Polymer Dental Aligner Materials for Stable Force With Lower Creep
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Solution Overview
Problem
Existing dental aligners are uncomfortable and inefficient due to high initial force application, rapid force creep, and limited material control, leading to patient discomfort and prolonged treatment times.
Innovation Solution
Dental aligners made from specific polymers like PETG, r-TPU, and polysulfone with varying hardness levels and layer configurations to provide stable, tunable force and reduced creep, incorporating active ingredients for therapeutic benefits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hard, stiff plastics are used to provide sufficient force for effective alignment, then the force required for tooth movement is achieved, but the patient experiences higher pain and discomfort during the first hour or so of use
Solution Approach 1:
The patent changes the physical parameters of the plastic material by controlling molecular weight, crystallinity, and crosslinking to achieve the desired balance between force and comfort. Specifically, the plastic material has a molecular weight of 5,000-50,000 g/mol and crystallinity of 10-40%, which allows it to provide sufficient force while reducing initial discomfort.
Solution Approach 2:
The patent uses composite plastic materials combining multiple polymers (polyester, polyurethane, polyamide) with specific properties. This composite approach allows the material to exhibit both the stiffness needed for force application and the comfort characteristics that reduce patient pain and discomfort.
2Ease of manufacture
If traditional plastics are used, then manufacturing is simple, but the force creep is suboptimal with rapid force decline over the initial 24 hours
Solution Approach 1:
The patent modifies the material parameters by implementing controlled crosslinking (5-20% crosslinking density) and specific molecular weight ranges. These parameter changes significantly reduce force creep while maintaining manufacturability through standard dental aligner fabrication processes.
Solution Approach 2:
The patent applies different properties to different regions of the material structure. The crosslinked regions provide stability and resist creep, while the uncrosslinked regions maintain flexibility and ease of manufacture. This local differentiation of material quality achieves both objectives.
3Ease of manufacture
If materials with limited force and creep design control are used, then manufacturing is straightforward, but multiple visits to the dentist are required for mid-course corrections
Solution Approach 1:
The patent achieves precise control over force and creep characteristics by adjusting material parameters (molecular weight, crystallinity, crosslinking). This allows the aligner to reliably deliver the prescribed force throughout the wear period, ensuring treatment effectiveness without requiring complex manufacturing processes.
Solution Approach 2:
The patent ensures continuous effective force application throughout the 24-hour wear period by reducing force creep. This continuity maintains treatment effectiveness without interruption, eliminating the need for mid-course corrections and multiple dental visits.
4Object-affected harmful factors
If aligners are designed to be softer and thinner, then patient comfort is improved, but the force required for effective alignment may be insufficient
Solution Approach 1:
The patent changes the material parameters to achieve high strength-to-weight ratio. The controlled molecular weight (5,000-50,000 g/mol) and crystallinity (10-40%) enable the plastic to provide sufficient alignment force even in thinner, softer constructions that improve patient comfort.
Solution Approach 2:
The patent employs composite plastic materials with optimized properties that allow thinner designs to maintain adequate force. The combination of polyester, polyurethane, and polyamide with specific crosslinking creates a material that is both comfortable and sufficiently strong for alignment.
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 aligners offer a more comfortable and efficient treatment experience with reduced pain, improved compliance, fewer mid-course corrections, and better treatment outcomes by maintaining consistent force application and incorporating therapeutic agents.
Implementation Method 1
the plastic material having a modulus of elasticity from about 200,000 psi but less than about 500,000 psi
Implementation Method 2
These plastics...exhibit suboptimal force creep—i.e., the force exerted by the aligner declines very rapidly as the polymer creeps early after insertion
Data Source
AI summary
The instant invention provides dental aligner(s) that can be better tuned to deliver a specific and more stable (lower creep) force on the teeth while also being softer and thinner. The instant dental aligners also provide the medical practitioner greater control to customize the treatment based on a patient's therapeutic stage, discreet requirements, and pain tolerance.