Modular Occlusal Blocks for Durable Orthodontic Aligners
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Solution Overview
Problem
Existing mandibular relocation devices suffer from significant deformation and crushing under occlusal forces, and fabrication processes are lengthy and difficult due to challenges in handling occlusal blocks during thermoforming.
Innovation Solution
The development of occlusal blocks with modular support structures and interlocking features, coupled using methods like adhesive or laser welding, which are designed to resist plastic deformation and facilitate easy assembly and integration into orthodontic appliances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If occlusal blocks are made from traditional materials and structures, then they can be easily fabricated, but they suffer from significant deformation and crushing under occlusal forces
Solution Approach 1:
The occlusal block is divided into multiple segments or sections that can be separately fabricated and then assembled together. This segmentation allows each part to be manufactured more easily while the assembled structure provides the necessary strength and resistance to occlusal forces through the interlocking of segments
Solution Approach 2:
The invention uses composite material structures combining different materials with complementary properties. The composite construction provides both the strength needed to resist crushing under occlusal forces and manufacturability through the selection of materials that are easier to work with during fabrication
2Manufacturing precision
If occlusal blocks are filled with material in cavities during fabrication, then they can achieve desired shape, but the process is difficult to handle resulting in long fabrication times
Solution Approach 1:
Support structures and cavity definitions are prepared in advance before the main fabrication process. This preliminary action allows the subsequent material filling and shaping to proceed more quickly and with greater precision, reducing overall fabrication time while maintaining shape accuracy
Solution Approach 2:
The invention replaces traditional mechanical handling and manual filling processes with automated or assisted systems. This substitution reduces the difficulty of handling materials during fabrication and significantly decreases fabrication time while maintaining or improving shape precision
3Reliability
If occlusal blocks are designed with simple structures, then they are easy to fabricate, but they cannot provide sufficient durability under normal wear
Solution Approach 1:
The occlusal block employs a segmented structure where multiple simpler components are assembled to create a durable whole. Each segment can be fabricated using straightforward processes, but their interlocking arrangement provides the enhanced durability needed to withstand normal wear over time
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 occlusal blocks provide improved durability and resilience to occlusal forces, enabling efficient mandibular relocation with reduced fabrication time and improved appliance functionality.
Implementation Method 1
resilience to plastic deformation and crushing or collapsing under occlusal forces
Implementation Method 2
coupled using methods like adhesive or laser welding
Implementation Method 3
coupled using methods like adhesive or laser welding
Data Source
AI summary
A method of fabricating an orthodontic aligner may include forming a mold for an orthodontic aligner. The mold may include tooth receiving cavities shaped to move teeth of a patient form a first orientation towards a second orientation and a receptacle shaped to receive a base of a mold for an occlusal block. The method may include inserting a mold for an occlusal block into the receptacle, the mold for the occlusal block including a base for insertion into the receptable and a block support structure coupled to the base. The method may also include overmolding a sheet of aligner material over the mold for the orthodontic aligner and the mold for the occlusal block and removing the sheet of aligner material from the mold for the orthodontic aligner while retaining the block support structure in the orthodontic aligner.