Orthodontic Bracket Pod with Upstanding Tabs
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Solution Overview
Problem
Existing packaging for prepasted orthodontic brackets often results in loss or insufficient bonding material during shipping due to the bracket engaging the pod's bottom, and prior solutions with alignment devices are cumbersome for clinicians, while lacking stability features to prevent bracket movement.
Innovation Solution
A packaging system with pods that have upstanding tabs to support the bracket above the pod's bottom, a cover to prevent adhesive curing, and stabilizing tabs to maintain the bracket's position, ensuring the adhesive remains intact and usable upon arrival.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bracket engages the bottom of the pod during shipping, then the packaging structure is simple, but bonding material is lost or becomes insufficient
Solution Approach 1:
The patent introduces an intermediary element (support structure with upstanding walls and stabilizing tabs) between the bracket and the pod bottom. This mediator prevents direct contact between the bonding material and pod bottom, eliminating material loss while maintaining packaging simplicity.
Solution Approach 2:
The solution moves from a single-plane contact (bracket bottom to pod bottom) to a multi-dimensional support system with upstanding walls and stabilizing tabs that engage the bracket at multiple points, preventing material loss without complex packaging.
2Loss of substance
If a jig or alignment device is connected to the bracket to suspend it above the pod bottom, then bonding material loss is prevented, but the device complexity increases and clinician operation becomes cumbersome
Solution Approach 1:
The patent extracts the alignment function from a separate jig device and integrates it directly into the pod structure through upstanding walls and stabilizing tabs. This eliminates the need for separate alignment devices while maintaining the suspension function.
Solution Approach 2:
The support and alignment functions are merged into a single integrated pod structure. The upstanding walls and stabilizing tabs simultaneously provide suspension and alignment, eliminating the need for separate jigs and reducing overall device complexity.
3Loss of substance
If the bracket is spaced from the pod bottom by upstanding ridges without stabilizing tabs, then bonding material loss is prevented, but the bracket can move along the projections and disturb the bonding material
Solution Approach 1:
The pod structure combines different functional elements (upstanding walls for spacing, stabilizing tabs for positioning) into a composite support system. This composite structure simultaneously prevents material loss and ensures bracket stability during shipping.
Solution Approach 2:
Different parts of the pod structure have specialized functions: upstanding walls provide spacing to prevent material loss, while stabilizing tabs provide localized engagement to prevent bracket movement. Each element is optimized for its specific function.
Data Source
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AI summary
A package for prepasted brackets mountable on the teeth of a patient wherein the bracket is mounted in a pod and is removable from the pod with adhesive on the back of the bracket so it can be directly placed in position on the tooth of a patient. The bracket includes a body and a base and a layer of light curable or otherwise curable polymer resin on the base which is later curable by use of light energy or otherwise. The package includes a carrier for the bondable brackets and is enclosed by a flap over the top of the pod compartment and held in place on supports or tabs extending upwardly from the bottom of the pod to prevent the adhesive on the base from engaging the bottom of the pod. Stabilizing means is provided in the pod to inhibit shifting of the bracket during shipment.