechanical adjustment components during device use, reducing the number of parts that can fail and improving overall device reliability and durability.
Data Source
AI summary
Disclosed herein are mandibular advancement devices comprising an upper splint and a lower splint, where the upper splint comprises one or more upper fins, where each upper fin is located at a distance UD from back of the upper splint; the lower splints comprise one or more lower fins, where each lower fin is located at a distance LD from back of the lower splint; where the position of the upper and lower fins is unchangeable. Also disclosed are methods of reducing partial constriction of airway during sleep for a patient, the method comprising identifying a patient in need thereof; and administering to the patient the disclosed mandibular advancement device. Also disclosed are methods of manufacturing a mandibular advancement device, the method comprising obtaining measurements from a patient's dentition; digitally designing a mandibular advancement device; and milling the mandibular advancement device.