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  • 专利说明
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    • 专利摘要:
    "PRODUCTION METHOD OF A PHYSICAL PROTOTYPE THAT REPRESENTS A COMPOSITE FORMAT OF THE PATIENT'S DENTAL ARCADE AND THE POSITIVE FORMAT OF A SET OF ANALOGS, PHYSICAL PROTOTYPE, PARTS KIT AND A METHOD OF PRODUCTION OF A METHOD OF PRODUCTION OF A METHOD OF PRODUCTION invention refers to a method for producing a physical prototype, the method comprises the steps of providing a virtual dental arch, a virtual set of orthodontic brackets for the virtual dental arch and a virtual set of analogues. Each analogue is associated with a virtual bracket of the set of brackets and the format of at least one of the analogs differs from the format of the associated bracket. The method further comprises the steps of providing a virtual prototype in which the virtual dental arch and the set of virtual analogues are combined, and making the physical prototype based on the virtual prototype. The physical prototype represents a shape composed of the shape of the dental arch and the shape of the set of analogues. The invention facilitates the attachment of brackets to a patient's teeth.
    公开号:BR112015013508B1
    申请号:R112015013508-0
    申请日:2013-12-04
    公开日:2021-02-23
    发明作者:Dietmar Blees；Ralf M. Paehl；Ralf Schlimper
    申请人:3M Innovative Properties Company；
    IPC主号:
    专利说明:

    FIELD OF THE INVENTION
    [001] The invention relates to a method for manufacturing a physical prototype that represents a shape composed of the shape of a patient's dental arch and the shape of a set of analogues. The analogs approximate or replicate the orthodontic bracket format. The physical prototype particularly represents a precise position of the brackets and facilitates the manufacture of a transfer tray for the brackets. BACKGROUND OF THE INVENTION
    [002] Orthodontic brackets are used in orthodontic treatments to move one or more teeth from an initial position (sometimes called a malposition or malocclusion) to a desired position in a patient's dentition. For example, through orthodontic treatment, the patient's teeth can be moved so that the sides of the lips are aligned with each other, to achieve or maximize a pleasing appearance from the aesthetic point of view of the entire dentition. In addition, in some cases, one or more teeth can be moved to correct a malocclusion. The movement of teeth is typically achieved by a pre-pulled elastic archwire that is fixed, via brackets, to the teeth, and which applies a force to the teeth in the direction of the desired position over a longer period of time.
    [003] The brackets are typically glued to the patient's teeth and the elastic thread is connected to the brackets. The wire is typically shaped to match the position of the brackets in the desired position of the teeth, so that at the initial position of the teeth, the wire can be connected to the brackets only under pre-tensioning. Consequently, the wire (archwire), once installed in the brackets, is elastically deformed or pre-tensioned in the initial position of the teeth and the restoring force to return to the undeformed shape of the wire, causes the teeth to be pushed in the direction of the desired position.
    [004] The so-called treatment planning systems have been used to determine the desired position of the teeth in a computer simulation before any real treatment. Such a planning system helps, for example, to avoid collisions between the teeth and the brackets in the positions of the tooth outside the initial position, and also allows the brackets and the wire to be designed and arranged to correspond to a series of clinical situations, for example. example, with the position of the teeth in the initial position, in the desired position and positions in between. In particular for lingual brackets, such treatment planning is widely used. Often, lingual brackets are individually designed for each tooth and patient because, in addition to the lip surfaces of a tooth, the lingual surfaces can vary greatly in shape from one another, so that one shape simply cannot be used. bracket "one fits all". Some treatment planning systems also allow you to design custom brackets that precisely match a tooth surface and a patient's required clinical situations. Consequently, custom brackets typically have to be placed precisely at the positions on the teeth that are predetermined during treatment planning. To facilitate accurate positioning of brackets on a patient's teeth and for reference by the orthodontist, brackets are often supplied pre-positioned in a plaster model that replicates the patient's teeth.
    [005] Such a plaster model, in which the brackets are placed, is sometimes used in orthodontics to make a so-called transfer tray to facilitate the positioning of the bracket on a patient's teeth. Typically, a transfer tray is adapted to hold a complete set of brackets in the predetermined position and allow the brackets to be placed and attached to the teeth in one step.
    [006] For example, US 7,020,963 features an indirect connection device that is made by initially placing spacer material in a replica of the patient's tooth structure. Then, a tray is formed on the spacer material and hardened. Then, the spacer material is removed from the replica of the teeth and orthodontic appliances are placed on the replica in the desired locations. A matrix material is placed between the tray and the replica and is allowed to harden. The tray and the brackets (which are embedded in an internal wall of the tray) are then separated from the plaster model.
