Phase-Separated 3D Printed Composites for Orthodontic Appliances
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Solution Overview
Problem
Existing orthodontic appliances lack materials with dual characteristics of stiffness and elasticity, limiting their effectiveness in repositioning teeth efficiently.
Innovation Solution
The development of composite materials formed from a single resin with distinct continuous phases, where a more reactive component forms a soft phase and a less reactive component forms a hard phase, enabling 3D printing and polymerization to create orthodontic appliances with varying hardness properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric materials with dual characteristics of stiffness and elasticity are used, then orthodontic appliance effectiveness is improved, but material complexity increases
Solution Approach 1:
The patent employs composite materials consisting of a first polymerizable component (forming soft phase) and a second polymerizable component (forming hard phase) to achieve dual characteristics of stiffness and elasticity. This composite approach allows the orthodontic appliance to simultaneously exhibit flexibility for comfort and hardness for effective tooth repositioning, resolving the contradiction between reliability and material complexity.
Solution Approach 2:
The invention creates distinct continuous phases within the polymeric material where the first polymerizable component forms a soft continuous phase and the second forms a hard continuous phase. This local differentiation of material properties within the same appliance enables different regions to provide different mechanical characteristics, achieving both stiffness and elasticity in a single material system.
2Strength
If composite materials with distinct continuous phases are created from a single resin, then mechanical properties are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple polymerizable components into a single resin formulation, where the first and second polymerizable components are combined in one liquid resin. This merging simplifies manufacturing by allowing the composite material to be processed as a single homogeneous liquid before polymerization, while still enabling the formation of distinct continuous phases with different mechanical properties after curing.
Solution Approach 2:
The invention utilizes differences in polymerization parameters between the first and second polymerizable components to control phase separation. By selecting components with different reactivity, molecular weights, or functional groups, the patent achieves spontaneous formation of distinct continuous phases during polymerization, enhancing mechanical properties without requiring complex external manufacturing interventions.
3Strength
If phase separation is used to create composite materials, then toughness and flexibility are increased, but process complexity increases
Solution Approach 1:
The patent employs self-service phase separation where the first and second polymerizable components spontaneously separate into distinct continuous phases during the polymerization process itself. This self-organizing behavior is driven by differences in component reactivity and compatibility, eliminating the need for external phase separation equipment or complex processing steps while achieving enhanced toughness and flexibility.
Solution Approach 2:
The invention exploits phase transitions during polymerization to create the composite structure. As the resin polymerizes, the first and second polymerizable components undergo phase separation, transitioning from a homogeneous liquid mixture to a multiphase solid network. This phase transition naturally creates the desired composite morphology with distinct soft and hard continuous phases, improving mechanical properties without adding process complexity.
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 composite materials provide enhanced mechanical properties, such as increased toughness and flexibility, allowing for effective tooth repositioning and improved orthodontic treatment outcomes.
Implementation Method 1
methods, systems, and devices for the generation of composite materials from a single resin using phase separation
Implementation Method 2
initiating a polymerization reaction by curing the resin
Data Source
AI summary
The present disclosure provides methods, systems, devices, and kits for creating composite materials from a single resin, the composite materials having multiple continuous phases. The disclosure includes a process to three-dimensionally print objects (e.g., orthodontic appliances) with composite properties. In some aspects, the composite properties are formed from a single formulation with components that, when processed, have hard and soft continuous phases. In some aspects, the composite properties are formed by separately processing the hard phase components and the soft phase components. In some aspects, the composite materials and devices are three-dimensionally printed using the processed material.