ORAL APPLIANCES WITH MAJOR CONNECTORS AND METHODS FOR MANUFACTURE

• US 20090308403A1
• Filed: 06/14/2009
• Published: 12/17/2009
• Est. Priority Date: 09/08/2000
• Status: Active Grant

• Current Assignee: DOC Brands Incorporated
• Original Assignee: BITE Tech Incorporated (GF Capital Bite Tech Holdings LLC)
• Inventors: Kittlesen, Jon D., Molhoek, Robert C., Roettger, Mark, Bradshaw, Paul L., Broadbent, Paul A., Belvedere, Paul C., Cross, Henry D. III, Ballanoff, William L.
• Granted Patent: US 8,113,206 B2
• Time in Patent Office: Days
• US Class Current: 128/861
• CPC Class Codes: A61F 5/566 Intra-oral devices
• CPC Class Codes: A63B 71/085 Mouth or teeth protectors A63B71/081 takes precedence

Abstract

Oral appliances adapted to for spacing the occlusal surfaces of the teeth of a user are disclosed. The oral appliances have a major connector interconnecting a first bite pad and a second bite pad. The first bite pad can include a first spacer and the second bite pad can include a second spacer that are configured to maintain the spacing of the occlusal surfaces of opposing teeth of a user during clenching or upon an impact to the jaw. Methods for the manufacture of composite oral appliances are also disclosed. The methods include forming a composite oral appliance over a model of a user'"'"'s mouth.

Claims

1. An oral appliance, comprising:

a first body configured to be secured over one or more teeth of a user, the first body comprising a composite structure, the composite structure comprising at least an outer layer secured over an inner layer, the first body further defining at least a first bite pad, the composite structure at the first bite pad comprising at least a first spacer secured between an outer layer secured and an inner layer, the first bite pad in a position to contact at least one of a molar a premolar of user, an inner surface of the inner layer defining an exterior shape of at least a portion of the teeth of a user;

a second body configured to be secured over at least some teeth of a user, the second body comprising a composite structure, the composite structure comprising at least an outer layer secured over an inner layer, the second body further defining at least a second bite pad, the composite structure at the second bite pad comprising at least a second spacer secured between an outer layer secured and an inner layer, the second bite pad in a position to contact at least one of a molar and a premolar when worn by the user, an inner surface of the inner layer defining an exterior shape of at least a portion of the teeth of a user; and

a major connector defining a first mounting portion and a second mounting portion, the first mounting portion secured to the first body and the second mounting portion secured to the second body.

2. An oral appliance, as in claim 1, comprising the major connector extending from a buccal edge of the first body and having a first mesial bend and the major connector extending from a buccal edge of the first body and having a second mesial bend, an arch of the major connector extending between the first mesial bend and the second mesial bend with the first mesial bend and the second mesial bend configured to position the arch of the major connector adjacent to one of incisors of the user and the gum line adjacent to the incisors of the user.

3. An oral appliance, as in claim 1, comprising the major connector extending from a mesial edge of the first body and the major connector extending from a mesial edge of the first body, an arch of the major connector extending between the first body and the second body with the arch of the major connector configured to be positioned adjacent to one of incisors of the user and the gum line adjacent to the incisors of the user.

4. A method for manufacturing an oral appliance, comprising:

providing a model of one of an upper set of teeth and a lower set of teeth;

forming an inner blank over at least a portion of the model;

positioning a first spacer and a second spacer on an upper surface of the inner blank over at least one of a molar and a premolar of the model;

forming an outer blank over at least a portion of the model;

securing the outer blank over the inner blank to form at least a first bite pad securing at least the first spacer and a second bite pad securing at least a second spacer to relatively secure at least a portion of the outer blank, the first spacer, the second spacer, and the inner blank together as a composite structure; and

securing a major connector between the first bite pad and the second bite pad.

5. The method for manufacturing a composite oral appliance, as in claim 4, further comprising the step of forming the inner blank, comprising:

positioning the model in a forming chamber of a pressure forming apparatus;

sealingly engaging an inner blank between the forming chamber and a high pressure chamber of the pressure forming apparatus; and

generating a pressure differential between the forming chamber and the high pressure chamber to draw a portion of the blank over the model.

6. The method for manufacturing a composite oral appliance, as in claim 4, further comprising the step of forming the outer blank, comprising:

sealingly engaging an outer blank between the forming chamber and a high pressure chamber of the pressure forming apparatus; and

generating a pressure differential between the forming chamber and the high pressure chamber to draw a portion of the blank over the first spacer and the second spacer and the first blank.

7. The method for manufacturing a composite oral appliance, as in claim 5, further comprising the step of forming a first body including the first spacer and a second body including the second spacer, and the first body secured to the second body by the major connector.

8. The method for manufacturing a composite oral appliance, as in claim 4, further comprising the steps of:

forming a first body including the first spacer and the second body including the second spacer from the composite structure; and

securing with the first body secured to the second body with major connector by securing a first retention portion of the major connector within the first body and securing a second retention portion of the major connector within the second body.

9. A method for manufacturing an oral appliance, comprising:

providing a model of one of an upper set of teeth and a lower set of teeth;

providing an inner material over the surface of at least one of a molar and a premolar of the model;

positioning a first spacer and a second spacer on an upper surface of the inner material over at least one of a molar and a premolar on both a left side and a right side of the model;

forming an outer blank over at least a portion of the first spacer, the second spacer, the inner material and the model to relatively secure at least a portion of the outer blank, the first spacer, the second spacer, and the inner material together as a composite structure; and

securing the major connector in at least one of the inner blank and the inner material.

10. The method for manufacturing a composite oral appliance, as in claim 9, further comprising the step of forming the outer blank, comprising:

positioning the model in a forming chamber of a pressure forming apparatus;

sealingly engaging a first blank between the forming chamber and a high pressure chamber of the pressure forming apparatus; and

generating a pressure differential between the forming chamber and the high pressure chamber to form at least a portion of the first blank over the first spacer and the second spacer and the inner material.

11. The method for manufacturing a composite oral appliance, as in claim 9, further comprising the step of forming a first body including the first spacer and a second body including the second spacer, and securing the first body to the second body with the major connector.