Multilayer dental appliances and related methods and systems

• US 9,655,693 B2
• Filed: 04/18/2016
• Issued: 05/23/2017
• Est. Priority Date: 05/14/2012
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Li, Chunhua, Chen, Yan, Meyer, Klaus, Pudleiner, Heinz, Nickel, Joerg
• Primary Examiner(s): Rodriguez, Cris L
• Assistant Examiner(s): Mai, Hao D
• Application Number:
  US15/132,171
• Publication Number:
  US 20160228215A1
• Time in Patent Office: 400 Days
• CPC Class Codes: A61C 13/00 Dental prostheses; Making same tooth crowns for capping teeth A61C5/70; dental implants A61C8/00
• CPC Class Codes: A61C 19/06 Implements for therapeutic treatment radiation therapy A61N5/00
• CPC Class Codes: A61C 7/00 Orthodontics, i.e. obtaining or maintaining the desired position of teeth, e.g. by straightening, evening, regulating, separating, or by correcting malocclusions
• CPC Class Codes: A61C 7/08 Mouthpiece-type retainers or positioners, e.g. for both the lower and upper arch arch-shaped medicament applicators for teeth or gums A61C19/063; mouthguards for protecting the teeth of sportsmen A63B71/085
• CPC Class Codes: A61F 5/56 Devices for preventing snoring by influencing the respiratory system by gas treatment A61M16/00
• CPC Class Codes: A63B 71/085 Mouth or teeth protectors A63B71/081 takes precedence
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2995/0026 Transparent
• CPC Class Codes: B29K 2995/007 Hardness
• CPC Class Codes: B29K 2995/0077 Yield strength; Tensile strength
• CPC Class Codes: B29K 2995/0082 Flexural strength; Flexion stiffness
• CPC Class Codes: B29L 2031/753 Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2274/00 Thermoplastic elastomer material thermoplastic elastomer fibres B32B2262/0215, thermoplastic elastomer particles B32B2264/0221, thermoplastic elastomer foam B32B2266/0292
• CPC Class Codes: B32B 2307/40 having particular optical properties light or UV resistant B32B2307/71
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 2307/536 : Hardness
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2319/00 : Synthetic rubber natural rubber B32B2317/22
• CPC Class Codes: B32B 2323/00 : Polyalkenes
• CPC Class Codes: B32B 2323/04 : Polyethylene
• CPC Class Codes: B32B 2323/10 : Polypropylene
• CPC Class Codes: B32B 2323/16 : EPDM, i.e. ethylene propylene diene monomer
• CPC Class Codes: B32B 2333/04 : Polymers of esters
• CPC Class Codes: B32B 2367/00 : Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2371/00 : Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone
• CPC Class Codes: B32B 2375/00 : Polyureas; Polyurethanes
• CPC Class Codes: B32B 2377/00 : Polyamides
• CPC Class Codes: B32B 2383/00 : Polysiloxanes
• CPC Class Codes: B32B 25/08 : of synthetic resin
• CPC Class Codes: B32B 25/14 : comprising synthetic rubber copolymers B32B25/18 and B32B25/20 take precedence
• CPC Class Codes: B32B 25/20 : comprising silicone rubber
• CPC Class Codes: B32B 2535/00 : Medical equipment, e.g. bandage, prostheses, catheter medical patches B32B2556/00
• CPC Class Codes: B32B 2555/00 : Personal care
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/281 : comprising polyimides
• CPC Class Codes: B32B 27/283 : comprising polysiloxanes
• CPC Class Codes: B32B 27/285 : comprising polyethers
• CPC Class Codes: B32B 27/286 : comprising polysulphones; polysulfides
• CPC Class Codes: B32B 27/30 : comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 7/022 : Mechanical properties
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31565 : Next to polyester [polyethylene terephthalate, etc.]
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]

Abstract

A dental appliance for positioning a patient'"'"'s teeth includes a removable orthodontic tooth positioning appliance having teeth receiving cavities shaped to directly receive at least some of the patient'"'"'s teeth and apply a resilient positioning force to the patient'"'"'s teeth. The appliance includes a hard polymer layer having a hard polymer layer elastic modulus disposed between a first soft polymer layer having a first soft polymer layer elastic modulus and a second soft polymer layer having a second soft polymer layer elastic modulus. The hard polymer layer elastic modulus is greater than each of the first soft polymer layer elastic modulus and the second soft polymer layer elastic modulus. At least one of the first soft polymer layer and the second soft polymer layer has a flexural modulus of greater than about 35,000 psi.

Claims

1. An orthodontic appliance for repositioning a patient'"'"'s teeth, the appliance comprising:

a shell having a plurality of teeth receiving cavities shaped to apply a repositioning force to the patient'"'"'s teeth, wherein the shell is formed from a multilayer material configured to reduce degradation of the repositioning force over time when the shell is worn on the patient'"'"'s teeth, the multilayer material comprising;

a first soft polymer layer and a second soft polymer layer each having a thickness in a range from 25 μ

m to 100 μ

m and a compression set greater than 40% after 24 hours at 70°

C., wherein the first and second soft polymer layer each comprise a thermoplastic polyurethane elastomer; and

a hard polymer layer disposed between the first and second soft polymer layers and having a thickness in a range from 400 μ

m to 1100 μ

m, a tensile modulus greater than 150,000 psi, and a tensile strength at yield between 4000 psi and 6500 psi, wherein the hard polymer layer comprises a co-polyester.

