Methods for making multilayer dental aligners

Patent metadata

Field	Value
Publication number	US-11766314-B2
Application number	US-202318107742-A
Country	US
Kind code	B2
Filing date	Feb 9, 2023
Priority date	May 14, 2012
Publication date	Sep 26, 2023
Grant date	Sep 26, 2023

Abstract

A multilayer sheet comprising first and second layers is provided. The first layer consists of a co-polyester. The second layer consists of a thermoplastic polyurethane elastomer having an elongation at break of greater than 200%, a hardness of 60A to 85D, an ultimate tensile strength of greater than about 5000 psi, and a light transmission between 400 nm and 800 nm of greater than about 75%. A mold is provided and the multilayer sheet is thermoformed over the mold to form a plurality of tooth-receiving cavities configured to receive and reposition a patient's teeth from a first arrangement toward a second arrangement. Excess material is trimmed from the thermoformed multilayer sheet to form a multilayer dental aligner.

First claim

What is claimed is:

1. A method of making a multilayer dental aligner, the method comprising:
providing a multilayer sheet comprising polymer layers, the polymer layers comprising:
a first layer consisting of a co-polyester; and
a second layer consisting of a thermoplastic polyurethane elastomer, wherein the thermoplastic polyurethane elastomer has an elongation at break of greater than 200%, a hardness of 60A to 85D, an ultimate tensile strength of greater than about 5000 psi, and a light transmission between 400 nm and 800 nm of greater than about 75%;

providing a mold;
thermoforming the multilayer sheet over the mold to form a plurality of tooth-receiving cavities configured to receive and reposition a patient's teeth from a first arrangement toward a second arrangement; and
trimming excess material from the thermoformed multilayer sheet to form the multilayer dental aligner.

2. The method of claim 1 , wherein the co-polyester has an elongation at break of greater than 70% and a tensile strength at yield of between about 4000 psi and 6500 psi.

3. The method of claim 1 , wherein the co-polyester has a flexural modulus greater than 150,000 psi.

4. The method of claim 1 , wherein the thermoplastic polyurethane elastomer has a flexural modulus greater than 35,000 psi.

5. The method of claim 1 , wherein the thermoplastic polyurethane elastomer has a compression set at about 70° C. of greater than 40% after 24 hours.

6. The method of claim 1 , wherein the first layer is coextruded with or laminated to a third layer.

7. The method of claim 1 , wherein the polymer layers of the multilayer sheet further comprises a third layer disposed between the first layer and the second layer.

8. The method of claim 1 , wherein the polymer layers of the multilayer sheet further comprises a third layer, and wherein the third layer comprises a same or different co-polyester.

9. The method of claim 1 , wherein the polymer layers of the multilayer sheet further comprises a third layer, and wherein the third layer comprises a same or different thermoplastic polyurethane elastomer with a hardness of about 60A to about 85D.

10. The method of claim 1 , wherein the first layer is thicker than the second layer.

11. A multilayer dental aligner for positioning a patient's teeth from a first arrangement toward a second arrangement, the multilayer dental aligner comprising:
a multilayer sheet comprising:
a first layer consisting of a co-polyester; and
a second layer consisting of a thermoplastic polyurethane elastomer, wherein the thermoplastic polyurethane elastomer has an elongation at break of greater than 200%, a hardness of 60A to 85D, an ultimate tensile strength of greater than about 5000 psi, and a light transmission between 400 nm and 800 nm of greater than about 75%;

wherein the multilayer sheet forms a plurality of tooth-receiving cavities configured to receive and reposition the patient's teeth from the first arrangement toward the second arrangement.

12. The multilayer dental aligner of claim 11 , wherein the co-polyester has an elongation at break of greater than 70% and a tensile strength at yield of between about 4000 psi and 6500 psi.

13. The multilayer dental aligner of claim 11 , wherein the co-polyester has a flexural modulus greater than 150,000 psi.

14. The multilayer dental aligner of claim 11 , wherein the thermoplastic polyurethane elastomer has a flexural modulus greater than 35,000 psi.

15. The multilayer dental aligner of claim 11 , wherein the thermoplastic polyurethane elastomer has a compression set at about 70° C. of greater than 40% after 24 hours.

16. The multilayer dental aligner of claim 11 , wherein the first layer is coextruded with or laminated to a third layer.

17. The multilayer dental aligner of claim 11 , wherein the polymer layers of the multilayer sheet further comprises a third layer disposed between the first layer and the second layer.

18. The multilayer dental aligner of claim 11 , wherein the polymer layers of the multilayer sheet further comprises a third layer, and wherein the third layer comprises a same or different co-polyester.

19. The multilayer dental aligner of claim 11 , wherein the polymer layers of the multilayer sheet further comprises a third layer, and wherein the third layer comprises a same or different thermoplastic polyurethane elastomer with a hardness of about 60A to about 85D.

20. The multilayer dental aligner of claim 11 , wherein the first layer is thicker than the second layer.

21. A multilayer dental aligner for positioning a patient's teeth from a first arrangement toward a second arrangement, the multilayer dental aligner comprising:
a multilayer sheet comprising:
a first layer containing a single polymer, wherein the single polymer of the first layer is a co-polyester; and
a second layer containing a single polymer, wherein the single polymer of the second layer is a thermoplastic polyurethane elastomer, wherein the second layer has an elongation at break of greater than 200%, a hardness of 60A to 85D, an ultimate tensile strength of greater than about 5000 psi, and a light transmission between 400 nm and 800 nm of greater than about 75%;

wherein the multilayer sheet forms a plurality of tooth-receiving cavities configured to receive and reposition the patient's teeth from the first arrangement toward the second arrangement.

22. The multilayer dental aligner of claim 21 , wherein the first layer has an elongation at break of greater than 70% and a tensile strength at yield of between about 4000 psi and 6500 psi.

23. The multilayer dental aligner of claim 21 , wherein the first layer has a flexural modulus greater than 150,000 psi.

24. The multilayer dental aligner of claim 21 , wherein the first second layer has a flexural modulus greater than 35,000 psi.

25. The multilayer dental aligner of claim 21 , wherein the first second layer has a compression set at about 70° C. of greater than 40% after 24 hours.

26. The multilayer dental aligner of claim 21 , wherein the first layer is coextruded with or laminated to a third layer.

27. The multilayer dental aligner of claim 21 , wherein the polymer layers of the multilayer sheet further comprises a third layer disposed between the first layer and the second layer.

28. The multilayer dental aligner of claim 21 , wherein the polymer layers of the multilayer sheet further comprises a third layer, and wherein the third layer comprises a same or different co-polyester.

29. The multilayer dental aligner of claim 21 , wherein the polymer layers of the multilayer sheet further comprises a third layer, and wherein the third layer comprises a same or different thermoplastic polyurethane elastomer.

30. The multilayer dental aligner of claim 21 , wherein the first layer is thicker than the second layer.

Assignees

• Align Technology Inc

Inventors

• Li Chunhua
• Chen Yan
• Pudleiner Heinz
• Meyer Klaus
• Nickel Joerg
• Pehlert Craig

Classifications

• A61C7/08 Primary

  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 title

• B29C51/14

  using multilayered preforms or sheets · CPC title

• B32B7/022

  Mechanical properties · CPC title

• B32B25/08

  of synthetic resin · CPC title

• B32B25/20

  comprising silicone rubber · CPC title