    [007] In another example as revealed in WO 01/80761, treatment planning software virtually superimposes brackets on teeth to generate a three-dimensional model that comprises three-dimensional teeth plus virtual brackets in their intended locations. This three-dimensional model is supplied to a stereolithography instrument (SLA - stereo lithography) to manufacture a plastic model of the teeth with the brackets superimposed on them. A thermoplastic sheet is placed above the SLA model and the model and sheet are placed inside a pressure chamber. The chamber is pressurized so that the sheet surrounds the dentition and the brackets. Thus, the sheet obtains small indentations where the brackets can be located.
    [008] Although a variety of different solutions for accurate positioning of brackets are available, there is still a desire to provide a solution that helps to maximize positioning accuracy and minimize orthodontic treatment costs. DESCRIPTION OF THE INVENTION
    [009] The invention, in one aspect, relates to a method for manufacturing a physical prototype as defined in claim 1. The physical prototype represents a shape composed of the positive shape of a patient's dental arch and the positive shape of a set of analogues. The positive shape of a patient's dental arch and the positive shape of a set of analogues, preferably overlap additively, for example, without overlapping and positioned directly in an adjacent position. The shape of the dental arch and the set of analogues together preferably form a contiguous piece, for example, they cannot be assembled from pre-finished analogues, on the one hand, and a pre-finished dental arch, on the other hand .
    [010] The method comprises the steps of: - providing a virtual dental arch that replicates at least part of a patient's dental arch; - supply a virtual set of orthodontic brackets to the virtual dental arch; - provide a virtual set of analogues, each analog being associated with a virtual bracket of the virtual set of brackets, in which one or more of the virtual analogs approximate the formats of their associated virtual brackets; - in which the formats of said one or more of the analogues differ, each, from the formats of its associated brackets; - provide a virtual prototype in which the virtual dental arch and the set of virtual analogues are combined; and - manufacture the physical prototype based on the virtual prototype.
    [011] The invention can be advantageous in the preparation of a transfer tray for brackets. In particular, the invention preferably makes it possible to provide a transfer tray in which the brackets can be removably placed and positioned without substantially damaging the transfer tray. The invention is also advantageous in that the brackets are preferably easily placed in the tray. In particular, a user who places a bracket in the tray can recognize a noticeable "snap fit" feedback once the bracket is placed in the proper position. In addition, a transfer tray prepared by the use of the invention preferably allows the precise positioning of the brackets, but the removal of the brackets with relatively low forces. Thus, such a tray, after use to stick the brackets to a patient's mouth, can be easily removed, whereby the risk of destroying (detaching) the brackets can be minimized. In addition, a physical prototype, as can be obtained by the method of the invention, typically allows the production of a transfer tray by the dentist or orthodontist. Therefore, there may be no need to obtain a transfer tray from a dental laboratory. This allows, for example, to remake a tray, or a partial tray, in the case of a bracket detaching from a patient's tooth. Additionally, the invention makes it possible to provide a physical prototype in which the position of the brackets with respect to the dental arch is provided without manual assembly tolerances. Thus, a transfer tray replicated from the prototype is preferably adapted to precisely position the brackets in relation to a patient's teeth. The invention is particularly advantageous in that it allows a "digital workflow" between an orthodontist and a bracket manufacturer to prepare the brackets and transfer tray. In particular, the orthodontist may not need to send a physical plaster cast of the patient's poorly positioned teeth to the bracket manufacturer. In addition, the preparation of the physical prototype can help to minimize the time for preparation because an assembly step to manually place the analogs or brackets on a physical model of the dental arch is not necessary.
    [012] For the purpose of this specification, the term "virtual" refers to a three-dimensional computer representation of an object, preferably based on a mathematical representation of a three-dimensional format in the form of data and which can be processed by a computer Such virtual objects in the form of data, including their visualizations (for example, wire frames or digital versions) are widely known in the field of Computer Aided Design (CAD).
    [013] For the purpose of this specification, the term "set of" refers to "a plurality of". In one embodiment, one or more of the set of virtual analogues represents the format of the associated virtual bracket, while the remaining virtual analogues of the same set of virtual analogues only approximate the format of the associated virtual bracket. In this modality, the format of an analogue, representing the format of the associated virtual bracket, preferably corresponds, substantially exactly, in format, to the format of the respective associated virtual bracket. The term "substantially exactly", in this respect, means that the formats are exactly identical, except for the possible presence of tolerances that may result from the manufacture of analogues. Additionally in this modality, the format of an analogue that approximates the format of the associated virtual bracket, preferably differs from the format of the respective associated virtual bracket. Preferably, the shape of an analogue that approximates the shape of the associated virtual bracket extends beyond the contours of the shape of the associated virtual bracket.
    [014] In one embodiment, the method comprises capturing a shape of a patient's dental arch and thus providing the virtual dental arch. The shape of a patient's dental arch can be captured by intra-oral scanning of at least parts of the patient's dentition, which includes the teeth, or by scanning a physical model, for example, of a mold in plaster of a patient's teeth. Scanning devices that provide a virtual dental arch in the form of data are available, for example, under the designation Lava ™ Scan ST and Lava ™ Chairside Oral Scanner C.O.S, both from 3M Deutschland GmbH.
