Temperature-Controlled Precision Bending of Orthodontic Wires
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Solution Overview
Problem
Existing tools for precision bending and reshaping of dental components like orthodontic wires and prosthetic clasps face challenges due to the materials' physical properties, particularly those made from plastic and nickel titanium, which require precise temperature control to avoid returning to their original shape, and existing methods lack precision and risk damage.
Innovation Solution
A precision configuration system comprising a plier device with a heat transfer clamp member and temperature controller, allowing for precise temperature-controlled bending and reshaping of components by using a plier device with double jaw teeth and a single jaw tooth that can electro-thermally heat the component, along with a bending force transducer and component configuration computer system to apply controlled forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional three prong wire pliers are used to bend metal or plastic wires at room temperature, then the device structure is simple and easy to operate, but the wires return to their original shape due to elastic properties and precision bending cannot be achieved
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the wire to a specific range that allows non-elastic movement of atoms and molecules. This temperature parameter change enables permanent deformation and precision bending, resolving the contradiction between bending precision and device complexity by using thermal energy to alter material properties rather than increasing mechanical complexity
Solution Approach 2:
The patent introduces temperature control as an intermediary mechanism between the plier device and the wire. By using heat as a mediator to change the wire's physical state and enable permanent deformation, the system achieves precision bending without requiring complex mechanical structures, thus resolving the contradiction between manufacturing precision and device complexity
2Manufacturing precision
If temperature is increased to change the shape of plastic or nickel titanium wires, then precision bending can be achieved, but the wires may be melted or damaged due to excessive heat
Solution Approach 1:
The patent implements feedback control by continuously monitoring the temperature of the wire during the heating process and adjusting the heat input accordingly. This feedback mechanism ensures the temperature remains within the optimal range for non-elastic deformation without exceeding the melting or damage threshold, thereby achieving precision reshaping while preventing heat damage
Solution Approach 2:
The patent applies preliminary action by pre-setting the temperature control system to the specific temperature range required for non-elastic movement of the wire material. This preliminary configuration of the heating system ensures that the wire reaches the optimal temperature for shaping before bending forces are applied, preventing both insufficient heating and excessive heat damage
3Ease of manufacture
If room temperature bending is attempted on elastic materials, then no heating equipment is needed, but the materials return to their original shape due to elastic recovery
Solution Approach 1:
The patent utilizes phase transitions by heating the wire to a temperature range where the material transitions from an elastic state to a non-elastic or plastic state. This phase transition enables permanent shape changes without elastic recovery, resolving the contradiction between process simplicity and shape stability by using thermal energy to fundamentally alter the material's mechanical behavior
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
Enables precise, temperature-controlled bending and reshaping of components without melting or damaging them, ensuring accurate configuration and maintaining the desired shape post-cooling.
Implementation Method 1
The heating coil generates heat and transfers the generated heat to the single jaw tooth of the second clasp member via the clamping element to heat the component positioned and accommodated within the receptacle
Implementation Method 2
The heating coil generates heat and transfers the generated heat to the single jaw tooth of the second clasp member via the clamping element
Implementation Method 3
The single jaw tooth is configured to contact and electro-thermally heat the component positioned and accommodated within the receptacle
Data Source
AI summary
A precision configuration system includes a plier device having clasp members, a heat transfer clamp member, a bending force transducer, and a temperature controller. One clasp member has a single jaw tooth that contacts and heats a component, for example, a wire positioned by a component holder and accommodated within a receptacle defined between double jaw teeth of the other clasp member. The heat transfer clamp member includes a heating coil that generates and transfers heat to the single jaw tooth. The bending force transducer controls magnitude and direction of bending forces applied by the plier device to precision bend and reshape the component at one or more bending points on the component based on force commands received from a component configuration computer system. The temperature controller controls the generation and transfer of heat to the single jaw tooth to facilitate temperature controlled, precision bending and reshaping of the component.