Weakened-Region Dental Mold for Removing Undercut Thermoformed Shells
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Solution Overview
Problem
The challenge with existing molds is the removal of shells formed around them, particularly when features with significant undercuts or complex shapes are involved, which can damage or deform the shells during removal.
Innovation Solution
The use of breakable or deflectable molds with segmented configurations and weakened regions allows for the incorporation of complex features and undercuts, enabling the molds to be separated into sections without damaging the shells by breaking or deflecting at these regions, facilitating easier shell removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If molds include features with significant undercuts or complex shapes, then the shells can achieve enhanced features and correct dental issues, but the shells may be damaged or deformed during removal from the mold
Solution Approach 1:
The mold is divided into multiple sections that can be separated from each other. The shell is formed around the complete mold, then the mold sections are separated and removed individually, allowing complex features with undercuts to be replicated without damaging the shell during removal.
Solution Approach 2:
The mold sections are pre-positioned and secured together before shell formation. After the shell is formed and cured, the sections are then separated in a controlled manner, allowing the shell to be released without damage while maintaining the complex features during the critical formation phase.
2Strength
If the mold is made as a single solid piece, then the structure is strong and stable, but shells with complex features cannot be removed without damage
Solution Approach 1:
The mold is segmented into multiple sections that are joined together to form a complete mold structure. Each section maintains sufficient strength for shell formation, but the segments can be separated for easy shell removal, resolving the conflict between structural strength and removal ease.
Solution Approach 2:
The mold transitions from a static solid structure during shell formation to a dynamic separable structure during removal. The sections are firmly held together during forming but can be easily separated afterward, allowing the mold to adapt its structural characteristics to different operational phases.
3Stability of the object's composition
If the mold sections are strongly joined, then the mold maintains structural integrity during shell formation, but the sections cannot be separated for shell removal
Solution Approach 1:
The mold is divided into sections connected by separable joints that provide stability during formation but allow separation for removal. The segmented design with controlled connection points enables both structural integrity and ease of disassembly.
Solution Approach 2:
The sections are joined with sufficient strength to maintain stability during shell formation, but the connection is intentionally designed to be separable. The joining force is partial rather than complete, providing just enough stability for formation while allowing subsequent separation.
Data Source
AI summary
A mold is for thermoforming a dental appliance. The mold includes a first section of the mold and a second section of the mold. The second section includes a feature having a complex shape, an undercut, or a bite edge. The mold further includes a weakened region that joins the first section to the second section. The weakened region is breakable, deflectable, or deformable in response to a first threshold force to enable the first section and the second section to be removed from the dental appliance after the dental appliance is formed over the mold. The first threshold force is less than a second threshold force that would damage or permanently deform the dental appliance.