Multilayer Copolyester Dental Aligner Sheets
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Solution Overview
Problem
Traditional dental aligners face challenges in maintaining sufficient force over time and durability, particularly in multilayer plastic sheets used for thermoformed dental appliances, which require tailored modulus properties and improved tear resistance.
Innovation Solution
Multilayer film/sheet structures with specific layer compositions, including outer layers made of polyesters with terephthalic acid and glycol components, and a core layer of copolyesters, are developed to achieve customizable modulus and enhanced tear force retention, produced through extrusion or lamination processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multilayer plastic sheets are used for dental aligners, then freedom to tailor properties is improved, but manufacturing complexity increases
Solution Approach 1:
The dental aligner sheet is divided into multiple layers, each with distinct material compositions and properties. The outer layers provide durability and tear resistance, while the core layer provides flexibility and force retention, allowing independent optimization of each layer's properties to meet specific performance requirements.
Solution Approach 2:
The patent combines different polymer materials in a multilayer structure, where each layer is made from specific polymers selected for their unique properties. This composite approach enables the final product to exhibit a combination of characteristics that cannot be achieved with a single material, including optimized tear strength, flexibility, and force retention.
2Strength
If outer layers with specific polyester composition are used, then tear force and force retention are improved, but material selection complexity increases
Solution Approach 1:
The outer layers are specifically designed with a polyester composition containing terephthalic acid and specific glycol components in controlled amounts, giving them enhanced tear resistance and force retention properties localized to where they are most needed for dental aligner performance.
Solution Approach 2:
The patent specifies precise compositional parameters for the outer layer polyester, including the amount of terephthalic acid (60-90 mol%) and specific glycol components (1,4-cyclohexanedimethanol and 1,3-cyclobutanediol), to achieve optimal tear force and force retention properties for dental applications.
3Adaptability or versatility
If core layer with different polyester is used, then modulus customization is improved, but layer differentiation complexity increases
Solution Approach 1:
The core layer is differentiated from the outer layers by using a different polyester composition, allowing independent control of the core's mechanical properties including modulus and flexibility, while the outer layers maintain their tear-resistant characteristics.
Solution Approach 2:
The core layer employs a distinct polyester composition optimized for providing flexibility and force retention, while the outer layers use a different polyester formulation optimized for tear resistance, creating localized property optimization throughout the multilayer structure.
Data Source
AI summary
Provided are copolyester multilayer film/sheet structures which exhibit improved durability and customizable modulus properties which can be useful in many applications, including formed articles for use in the dental appliance market.