Mold with separable features

Patent metadata

Field	Value
Publication number	US-9943991-B2
Application number	US-201514716607-A
Country	US
Kind code	B2
Filing date	May 19, 2015
Priority date	May 21, 2014
Publication date	Apr 17, 2018
Grant date	Apr 17, 2018

Abstract

A mold comprises a main body and a separable feature. One or more weakened regions join the separable feature to the main body. The one or more weakened regions are breakable to enable the main body to be removed from a shell independently of the separable feature after the shell is formed over the mold.

First claim

What is claimed is:

1. A method comprising:
forming a shell over a mold comprising a separable feature, wherein the separable feature of the mold is joined to a main body of the mold by one or more first weakened regions, wherein the main body comprises a first section joined to a second section by one or more second weakened regions;
separating the separable feature from the main body of the mold at the one or more first weakened regions;
at least partially separating the first section from the second section at the one or more second weakened regions;
removing the separable feature of the mold from the shell;
separately removing the first section of the main body of the mold from the shell; and
separately removing the second section of the main body of the mold from the shell.

2. The method of claim 1 , wherein the mold comprises a 3D printed mold.

3. The method of claim 1 , wherein the mold comprises a mold of a dental arch for a patient and the shell comprises at least one of an orthodontic aligner, an orthodontic retainer or an orthodontic splint to be used for at least one of aligning, retaining, or positioning one or more teeth of the patient.

4. The method of claim 1 , wherein forming the shell comprises at least one of thermoforming or pressure forming the shell over the mold.

5. The method of claim 1 , further comprising:
identifying at least one of an undercut or a complex region that will be included in the mold;
determining where in the mold to place the separable feature relative to at least one of the undercut or the complex region; and
forming the mold.

6. The method of claim 5 , wherein the one or more first weakened regions are formed during the forming of the mold.

7. The method of claim 5 , further comprising:
processing the mold after formation of the mold to introduce the one or more first weakened regions to the mold.

8. The method of claim 1 , wherein the main body of the mold is breakable, the method further comprising:
breaking the main body of the mold at the one or more second weakened regions to enable the first section to at least partially separate from the second section.

9. The method of claim 1 , wherein the separable feature is retentive, and wherein the one or more weakened regions surround the separable feature.

10. The method of claim 1 , further comprising:
forming the main body;
separately forming the separable feature; and
securing the separable feature to the main body by the one or more first weakened regions prior to forming the shell.

Assignees

• Align Technology Inc

Inventors

• Tanugula Rohit
• Te Dennis
• Webber Peter
• Sambu Shiva P
• Tjhia Crystal

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

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29C51/34 Primary

  for undercut articles · CPC title

• B29L2031/753

  Medical equipment; Accessories therefor (bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008) · CPC title

• B29L2031/757

  Moulds, cores, dies · CPC title