Reinforced Orthodontic Aligner Inserts for Complex Undercuts
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Solution Overview
Problem
Current plastic orthodontic aligners face challenges in treating complex malocclusions due to susceptibility to crushing when used for geometries with large undercuts or complex features, limiting their effectiveness and introducing undesirable tradeoffs.
Innovation Solution
Incorporating hollow features in orthodontic aligners that are at least partially filled with objects to enhance structural strength, allowing for the application of forces to correct malocclusions traditionally treated by additional appliances, and providing additional functions such as jaw repositioning and hygiene improvement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional plastic orthodontic aligners are used for geometries with large undercuts or complex features, then the aligners can be removed from molds, but the aligners become susceptible to crushing and lose structural integrity
Solution Approach 1:
The patent embeds a support structure (inner shell or framework) within the hollow feature of the aligner to provide internal reinforcement. This nested configuration allows the outer shell to maintain its thin, removable design while the inner support structure prevents crushing and maintains structural integrity during wear.
Solution Approach 2:
The patent combines multiple materials with different properties: the outer shell is made of thin, flexible plastic for comfort and removability, while the inner support structure is made of stronger, more rigid material to prevent crushing. This composite construction resolves the contradiction between ease of manufacture and structural strength.
2Ease of operation
If the aligner shell is made thinner for comfort and removability, then patient comfort improves, but the aligner becomes more susceptible to crushing
Solution Approach 1:
The support structure is nested within the hollow feature of the thin shell, allowing the shell to remain thin for patient comfort while the internal support prevents crushing. The inner structure acts as a reinforcement skeleton that does not interfere with the outer shell's comfort properties.
Solution Approach 2:
The aligner is segmented into two functional parts: the thin outer shell that contacts the patient's teeth and provides comfort, and the internal support structure that provides mechanical strength. This segmentation allows each part to be optimized for its specific function without compromising the other.
3Reliability
If additional appliances are used to treat complex malocclusions, then treatment effectiveness improves, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple appliances into a single integrated aligner. The aligner combines tooth alignment features with built-in support structures that provide the additional strength normally requiring separate appliances, thereby maintaining treatment effectiveness while reducing device complexity and improving patient compliance.
Solution Approach 2:
The aligner is designed with multi-functionality, serving both as a tooth alignment device and as a structurally reinforced appliance capable of handling complex malocclusions. The hollow feature with embedded support structure allows the single appliance to perform multiple functions that traditionally required separate devices.
Data Source
AI summary
A method includes forming a plastic shell that has a hollow feature that includes a cavity. The method further includes inserting an object into the cavity, wherein the object is in a solid state and is preformed and shaped to fit into the cavity prior to the inserting of the object into the cavity, wherein the object provides structural strength to the plastic shell at a location of the hollow feature and does not interfere with a fit of the plastic shell onto a dental arch of a patient, the object having a shape that substantially matches a contour of the cavity prior to being inserted into the plastic shell.