    [015] In one modality, the method additionally comprises the step of positioning the virtual brackets in relation to the virtual dental arch. There are treatment planning systems that allow you to design and / or position virtual brackets in relation to a virtual dental arch with the aid of a computer. Such a system is described, for example, in US 7,811,087. Virtual brackets can be at least partially designed and / or retrieved from a database. Each bracket can be automatically and / or manually positioned in relation to a virtual tooth that is in the virtual dental arch.
    [016] In another modality, the method comprises the step of modifying the format of at least one virtual bracket to form at least one among the virtual analogues. Such modification is preferably carried out with the aid of a computer, for example, through the use of a CAD technique. Consequently, the person skilled in the art will recognize several possibilities for modifying a format, for example, by altering an existing format, adding or removing a format, virtually copying, cutting, extending, reducing or another suitable technique. The original format of any modified virtual bracket is preferably stored on the computer. In this way, the original virtual bracket may be available to manufacture a physical bracket.
    [017] The set of analogs can be provided assuming that the modified and unmodified virtual brackets form the set of analogues, by providing a virtual copy of any modified bracket and assuming any virtual bracket unchanged as analogue, or by providing a virtual copy of the altered and unchanged virtual brackets to create the analogues. The person skilled in the art will be able to create the set of analogues in any suitable mode, for example, using functions available in a CAD system, to provide a set of analogues in which the format of at least one of the analogues is different from the format associated bracket.
    [018] In one mode, the modification step comprises increasing a three-dimensional volume represented by the virtual bracket by selectively modifying only a portion of the bracket. For example, the modification step may comprise a flattening or reduction of an indentation present in the bracket format. The modification step may additionally comprise at least partially filling a space between portions of the bracket shape, or adding a virtual structure to the bracket shape. These cutouts underneath that can obstruct the placement of the brackets in the tray or, eventually, prevent a transfer tray from being removed, can be minimized. In addition, the modification step may optionally comprise reducing the three-dimensional volume by means of the selective modification of another portion of the bracket. For example, the modification step may comprise an edge rounding to take into account the abrasion of a physical bracket during a surface treatment step (for example during burr removal or polishing). In addition, the modification step may comprise maintaining, or substantially, at least a portion of the original format of the virtual bracket. In this way, the format of each virtual analogue can correspond substantially at least partially to the format of a virtual bracket of the virtual set of brackets.
    [019] In one embodiment, the physical prototype is produced by additive manufacturing, for example, a rapid prototyping or training technique. Such additive manufacturing is also sometimes referred to as stereolithography (SLA - Stereolithography) or 3D printing.
    [020] In another mode, the method comprises the step of providing a transfer tray for the set of brackets. The transfer tray is preferably provided through physical replication of the negative shape of at least part of the physical prototype. The step of providing the transfer tray may comprise providing a curable, pasty or liquid material, for example, a curable material. Suitable materials can be selected from among.
    [021] Preferably, the curable material is transparent or substantially transparent at least when cured.
    [022] In one embodiment, the method comprises the steps of: - providing an elastic cover to the physical prototype to cover at least part of the prototype tooth side by the cover; - provide a plastic cover to the prototype with the elastic cover being arranged between the plastic cover and the prototype; - deform the plastic cover over the prototype in such a way that it securely engages at least the tooth side of the prototype with the elastic cover contained between the plastic cover and the prototype; - replace the elastic cover with a pasty material or hardenable liquid; and - allowing the curable material to harden.
    [023] In a particular aspect, the invention is directed to a method of production of a transfer tray, comprising the steps of: - providing a physical prototype in a format that resembles or corresponds to a positive format of the dental arch of a patient with a set of brackets; - provide an elastic cover to the physical prototype to cover at least part of the prototype tooth side by the cover; - provide a plastic cover to the prototype with the elastic cover being arranged between the plastic cover and the prototype; - deform the plastic cover in relation to the prototype so that it securely encloses at least the tooth side of the prototype and so that it contains the elastic cover between the plastic cover and the prototype; - replace the elastic cover with a pasty material or hardenable liquid; and - allowing the curable material to harden.
    [024] The elastic covering can be produced from a material selected from dental impression materials, preferably having a Shore A hardness of about 20 after hardening, and can have a thickness within a range of about 2 to about 5 mm. The elastic covering preferably has a size (or area) that is suitable for wrapping at least part of the sides of the lip, the sides of occlusion and at least part of the lingual sides of the teeth represented in the physical prototype. Additionally, the elastic cover can be dimensioned to involve the entire physical prototype or multiple physical prototypes. In this way, the elastic cover may have a U-shape along a path that roughly corresponds to the path along which the occlusion sides of the teeth are arranged in the prototype. Alternatively, the elastic cover can be dimensioned to cover, in general, at least one projection area of one or more physical prototypes in a plane approximately parallel to the occlusion sides of the teeth in the prototype.
