Orthodontic Appliance Assembly via Rail-and-Channel Carrier

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Solution Overview

Problem

Orthodontic appliances with multiple pieces are difficult to assemble due to their small size and are prone to damage during assembly and handling, leading to assembly challenges for both manufacturers and clinicians.

Innovation Solution

An orthodontic system comprising a carrier structure and an assembly structure, where the assembly structure is movable relative to the carrier structure to align and mate complementary pieces with orthodontic appliances, facilitating the assembly of multipiece orthodontic appliances through a rail-and-channel interface, and potentially using additive manufacturing for improved precision and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If orthodontic appliances are made small and multipiece, then orthodontic treatment precision and customization are improved, but assembly difficulty and damage risk increase

Engineering Contradiction:

Improveorthodontic treatment precisionVSAvoidassembly difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The orthodontic appliance is divided into multiple separate pieces (bracket body and door component) that can be manufactured independently with high precision using additive manufacturing, then assembled together. This segmentation allows each component to be optimized separately while maintaining overall precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A carrier structure serves as an intermediary device that holds multiple orthodontic appliances in precise positions during assembly. The carrier structure with its array of wells provides a stable platform that maintains alignment between components, making assembly easier despite the small size of individual appliances.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If orthodontic appliances are made small and multipiece, then orthodontic treatment precision and customization are improved, but damage risk during assembly and handling increases

Engineering Contradiction:

Improveorthodontic treatment precisionVSAvoiddamage risk

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Multiple orthodontic appliances are pre-assembled onto the carrier structure in precise configurations before clinical use. This preliminary assembly on the carrier protects the small, fragile components during handling and transport, reducing damage risk while maintaining manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The carrier structure provides protective support for the fragile orthodontic appliances before they are transferred to the patient's mouth. The structured carrier prevents accidental drops, misalignment, or damage that could occur during handling of the small, delicate components.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Adaptability or versatility

If multipiece orthodontic appliances are assembled manually by clinicians, then clinical flexibility is improved, but assembly time and potential for error increase

Engineering Contradiction:

Improveclinical flexibilityVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Orthodontic appliances are pre-assembled on the carrier structure in the correct configuration before leaving the manufacturing facility. This preliminary assembly eliminates or reduces the need for time-consuming manual assembly by the clinician, while the carrier can still be adjusted to provide clinical flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The carrier structure serves multiple functions: it holds multiple appliances in precise positions during manufacturing, protects them during transport, and can be adapted in the clinical setting. This multi-functionality reduces the need for separate assembly steps while maintaining clinical versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12016747B2Systems and methods for manufacture of orthodontic appliances

Publication Date: 2024.06.25 SMILENEXT INC

AI summary

In some embodiments, systems, apparatuses, and methods are provided herein useful to orthodontic systems. In some embodiments, an orthodontic system includes a carrier structure including a base, a plurality of groups of support structures, a plurality of orthodontic appliances associated with one of the plurality of groups of support structures, and at least one rail extending from the base, and an assembly structure including a body, a plurality of complementary pieces associated with one of the plurality of orthodontic appliances, at least one channel configured to interface with the at least one rail to allow the assembly structure to be moved from a first position to a second position with respect to the carrier structure, wherein movement of the assembly structure with respect to the carrier structure causes the plurality of complementary pieces to mate with the plurality of orthodontic appliances.