Miscible Polyester Blends for Clear, Force-Persistent Dental Aligners

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Solution Overview

Problem

Existing orthodontic aligners and retainers made from high modulus polyesters cause discomfort due to repeated contact with oral tissues and have poor stress retention behavior in hydrated environments, leading to compromised mechanical properties and extended treatment times.

Innovation Solution

Development of miscible polyester blends comprising an amorphous first polyester and a semi-crystalline polyester elastomer, which form a homogeneous single-phase blend with enhanced transparency, force persistence, and improved optical properties, suitable for dental appliances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If high modulus polyester is used to form orthodontic aligner trays, then the trays can effectively exert stable and consistent repositioning force against teeth, but the trays cause discomfort when repeatedly contacting oral tissues and exhibit poor stress retention behavior in hydrated environments

Engineering Contradiction:

Improverepositioning forceVSAvoiddiscomfort to oral tissues

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by blending polyester with elastomer components to create a multi-phase polymeric material that combines the rigid force-exerting properties of polyester with the soft, comfortable properties of elastomers. This composite approach allows the aligner tray to maintain effective repositioning force while reducing discomfort to oral tissues through the elastomeric phases.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the physical and mechanical parameters of the polymeric material by adjusting the composition ratios of polyester and elastomer components, controlling molecular weight, and regulating the degree of crystallinity. These parameter changes enable optimization of both force retention and tissue comfort properties.

Inventive Principle:

Principle #35Parameter changes

2Force

If high modulus polyester is used in orthodontic aligner trays, then stable repositioning force is achieved, but stress retention behavior deteriorates in hydrated oral environments

Engineering Contradiction:

Improvestress retentionVSAvoidforce persistence in hydrated state

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The composite polymeric material combines polyester's structural integrity with elastomer's hydration resistance, creating a system where the elastomeric phases protect against moisture-induced stress loss while the polyester matrix maintains force-exerting capability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent creates local quality differentiation within the polymeric material by distributing elastomeric phases throughout the polyester matrix, allowing different regions to perform specialized functions: polyester regions provide structural stability while elastomer regions provide hydration resistance and stress retention.

Inventive Principle:

Principle #3Local quality

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 miscible polyester blends provide transparent, crack-resistant dental appliances with improved patient comfort, enhanced force persistence, and reduced treatment time by maintaining consistent tooth repositioning forces.

Implementation Method 1

The first and second polyesters are miscible, in that the first and second polyesters form a homogenous, single-phase blend

Methodology Applied

Scientific EffectMiscibility:

Implementation Method 2

a second, semi-crystalline polyester elastomer

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS20250339241A1Miscible polyester blends suitable for dental appliances and methods for forming the same

Publication Date: 2025.11.06 SOLVENTUM INTELLECTUAL PROPERTIES CO

AI summary

The present disclosure is directed to polyester blends featuring an amorphous first polyester and a second, semi-crystalline polyester elastomer. The first and second polyesters are miscible, in that the first and second polyesters form a homogenous, single-phase blend. The homogenous blend will exhibit a transparent melt and a single glass transition temperature. When used to form a sheet or film, the polyester blends demonstrate a low haze and enhanced force persistence.