    [025] The plastic cover (or plastically deformable cover, for example thermoplastic deformable) can be produced, for example, from Duran® available from Scheu Dental, Germany, and can have a thickness within a range of about 0 , 5 to about 1.5 mm. The plastic cover may have a size (or area) that corresponds to the size of the elastic cover, but is preferably a larger size.
    [026] The plastic cover is preferably deformed by gas pressure, for example by applying a pressure or vacuum only to one side of the cover to cause a relative pressure difference on the other side and thus causing the deformed coverage in relation to the prototype. The plastic cover can be heated before and / or during the deformation process to soften the material of which the plastic cover is made. This, so-called, thermoforming, can be done using a thermoforming device, for example as available under the designation 508DT, from Formech Inc., Chicago, IL, USA.
    [027] Preferably, the plastic cover is deformed so that it, together with the elastic cover, firmly envelops the teeth represented in the prototype. Thus, the elastic covering preferably acts as a spacer layer, causing the plastic covering to form around the teeth at a certain distance determined by the thickness of the elastic covering.
    [028] To replace the elastic cover with a pasty material or hardenable liquid, the plastic cover, if it is thermoformed, is naturally cooled, preferably. Thus, the plastic cover preferably obtains sufficient stiffness to be handled. The plastic cover and elastic cover can be removed from the physical prototype, and the elastic cover can be removed from the plastic cover. The plastic cover, after deformation, may have a indentation generally in the form of a recess, which approximates a proportional enlarged format, from the three-dimensional point of view, of the teeth (including the analogues) represented in the physical prototype. The indentation can be filled with the hardenable material that can be selected from Kanisil® and Odontosil ™. The prototype can be fitted to the deformed plastic cover in order to enclose the hardenable material between the prototype and the cover. The quantity of the curable material is preferably selected, so that during the pairing of the prototype and the cover, the curable material flows around (preferably to embed the relevant parts) of the teeth and analogues represented in the prototype. To minimize empty spaces or bubbles between the teeth and the curable material, the fitted prototype, the curable material and the cover can be exposed to a vacuum or pressure, for example, through the use of an autoclave or pressure chamber. Subsequently, the curable material can be allowed to harden or it can be cured. The hardened flowable material is preferably elastic and has a Shore hardness between about 50 shore A and 70 shore A, preferably about 60 Shore A. Preferably, the hardened flowable material and the deformed cover, in combination, form the transfer tray.
    [029] The prototype and the transfer tray, in a situation of fitting with each other, preferably define one or more axes of reference along a direction in which the transfer tray is at least partially removable from the prototype . Different sections (for example a section of a tooth) of the prototype and the transfer tray may define different reference axes (or slightly different reference axes), however, below, reference is made as a reference axis only, for the sake of simplicity. The modification of the shape of one or more of the brackets preferably comprises a reduction or elimination of a cut underneath formed by at least one of the brackets and suitable for locking or retaining the transfer tray against movement along the reference axis . In other words regarding a bracket shape, the shape of the associated analog can provide less retention of the transfer tray paired in the physical prototype.
    [030] In one embodiment, the transfer tray replicates the negative shape of only part of the physical prototype, for example the shape of only one analog and the shape of at least part of a tooth in the dental arch. A partial transfer tray may, for example, allow a bracket to be replaced or replaced in a patient's mouth. The prototype can be adapted so that the transfer tray obtains one or more separation markers at predetermined positions. A transfer tray user can separate (for example, cut) the tray on a separation marker and thereby obtain a partial transfer tray. The prototype can therefore be provided so that it comprises one or more ridges or ridges that replicate the corresponding recesses or notches in the tray. Instead of or in addition to a separation marker, a placeholder in the prototype can be provided in the form of a raised or recessed structure, such as, for example, a placeholder that indicates the center of a tooth. In addition, the prototype can be supplied so that it comprises raised or lowered numbers that indicate the number and / or the number of the tooth quadrant. In another modality, the method comprises the step of placing one or more brackets in respective one or more receptacles, in which each receptacle corresponds to the negative shape of an analog associated with the bracket. This can be done bracket by bracket manually or by taking a set of brackets pre-positioned on a physical model of the patient's teeth, in which the empty transfer tray (without the brackets) is fitted to the physical model of the patient's teeth including brackets and separating the transfer tray from the patient's teeth model. In the last step, the brackets, preferably, are retained in the transfer tray and are released from the model. This can be achieved through a relatively light temporary bond between the brackets and the model.
    [031] In another aspect, the invention relates to a physical prototype obtained from the method of any of the preceding claims.
