Orthodontic Transfer Tray with Release Agent Barrier
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Solution Overview
Problem
Existing indirect bonding systems for orthodontic brackets face issues with excess adhesive ('flash') overflowing into critical spaces, which can render brackets clinically deficient by preventing proper archwire seating or ligation, and are difficult to remove, affecting the precision and ease of bracket placement.
Innovation Solution
Introducing a volume constant filler material into the receptacles of the transfer tray, which can be introduced after tray formation or coupled with the bracket, to protect vulnerable spaces from excess adhesive and facilitate easy removal without compromising precision placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied to the base of each appliance during indirect bonding, then the brackets are bonded to the patient's teeth at predetermined locations, but excess adhesive overflows into critical spaces on the bracket, rendering the bracket clinically deficient
Solution Approach 1:
A release agent is applied to the receptacle of the transfer tray before the bracket is placed in it. This preliminary application of the release agent creates a protective barrier that prevents excess adhesive from adhering to the receptacle walls and overflowing into critical bracket spaces during the bonding process.
Solution Approach 2:
The release agent acts as an intermediary substance between the adhesive and the receptacle. It allows the adhesive to be applied generously for reliable bonding while preventing it from sticking to the receptacle, thus eliminating the harmful overflow effect without compromising the bonding reliability.
2Manufacturing precision
If the transfer tray is formed to precisely match the bracket shape, then precise placement is achieved, but excess adhesive can still overflow into voids between the bracket and receptacle
Solution Approach 1:
The release agent is applied to the receptacle surfaces before bracket placement, preemptively preventing adhesive from occupying the void spaces between the bracket and receptacle during the bonding process.
Solution Approach 2:
The release agent serves as a mediating layer that allows the adhesive to remain confined to the bracket base while preventing it from extending into the voids, thus eliminating the harmful effect of adhesive in critical spaces.
3Ease of operation
If the transfer tray is removed after bonding, then the bracket remains on the tooth, but excess adhesive in critical spaces can prevent proper archwire seating or ligation
Solution Approach 1:
By applying the release agent before bracket placement, the receptacle surfaces are pre-protected against adhesive contamination, ensuring that critical bracket spaces remain clear and functional after tray removal.
Solution Approach 2:
The release agent acts as a protective intermediary that prevents adhesive from invading critical bracket features, thereby maintaining bracket functionality for proper archwire seating and ligation after the transfer tray is removed.
Data Source
AI summary
A method of making a transfer tray includes providing a physical mockup having a shape that corresponds to a positive shape of a patient's dental arch and a positive shape of one or more bracket analogs. A transfer tray may be formed over the physical mockup, with the transfer tray representing a negative replica of at least a portion of the mockup. One or more receptacles are accordingly formed in the ray, each receptacle approximating a least a portion of the shape of a bracket analog. A bracket associated with a bracket analog is placed into a receptacle of the one or more receptacles and a filler material is introduced into at least one receptacle.