2. The appliance of claim 1, wherein the first and second soft polymer layers each have a thickness in a range from 30 μ

m to 90 μ

m.

3. The appliance of claim 1, wherein the hard polymer layer has a thickness in a range from 500 μ

m to 900 μ

m.

4. The appliance of claim 1 wherein the hard polymer layer has a thickness in a range from 550 μ

m to 750 μ

m.

5. The appliance of claim 1, wherein the first and second soft polymer layers each comprise a hardness of 60A to 85 D, an ultimate tensile strength greater than 5000 psi, an elongation at break greater than 200%, a flexural modulus greater than 35,000 psi, and a light transmission between 400 nm and 800 nm greater than about 75%.

6. The appliance of claim 1, wherein the hard polymer layer comprises an elongation at yield greater than 4%, an elongation at break greater than 70%, a flexural modulus greater than 150,000 psi, and a light transmission between 400 nm and 800 nm greater than about 75%.

7. The appliance of claim 1, wherein the multilayer material has elastic properties configured to reduce degradation of the shape of the plurality of teeth receiving cavities over time when the shell is worn on the patient'"'"'s teeth.

8. The appliance of claim 1, wherein the first and second soft polymer layers each comprise the thermoplastic polyurethane elastomer in combination with a thermoplastic elastomer, a block copolymer elastomer, a thermoplastic co-polyester elastomer, or a combination thereof.

9. The appliance of claim 1, wherein the hard polymer layer comprises the co-polyester in combination with a polyester, a thermoplastic polyurethane, a polypropylene and polyethylene copolymer, a cyclic block copolymer, a polyethylene terephthalate, a polybutylene terephthalate, a polyethersulfone, a polytrimethylene terephthalate, or a combination thereof.

10. The appliance of claim 1, wherein the stress relaxation of the hard polymer layer is greater than 10% at 24 hours tested at between 90% to 100% relative humidity.

11. An orthodontic system for repositioning a patient'"'"'s teeth, comprising:

a plurality of incremental position adjustment appliances having teeth receiving cavities shaped to directly receive at least some of the patient'"'"'s teeth and apply a resilient positioning force to the patient'"'"'s teeth, wherein the appliances are successively worn by a patient to move teeth from one arrangement to a successive arrangement, and wherein at least one of the appliances comprises;

a shell having a plurality of teeth receiving cavities shaped to apply a repositioning force to the patient'"'"'s teeth, wherein the shell is formed from a multilayer material configured to reduce degradation of the repositioning force over time when the shell is worn on the patient'"'"'s teeth, the multilayer material comprising;

a first soft polymer layer and a second soft polymer layer each having a thickness in a range from 25 μ

m to 100 μ

m and a compression set greater than 40% after 24 hours at 70°

C.; and

a hard polymer layer disposed between the first and second soft polymer layers and having a thickness in a range from 400 μ

m to 1100 μ

m, a tensile modulus greater than 150,000 psi, and a tensile strength at yield between 4000 psi and 6500 psi,

wherein the first and second soft polymer layer each comprise a thermoplastic polyurethane elastomer and the hard polymer layer comprises a co-polyester.

12. The system of claim 11, wherein the first and second soft polymer layers each have a thickness in a range from 30 μ

m to 90 μ

m.

13. The system of claim 11, wherein the hard polymer layer has a thickness in a range from 500 μ

m to 900 μ

m.

14. The system of claim 11, wherein the hard polymer layer has a thickness in a range from 550 μ

m to 750 μ

m.

15. The system of claim 11, wherein the first and second soft polymer layers each comprise a hardness of 60A to 85 D, an ultimate tensile strength greater than 5000 psi, an elongation at break greater than 200%, a flexural modulus greater than 35,000 psi and a light transmission between 400 nm and 800 nm greater than about 75%.

16. The system of claim 11, wherein the hard polymer layer comprises an elongation at yield greater than 4%, an elongation at break greater than 70%, a flexural modulus greater than 150,000 psi, and a light transmission between 400 nm and 800 nm greater than about 75%.

17. The system of claim 11, wherein the multilayer material has elastic properties configured to reduce degradation of the shape of the plurality of teeth receiving cavities over time when the shell is worn on the patient'"'"'s teeth.

18. The system of claim 11, wherein the first and second soft polymer layers each comprise the thermoplastic polyurethane elastomer in combination with a thermoplastic elastomer, a block copolymer elastomer, a thermoplastic co-polyester elastomer, or a combination thereof.

19. The system of claim 11, wherein the hard polymer layer comprises the co-polyester in combination with a polyester, a thermoplastic polyurethane, a polypropylene and polyethylene copolymer, a cyclic block copolymer, a polyethylene terephthalate, a polybutylene terephthalate, a polyethersulfone, a polytrimethylene terephthalate, or a combination thereof.

20. The system of claim 11, wherein the stress relaxation of the hard polymer layer is greater than 10% at 24 hours tested at between 90% to 100% relative humidity.