    [032] In yet another aspect, the invention relates to a kit of parts, which comprises: - a set of brackets being adapted to be placed in a patient's dental arch, and - a physical prototype representing a format composed of the positive shape of a patient's dental arch and a positive shape of a set of analogues, in which each is associated with the shape of a bracket in the set of brackets, and - in which the shapes of one or more of the analogues, approximate those formats of its associated brackets; and - in which said one or more of the analogs each has a different format than its associated brackets.
    [033] In one embodiment, the kit comprises a transfer tray to place the set of brackets in a patient's dental arch. Such a transfer tray can be used to transport the brackets from the bracket manufacturer to a dentist or orthodontist, and / or to glue the brackets on a patient's teeth in a position predetermined by the transfer tray.
    [034] In another modality, the kit additionally comprises one or more wires for assembly with the set of brackets. BRIEF DESCRIPTION OF THE DRAWINGS
    [035] Figure 1 is a perspective view of a physical prototype according to an embodiment of the invention;
    [036] Figure 2 is an enlarged partial view of Figure 1;
    [037] Figure 3 is a schematic cross-sectional view of a virtual prototype according to an embodiment of the invention; and
    [038] Figures 4 to 11 are schematic cross-sectional views that illustrate a method of producing a transfer tray according to an embodiment and aspect of the invention. DESCRIPTION OF ACCOMPLISHMENTS OF THE INVENTION
    [039] Figure 1 shows a physical prototype 1 representing a shape composed of the positive shape of a patient's dental arch 2 and the positive shape of a set of analogs 3 (for the sake of clarity, not each of the shown analogs is referred to by a reference line in the figure). Analogues 3 represent or approximate orthodontic brackets as they are used, in combination with a wire, to move a patient's teeth from a poor position in the direction of a desired position. In physical prototype 1, a patient's teeth are represented as being poorly positioned, as illustrated in more detail in Figure 2.
    [040] Physical prototype 1 can be used to shape, from a physical point of view, a transfer tray (not shown in this Figure) to glue brackets in a predetermined position by the transfer tray on a patient's teeth. The transfer tray forms a negative replica of at least part of the physical prototype 1. Such a transfer tray can be obtained, for example, by taking an impression of the physical prototype 1, by molding with overlapping of the physical prototype 1 or with another technique in which the positive physical model 1 is used, preferably directly, forming a negative replica. Physical model 1 is preferably configured to provide predetermined lower cuts that, on the one hand, allow orthodontic brackets to be retained or secured within the transfer tray, but on the other hand, facilitate removal of the transfer tray from the prototype physical 1 or a patient's teeth without destroying the transfer tray or breaking a bracket, removing it from a patient's teeth. Due to the fact that the shape of orthodontic brackets often forms lower cuts that hinder or block non-destructive removal of the transfer tray, brackets are represented in physical prototype 1 by analogs 3 that may not form exact replicas of brackets, but they only approach the shape of the bracket to control lower cuts towards a desired level. It is noted, however, that a bracket that fits the desired level of lower cuts can be represented by an analogue that forms an exact replica of that bracket, while a bracket that forms an undesired lower cut, can be represented by an analogue that has an approximate shape of such a bracket. Consequently, a transfer tray replicated from the physical prototype obtains, preferably, a shape that has the level of cutouts that allows the retention of the brackets and the non-destructive removal of a patient's teeth.
    [041] Physical prototype 1 in the example is produced by additive manufacturing and thus dental arch 2 and analogs 3 are formed in one piece on physical prototype 1. Physical prototype 1 may, in particular, not be obtained or consist of of a set of analogs 3 in the dental arch 2. Consequently, the position of the analogs 3 in relation to the dental arch 2 can be determined with the aid of a computer and manual assembly tolerances can be avoided.
    [042] The manufacture of the physical prototype in this example is based on a virtual prototype prepared on a computer system. Such a virtual prototype preferably corresponds to a mathematical representation of a three-dimensional format that can be processed by a computer, for example, a CAD (Computer Aided Design) system. In addition, the virtual prototype is preferably available in the form of computational data that can be used to control an additive manufacturing machine to produce the physical prototype in a format as defined by the virtual prototype. The virtual prototype can be designed or generated by superimposing or merging a patient's virtual dental arch with a set of virtual analogues, as additionally described in Figure 3.
    [043] Figure 3 shows a cross section of a virtual prototype 10. Virtual prototype 10 combines the format of virtual analogues (in this view represented by virtual analog 12) and the shape of a virtual dental arch 11. Virtual analog 12 and the virtual dental arch 11 can be obtained from separate independent virtual parts, or by supplying the dental arch 11 and adding the virtual analog 12 to the dental arch 11 with the aid of a computer, for example, by the additive design or modification of the dental arch 11. The person skilled in the art will be able to use other techniques, as known in the field of Computer Aided Projects, to provide the virtual prototype 10 and to combine the formats of the virtual analogues and the virtual dental arch.
