Thermal Separation of Deep-Drawn Thermoform Dental Aligners
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Solution Overview
Problem
The existing methods for manufacturing jaw-spanning dental apparatuses, such as aligners or bite splints, involve complex and time-consuming manual cutting and trimming of deep-drawn thermoform films, which can lead to sharp edges and increased risk of damage.
Innovation Solution
A device that uses a separating element heated to at least the glass temperature of the thermoform film to simultaneously separate and refine the deep-drawn thermoform film, reducing the need for manual intervention and minimizing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual cutting and trimming of deep-drawn thermoform film is performed using milling, grinding and polishing tools, then the thermoform film can be separated and edges can be refined, but the process becomes time-consuming and complex with multiple working steps
Solution Approach 1:
The patent combines cutting and edge refinement operations into a single thermal separation process. The separating element with heating means performs both separation along the separation contour and simultaneous refinement of edges by heating the thermoform film to at least its glass transition temperature, eliminating the need for separate milling, grinding, and polishing steps.
Solution Approach 2:
The patent changes the physical state of the thermoform film by heating it to at least its glass transition temperature during separation. This parameter change allows the material to become more pliable and easier to refine simultaneously with separation, enabling both cutting and edge smoothing in one operation without degradation or unnecessary melting.
2Productivity
If manual cutting and trimming operations are performed on deep-drawn thermoform film, then separation can be achieved, but sharp edges are produced and the risk of damaging the dental apparatus increases
Solution Approach 1:
The patent heats the thermoform film to at least its glass transition temperature during separation, changing its physical properties to make it more pliable. This allows the separating element to create smooth, rounded edges without sharp protrusions, reducing the risk of damage to the dental apparatus while maintaining fast separation speed.
Solution Approach 2:
The patent replaces mechanical cutting tools (milling, grinding, polishing tools) with a thermal separation process using a heated separating element. This substitution eliminates the mechanical forces that create sharp edges and potential damage, while still achieving rapid separation through thermal softening of the material.
3Productivity
If heating temperature is increased to separate thermoform film quickly, then separation speed improves, but degradation and unnecessary melting of the thermoform film occurs
Solution Approach 1:
The patent precisely controls the heating temperature to reach at least the glass transition temperature of the thermoform film but maintains it below the degradation temperature. This parameter optimization enables fast separation through thermal softening while preventing material degradation and unnecessary melting that would compromise the integrity of the dental apparatus.
Solution Approach 2:
The patent employs temperature sensors to monitor the temperature of the thermoform film during the separation process. The heating means is controlled based on this feedback to maintain the temperature within the optimal range (at least glass transition temperature but below degradation temperature), ensuring both fast separation and material integrity.
4Manufacturing precision
If multiple separate operations are used for cutting and refining thermoform film, then each operation can be optimized, but the overall process complexity and number of working steps increases
Solution Approach 1:
The patent merges cutting and edge refinement operations into a single integrated thermal separation process. The separating element with heating means performs both functions simultaneously along the separation contour, reducing the number of working steps while maintaining precise separation accuracy through controlled thermal softening of the thermoform film.
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 device enables a single-step separation and refinement process, reducing the number of working steps, improving efficiency, and preventing damage to the dental apparatuses by avoiding unnecessary melting or degradation of the thermoform film.
Implementation Method 1
a heating means for regulating the heating of the separating element so as to increase the temperature of the thermoform film substantially to at least its glass temperature
Implementation Method 2
increase the temperature of the thermoform film substantially to at least its glass temperature; thermally separating the deep-drawn thermoform film
Data Source
AI summary
A device for separating a deep-drawn jaw-spanning dental apparatus such as an aligner or a bite splint of thermoform film that includes: a separating element for thermally separating the deep-drawn thermoform film and simultaneously refining the separated deep-drawn thermoform film; a heating means for regulating the heating of the separating element so as to increase the temperature of the thermoform film substantially to at least its glass temperature; a support for supporting the deep-drawn thermoform film relatively movable with respect to the separating element; a moving mechanism for moving the separating element along a separation contour of the deep-drawn jaw-spanning dental apparatus relative to the support; and a control unit adapted to control the heating means and the moving mechanism based on the separation contour.