Oral device, manufacturing apparatus and methods of making the same

Patent metadata

Field	Value
Publication number	US-11224500-B2
Application number	US-201916353242-A
Country	US
Kind code	B2
Filing date	Mar 14, 2019
Priority date	Mar 14, 2018
Publication date	Jan 18, 2022
Grant date	Jan 18, 2022

Abstract

A custom oral device is provided that fits on the maxillary or mandibular arch of a wearer. The oral device comprises a tray that corresponds with the shape and size of a wearer's oral anatomy. A soft liner is disposed within an occlusal channel of the tray having an upper surface that comprises an impression having features that correspond to at least a portion of the wearer's dentition and in which the wearer's teeth align. An apparatus and a method for making the custom oral device are provided.

First claim

We claim:

1. An apparatus for making a custom oral device that fits over dentition of a wearer, comprising:
a. a tray comprised of a polymeric material that fits over a dental arch of the wearer comprising
a tray outer surface and
a tray inner surface comprising an occlusal channel;

b. a lid that fits over the occlusal channel comprising a lid inner surface having a structure that comprises a dental replica of a portion of the wearer's dentition,

wherein the dental replica aligns within the occlusal channel of the tray when the lid and tray are assembled; and
c. a cavity between the structure corresponding to a portion of the wearer's dentition and the occlusal channel when the lid and the tray are assembled.

2. The apparatus of claim 1 , wherein the lid comprises an introduction port having an opening that extends from a lid outer surface into the cavity.

3. The apparatus of claim 1 , further comprising a seal between the tray and the lid around a perimeter of the apparatus when assembled.

4. The apparatus of claim 1 , wherein the dental replica comprises a replica of a coronal portion of anterior and posterior dentition.

5. The apparatus of claim 1 , wherein the structure on the lid inner surface further comprises a replica of gingiva.

6. The apparatus of claim 1 , wherein the tray is comprised of polymeric material that has a Shore D hardness value between 40 and 100 when cured.

7. The apparatus of claim 1 , wherein the tray is a full-arch dental splint that covers occlusal and incisal surfaces of the dentition of the wearer.

8. The apparatus of claim 1 , wherein the tray inner surface is comprised of a first material comprising a polymer composition that comprises reactive groups; and the apparatus further comprises a polymerizable soft liner material within the cavity comprising a second material adjacent the tray inner surface comprising reactive groups adjacent reactive groups of the tray inner surface.

9. The apparatus of claim 8 , wherein the soft liner material is between the dental replica of the lid and the occlusal channel of the tray.

10. A method of making a custom oral device for a wearer, comprising
a. obtaining a tray having an outer surface, an inner surface and an occlusal channel;
b. obtaining a lid having a structure comprising a dental replica of at least a portion of the wearer's dentition;
c. assembling the tray and the lid by aligning the dental replica of the lid within the occlusal channel of the tray to form a cavity;
d. providing a curable soft liner material within the cavity between the dental replica of the lid and the occlusal channel; and
e. curing the curable soft liner material to form a soft liner within the cavity.

11. The method of claim 10 , further comprising bonding a lower surface of the soft liner to the inner surface of the tray.

12. The method of claim 10 , wherein the inner surface of the tray comprises a polymeric material having reactive groups, and the method comprises chemically bonding the inner surface with the curable soft liner material during the curing step.

13. The method of claim 10 , comprising forming an impression of the dental replica in the soft liner.

14. The method of claim 10 , wherein providing a curable soft liner material within the cavity comprises injecting the curable soft liner material into the cavity through an introduction port in the lid.

15. The method of claim 10 , further comprising forming the lid and the tray through an additive manufacturing process.

16. The method of claim 10 , comprising forming the lid and the tray by a three-dimensional printing process, and forming the soft liner by introducing the curable soft liner material into the cavity by an injection molding process.

Assignees

• Glidewell James R Dental Ceramics Inc

Inventors

• Friebauer Wolfgang
• He Chunlin
• Kirkland Christopher J
• Solorzano Robert Ryan

Classifications

• A63B2209/00

  Characteristics of used materials · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• A61C13/0004

  Computer-assisted sizing or machining of dental prostheses · CPC title

• A61C13/34

  Making or working of models, e.g. preliminary castings, trial dentures; Dowel pins [4] · CPC title

• A61C13/0025

  Linings · CPC title