    [044] In the example, virtual analog 12 is obtained based on (for example, by modifying) a virtual bracket 13. In the example, it refers to a lingual bracket that is designed and manufactured, typically, individually for each tooth and patient. The person skilled in the art will recognize, however, that, although the present invention may provide certain advantages in the use of lingual brackets, it can be used, in the same way, in combination with lip brackets or a combination of lingual and lip brackets. One possibility of providing a virtual bracket is described, for example, in US 7,811,087. The bracket design can be done on a computer that stores a patient's three-dimensional virtual dental arch. The virtual dental arch can be obtained by scanning the patient's teeth or a physical model of the patient's teeth. In this way, the shape of a patient's dental arch, comprising the shape of the teeth and the relative position between them, can be provided in the form of a computer-processing representation. The computer can be equipped with a so-called treatment planning software that allows you to move the teeth in the virtual model to desired end positions. An important element of the bracket is the block through which the bracket is connected to a tooth. The geometry of the tooth-oriented block can be derived directly from tooth geometries represented in the virtual dental arch so that the block obtains a three-dimensional surface that fits substantially exactly on the corresponding tooth surface. This allows for relatively accurate positioning of the bracket on the tooth and helps to maximize bond strength. Another part of the bracket, the bracket body, which contains a slot for receiving a wire and other resources that allow the wire to be fixed in the slot, may be available on the computer as predefined virtual models, for example, in the form of a library of bracket bodies. To provide a virtual set of brackets for the virtual dental arch, certain predefined virtual structures can be defined. The bracket bodies are preferably aligned with their slits in relation to each other, for example, so that a virtual U-shaped wire can pass through the slits of all brackets. Once the slot position of the bracket bodies has been determined, the bracket bodies and the respective bracket blocks can be combined, for example, virtually fused to form the virtual bracket set. Common Computer Aided Design (CAD) programs have capabilities (for example, Boolean operations) to connect existing formats together. Optionally, the design of the virtual brackets, or parts of the brackets, can be adapted to take into account good articulation, hygiene requirements or other aspects, as needed.
    [045] Virtual brackets are used to provide the set of analogues based on them. Each analogue in the analogue group is associated with a virtual bracket of the virtual bracket set. In the example, virtual analog 12 and virtual bracket 13 are associated and have the same shape in the first areas 12a, 13a, however they have different shapes in the second areas 12b, 13b. In particular, the second areas 12b of the virtual analogue 12 comprise lower cuts reduced in relation to the lower cuts present in the second areas 13b of the virtual bracket 13. In the example, the lower cuts are structures that retain (in a physical prototype) an imaginary replica 20 against a separation of the virtual prototype 10 in a R direction. Thus, the reduced lower cuts in the second areas 12b of the analogs 12 are dimensioned to provide less retention than the lower cuts in the second areas 13b of the brackets 13. Therefore, in relation to to the shape of the bracket 13, the shape of the analogue 12 is adapted to facilitate the removal of a transfer tray that is made based on that shape of the analogue. As mentioned, one or more of the virtual analogs can substantially exactly match the format of the virtual bracket, although in most cases, the format of virtual analogs and the shape of virtual brackets may differ at least in areas that comprise lower cuts.
    [046] Virtual analogues can be provided by virtually replicating virtual brackets and eventually redrawing one or more portions of the replicated virtual bracket format. The computer may be able to determine a virtual holding force depending on the lower cuts present in one or more of the analogues. For example, a substantial and / or high number of lower cuts present in a set of analogues can lead to a relatively high holding force, while a substantially smaller and / or lesser number of lower cuts can lead to a more virtual holding force low. Consequently, the computer can be adapted to display a virtual holding force and, optionally, upper and lower limits for a desired virtual holding force for a user. Consequently, the user can adjust the lower cuts of the analogues by drawing. In this way, the retention force of the transfer tray in relation to the physical model can be determined during the virtual project, which can minimize the need to physically adjust the physical prototype and / or the transfer tray.
    [047] To provide a virtual prototype, the virtual dental arch and the set of virtual analogues can be combined, for example, fused or overlaid with the aid of the computer. The virtual prototype, which is preferably present in the form of three-dimensional data that can be processed by a computer, can be transmitted to an additive manufacturing machine that produces the physical prototype based on the virtual prototype.
    [048] Figure 4 shows a physical prototype 20 that has a set of analogues, where analog 22 is representative of this set in the Figure. The physical prototype 20 also represents the dental arch of a patient 21 which is represented by a tooth 21 '. Analog 22 and tooth 21 'are formed in one piece, and, in particular, are not assembled, but formed in a contiguous volume of material. Additionally, although not shown in the example, the complete set of analogues and the dental arch are formed in one piece. Analog 22 has a lower cut area 22b which, with respect to a lower cut area 23b (illustrated in dotted / dashed lines) of an imaginary associated bracket, is reduced. Note that the physical prototype 20 does not really include the brackets, and a part of a bracket is provided in the Figure just to illustrate the geometric difference between analog 22 and the associated bracket.
