Segmented Orthodontic Aligner with Flexible Zones

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Solution Overview

Problem

Conventional orthodontic aligners lack flexibility, leading to intermittent force delivery and inadequate engagement of teeth, particularly when teeth are not well-aligned, which can result in deviations from the intended treatment plan and require frequent revisions.

Innovation Solution

The development of an orthodontic appliance with a thin elastomeric shell featuring recesses and flexible zones created by 3D printing patterns or voids, allowing for enhanced flexibility through curved interconnecting elements that connect tooth-clasping elements, enabling firm engagement and controlled force application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional orthodontic aligners are used, then the appliance structure is simple and easy to manufacture, but the appliance lacks flexibility leading to intermittent force delivery and inadequate tooth engagement

Engineering Contradiction:

ImproveflexibilityVSAvoidappliance structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The appliance shell is segmented into multiple zones with different flexibility characteristics. Rigid zones provide structural support and force transmission, while flexible zones allow adaptation to tooth movement and maintain continuous engagement. This segmentation resolves the contradiction by enabling both flexibility and structural integrity within the same appliance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the appliance shell are assigned different mechanical properties. The shell includes rigid portions for stable force application and flexible portions for adaptation, creating local quality variations that simultaneously achieve flexibility where needed and structural stability where required, resolving the contradiction between adaptability and device complexity.

Inventive Principle:

Principle #3Local quality

2Reliability

If conventional orthodontic aligners are used, then the manufacturing process is straightforward, but the force delivery is intermittent and tooth engagement is inadequate

Engineering Contradiction:

Improvetooth engagementVSAvoidappliance structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The appliance incorporates dynamic flexible zones that adapt their shape and position in response to tooth movement. This dynamic capability ensures continuous and reliable tooth engagement throughout the treatment process, while the overall appliance structure remains relatively simple and manufacturable using conventional techniques.

Inventive Principle:

Principle #15Dynamics

3Force

If rigid appliance material is used, then the force application is strong, but the appliance cannot adapt to tooth movement resulting in intermittent force delivery

Engineering Contradiction:

Improveforce applicationVSAvoidadaptation to tooth movement

Core Design Contradiction:

ForceVSAdaptability or versatility

Solution Approach 1:

The appliance shell combines rigid and flexible zones with distinct local qualities. Rigid zones generate and transmit strong orthodontic forces, while flexible zones adapt to tooth movement and maintain continuous contact. This local differentiation resolves the contradiction between strong force application and adaptability to tooth movement.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The appliance utilizes composite construction with regions of different material properties within the same shell structure. This composite approach enables simultaneous presence of rigid force-transmitting zones and flexible adaptation zones, resolving the contradiction between strong force application and adaptability.

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If flexible appliance material is used, then the appliance can adapt to tooth movement, but the force delivery becomes weak and inconsistent

Engineering Contradiction:

ImproveflexibilityVSAvoidforce application

Core Design Contradiction:

Adaptability or versatilityVSForce

Solution Approach 1:

The appliance shell is divided into segmented zones with different mechanical properties. Flexible segments provide adaptation to tooth movement, while rigid segments ensure strong and consistent force delivery. This segmentation resolves the contradiction by distributing different functional requirements to different regions of the appliance.

Inventive Principle:

Principle #1Segmentation

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 appliance provides continuous, gentle forces for effective tooth movement, improving the precision and stability of orthodontic treatment by maintaining engagement with teeth throughout the treatment process, reducing the need for frequent plan revisions.

Implementation Method 1

The appliance provides continuous, gentle forces for effective tooth movement

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12144703B2Tooth-positioning appliance, systems and methods of producing and using the same

Publication Date: 2024.11.19 ARCHFORM INC

AI summary

Tooth-positioning appliances and apparatuses, components, methods, and techniques for producing and using tooth-positioning appliances are provided. An example tooth-positioning appliance for adjusting the position of teeth of a patient includes a tooth-clasping arrangement shaped to secure the orthodontic appliance to at least one tooth and a flexible arrangement connected to the tooth-clasping arrangement. The flexible arrangement is less rigid than the tooth-clasping arrangement.