Thermoforming multiple aligners in parallel

Patent metadata

Field	Value
Publication number	US-2021237333-A1
Application number	US-202117225925-A
Country	US
Kind code	A1
Filing date	Apr 8, 2021
Priority date	Mar 15, 2019
Publication date	Aug 5, 2021
Grant date	—

Abstract

A system is configured to manufacture an aligner. The system includes a heating section configured to heat a sheet of plastic to generate a heated sheet of plastic. The system further includes a plate configured to secure a mold associated with a dental arch of a patient. The plate includes a keyway and a pin. The mold includes a first feature configured to interface with the keyway and a second feature configured to interface with the pin. The system further includes a thermoforming chamber configured to thermoform the heated sheet of plastic to the mold that is secured to the plate via a first interface of the keyway with the first feature and a second interface of the pin with the second feature to generate a thermoformed sheet of plastic. The system further includes a cutting tool configured to trim the aligner from the thermoformed sheet of plastic.

First claim

What is claimed is:

1 . A system configured to manufacture an aligner, the system comprising:
a heating section configured to heat a sheet of plastic to generate a heated sheet of plastic; a plate configured to secure a mold associated with a dental arch of a patient, the plate comprising a keyway and a pin, wherein the mold comprises a first feature configured to interface with the keyway and a second feature configured to interface with the pin; a thermoforming chamber configured to thermoform the heated sheet of plastic to the mold that is secured to the plate via a first interface of the keyway with the first feature and a second interface of the pin with the second feature to generate a thermoformed sheet of plastic; and a cutting tool configured to trim the aligner from the thermoformed sheet of plastic.

2 . The system of claim 1 , wherein the first feature is a recess formed in a lower surface of the mold, and wherein the first feature is shaped to interface with the keyway to prevent change in orientation of the mold on the plate.

3 . The system of claim 1 , wherein the second feature is a recess formed in a lower surface of the mold, and wherein the second feature is shaped to interface with the pin to prevent movement of the mold in a plane defined by the plate, the plane comprising an x-direction and a y-direction on the plate.

4 . The system of claim 1 , wherein the mold further comprises a third feature configured to interface with a locking mechanism of the plate, and wherein the mold is further secured to the plate via the third feature.

5 . The system of claim 4 , wherein the third feature is a hole formed in the mold, wherein the locking mechanism is configured to extend through the third feature and overlap an upper surface of the mold to lock the mold in a z-direction that is orthogonal to a plane defined by the plate.

6 . The system of claim 1 , further comprising a loading station configured to secure the sheet of plastic to a pallet, wherein the sheet of plastic is to be surrounded with a mask prior to heating the sheet of plastic.

7 . The system of claim 6 , wherein the pallet comprises holding pins configured to pierce the sheet of plastic to secure the sheet of plastic to the pallet.

8 . The system of claim 1 , wherein an angle and position of the cutting tool are configured to be controlled to trim the thermoformed sheet of plastic along one or more trim lines.

9 . A system configured to manufacture an aligner, the system comprising:
a heating section configured to heat a sheet of plastic to generate a heated sheet of plastic; a plate configured to secure a mold associated with a dental arch of a patient, the plate comprising a locking mechanism and a pin, wherein the mold comprises a first feature configured to interface with the locking mechanism and a second feature configured to interface with the pin; a thermoforming chamber configured to thermoform the heated sheet of plastic to the mold that is secured to the plate to generate a thermoformed sheet of plastic; and a cutting tool configured to trim the aligner from the thermoformed sheet of plastic.

10 . The system of claim 9 , wherein the first feature is a hole formed in the mold, wherein the locking mechanism is configured to extend through the hole and overlap an upper surface of the mold to lock the mold in a z-direction that is orthogonal to a plane defined by the plate.

11 . The system of claim 9 , wherein the second feature is a recess formed in a lower surface of the mold, and wherein the second feature is shaped to interface with the pin to prevent movement of the mold in a plane defined by the plate, the plane comprising an x-direction and a y-direction on the plate.

12 . The system of claim 9 , further comprising a loading station configured to secure the sheet of plastic to a pallet, wherein the sheet of plastic is to be surrounded with a mask prior to heating the sheet of plastic.

13 . The system of claim 12 , wherein the pallet comprises holding pins configured to pierce the sheet of plastic to secure the sheet of plastic to the pallet.

14 . The system of claim 9 , wherein an angle and position of the cutting tool are configured to be controlled to trim the thermoformed sheet of plastic along one or more trim lines.

15 . A system configured to manufacture an aligner, the system comprising:
a heating section configured to heat a sheet of plastic to generate a heated sheet of plastic; a plate configured to secure a mold associated with a dental arch of a patient, wherein the mold comprises one or more features, wherein the one or more features are each configured to interface with a corresponding feature of the plate; a thermoforming chamber configured to thermoform the heated sheet of plastic to the mold that is secured to the plate via each corresponding interface of each of the one or more features with the corresponding feature of the plate to generate a thermoformed sheet of plastic; and a cutting tool configured to trim the aligner from the thermoformed sheet of plastic.

16 . The system of claim 15 , wherein the one or more features comprise a recess formed in a lower surface of the mold, and wherein the recess is shaped to interface with a keyway of the plate to prevent change in orientation of the mold on the plate.

17 . The system of claim 15 , wherein the one or more features comprise a recess formed in a lower surface of the mold, and wherein the recess is shaped to interface with a pin of the plate to prevent movement of the mold in a plane defined by the plate, the plane comprising an x-direction and a y-direction on the plate.

18 . The system of claim 15 , wherein the one or more features comprise a hole formed in the mold, wherein a locking mechanism of the plate is configured to extend through the hole and overlap an upper surface of the mold to lock the mold in a z-direction that is orthogonal to a plane defined by the plate.

19 . The system of claim 15 , further comprising a loading station configured to secure the sheet of plastic to a pallet, wherein the sheet of plastic is to be surrounded with a mask prior to heating the sheet of plastic.

20 . The system of claim 19 , wherein the pallet comprises holding pins configured to pierce the sheet of plastic to secure the sheet of plastic to the pallet.

21 . The system of claim 15 , wherein an angle and position of the cutting tool are configured to be controlled to trim the thermoformed sheet of plastic along one or more trim lines.

22 . The system of claim 15 , wherein the one or more features of the mold comprise a first feature and a second feature, wherein the mold is to be secured to the plate via a first interface of a first corresponding feature of the plate with the first feature of the mold and a second interface of a second corresponding feature of the plate with the second feature of the mold.

Assignees

• Align Technology Inc

Inventors

• Aguilar Mendez David
• Martínez González Luis Carlos
• Rito Martinez Mario Alfonso

Classifications

• B29C51/422

  to produce a temperature differential (B29C51/426 takes precedence) · CPC title

• B29C51/14

  using multilayered preforms or sheets · CPC title

• B29C51/22

  rotatable about an axis · CPC title

• B29C51/261 Primary

  Handling means, e.g. transfer means, feeding means (B29C51/44 takes precedence) · CPC title

• B29C51/18

  Thermoforming apparatus · CPC title