    [049] Physical prototype 20 in the example, is made of a light curable material, but in other examples, it can be made of a plastic material (for example, cast from a plastic fiber), metal, metal, natural plaster , cement or other chemically curable materials.
    [050] Figure 5 shows the physical prototype 20 with an elastic cover 24 and a plastic cover 25. The elastic cover 24 is placed on top of the occlusion side of the teeth, represented by physical prototype 20, and on top of the elastic cover 24 , a plastic cover is provided. The elastic cover with the plastic cover is deformed, preferably by an air pressure P applied to the elastic cover and plastic cover 24, 25 towards the physical prototype 20. This can be achieved by a vacuum generated below the elastic cover and plastic 24, 25 or a pressure above the elastic and plastic covers 24, 25. At least plastic cover 25 can be heated before and / or during deformation. As a result, the elastic and plastic covers 24, 25 are deformed as shown in Figure 6.
    [051] Figure 6 shows the physical prototype 20 covered by the elastic cover 24 and the plastic cover 25. The plastic cover 25 is preferably a transparent thermoplastic film that conforms to the external surface of the elastic cover 24. Preferably, it leaves the plastic cover 25 solidifies by cooling so that it is provided with sufficient rigidity for handling. As illustrated, the elastic cover 24 spaces the plastic cover 25 of the physical prototype 20.
    [052] In another example (not shown), instead of an elastic covering, a spacer coating can be used. Such a spacer coating can be obtained by applying a solidifiable liquid or pasty material over the physical prototype 20, and allowing the material to solidify. This can be done by immersion coating, or manual coating using a syringe or dispensing brush. In the solidified state, the coating material is preferably elastic or brittle, so that it is removed from the physical prototype at a later stage. A plastic cover can be deformed over the coated prototype, as described above.
    [053] In yet another example, a spacer coating can be applied to an additive manufacturing machine along with the construction of the physical model. In such a construction process, a relatively hard material and a relatively soft material can be printed in three dimensions, with the hard material forming the physical prototype and the soft material forming the spacer coating. The soft material can be a so-called backing material, which is typically used for vertical, layer-shaped printing of vertically spaced structures and removed after printing. An additive manufacturing machine that provides such a printing process is available, for example, under the designation Projet ™ Series from 3D Systems, USA.
    [054] Figure 7 illustrates a separation of the elastic cover 24 from the physical prototype 20 and the plastic cover 25. The elastic cover 24 can be arranged and the physical prototype 20 and the plastic cover 25 can be used to form the transfer tray for brackets, as described below.
    [055] Figure 8 shows the plastic cover 25 that has a cavity formed in the plastic cover 25 through the use of the coated physical prototype, as described above. A solidifiable material, preferably transparent, 26 'is received inside the cavity of the plastic cover 25. The physical prototype 20 is fitted in the plastic cover 25 and thus, immersed in the solidifiable material 26', which in this way, preferably distributes between the external surface of the physical prototype and the internal surface of the cavity, as shown in Figure 9. Optionally, the combined physical prototype 20, the solidifiable material 26 'and the plastic cover 25 are exposed to an overpressure in relation to normal atmospheric pressure to minimize the voids or bubbles in the solidifiable material 26 ', in particular between the outer surface of the physical prototype 20 and the inner surface of the solidifiable material 26'. The solidifiable material 26 'is allowed to solidify to provide a positioning layer 26 to the brackets. The positioning layer 26 in combination with the plastic cover 25 forms the transfer tray 27. The positioning layer 26 is preferably adapted so that it can position and retain the bracket and, additionally, such that it is deformable to receive brackets in it and remove the brackets from there. Consequently, the positioning layer 26 can be produced from a relatively elastic and soft material (when solidified). Therefore, the transfer tray 27 comprises the plastic cover 25, which preferably provides the tray with the necessary mechanical rigidity and stability, and the positioning layer 26, which provides the transfer tray preferably with receptacles in which the bracket can be retained precisely and removably. The positioning layer 26 has a shape approximately corresponding to the shape of the elastic cover described above, however, preferably, it is formed of a different material.
    [056] The positioning layer 26 and the plastic cover 25 can be trimmed to match only part of a patient's dental arch or make the impression tray fit properly in a patient's mouth. For use with the transfer tray 27, as illustrated in Figure 10, brackets (represented by bracket 30) are placed in associated receptacles on the positioning layer 26. Additionally, the positioning layer 26 and the plastic cover are correlated. The combined transfer tray 27 that includes the bracket 30 placed in the positioning layer 26, as shown in Figure 11. An adhesive can be applied to the surface of the bracket block 31 (there are additional brackets present in the tray) and the transfer tray can be placed on the teeth of a patient's mouth, where the adhesive is allowed to harden, or where it is allowed to harden, to establish a connection between the brackets in the tray and the patient's teeth. Once the connection is established, the plastic cover 25 can be removed, leaving the positioning layer 26 in place on the patient's teeth. The positioning layer 26, due to its elastic properties and is no longer supported by the plastic cover 25, can thus be easily peeled off the patient's teeth and the brackets can be glued there. As shown in the Figure, the spaces between the positioning layer 26 and the bracket 30 are present in the lower cut areas of the bracket 30, thus facilitating the separation between the positioning layer 26 and the bracket 30. Therefore, the forces in the brackets attached to the patient's teeth and, thus, the risk of breaking or affecting the joints during removal of the transfer tray, are minimized.
    [057] Due to the use of transparent materials for the positioning layer 26 and for the plastic cover 25, the proper positioning of the transfer tray 27, on a patient's teeth, is facilitated. In addition, the transparent material makes it possible to visually determine the proper positioning of the clamps within the transfer tray.
    权利要求:
    Claims (8)
    [0001]
    1. METHOD OF PRODUCTION OF A PHYSICAL PROTOTYPE (20) that represents a format composed of the positive shape of a patient's dental arch (21) and the positive shape of a set of analogues (22), the method being characterized by understanding the steps to: - provide a virtual dental arch (11) that replicates at least part of the patient's dental arch (2); - provide a virtual set of orthodontic brackets (13) for the virtual dental arch (11); - provide a virtual set of analogs (12), each analogue (12) being associated with a virtual bracket (13) of the virtual set of brackets, in which one or more of the virtual analogs (12) approximate the formats of their virtual brackets (13) associates; - in which the formats of the one or more analogues (12) differ from the formats of their associated brackets (13); - in which to form at least one of the virtual analogues (12), the format of at least one virtual bracket (13) is modified, in which the modification step comprises at least partially filling a space between the portions of the formats of its brackets ; - provide a virtual prototype (10) in which the virtual dental arch (11) and the set of virtual analogues (12) are combined; and - manufacture the physical prototype (20) based on the virtual prototype (10).
    [0002]
    2. METHOD, according to claim 1, characterized by additionally comprising the step of positioning the virtual brackets (13) in relation to the virtual dental arch (11).
    [0003]
    METHOD, according to any one of claims 1 to 2, characterized in that the physical prototype (20) is manufactured by additive manufacturing.
    [0004]
    METHOD according to any one of claims 1 to 3, characterized in that it further comprises the step of providing a transfer tray (27) for the set of brackets (30) through the physical replication of the negative shape of at least part of the physical prototype (20).
    [0005]
    5. METHOD, according to claim 4, characterized by comprising the steps of: - providing an elastic cover (24) on the physical prototype (20) to cover at least part of the tooth side of the prototype (20) by the cover (24 ); - provide a plastic cover (25) on the prototype (20) with the elastic cover (24) disposed between the plastic cover (25) and the prototype (20); - deform the plastic cover (25) on the prototype (20) in such a way that it securely engages at least part of the tooth side of the prototype (20) with the elastic cover (24) contained between the plastic cover (25) and the prototype ( 20); - replace the elastic cover (24) with a pasty material or hardenable liquid; and - allowing the curable material to harden.
    [0006]
    6. METHOD, according to claim 5, characterized by the hardenable material being selected from rubber, silicone, alginate and dental impression material.
    [0007]
    METHOD, according to any one of claims 4 to 6, characterized in that the transfer tray (27) replicates the negative shape of only part of the physical prototype (20).
    [0008]
    METHOD, according to any one of claims 4 to 7, characterized in that it further comprises the step of placing one or more brackets (30) in the respective one or more receptacles, in which each receptacle corresponds to the negative shape of an analog (22 ) associated with the bracket (30).
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    同族专利:
    公开号 | 公开日
    EP2931166A1|2015-10-21|
    JP6478918B2|2019-03-06|
    BR112015013508A2|2017-07-11|
    KR102157136B1|2020-09-17|
    RU2015126462A|2017-01-17|
    AU2013359874A1|2015-07-02|
    KR20150095747A|2015-08-21|
    US10639130B2|2020-05-05|
    AU2013359874B2|2017-03-09|
    JP2016500288A|2016-01-12|
    CN104837435B|2019-11-01|
    EP2931166B1|2019-10-09|
    WO2014093084A1|2014-06-19|
    CN104837435A|2015-08-12|
    AU2017203368B2|2018-08-23|
    DK2931166T3|2019-12-16|
    RU2638618C2|2017-12-14|
    AU2017203368A1|2017-06-08|
    SG11201504611PA|2015-07-30|
    IL239299A|2020-11-30|
    IL239299D0|2015-07-30|
    US20150313687A1|2015-11-05|
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    法律状态:
    2020-04-14| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-12-08| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-02-23| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 04/12/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    EP12196586.7|2012-12-11|
    EP12196586|2012-12-11|
    PCT/US2013/073041|WO2014093084A1|2012-12-11|2013-12-04|Mockup representing a dental arch including analogs approximating orthodontic brackets and method of making the mockup|
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