Abstract:
A system for straightening teeth includes a casting of teeth that is made of a rigid material, and a gum casting made of a flexible material that is joined to the teeth casting. A respective articulating tool for each tooth is provided with a post that is embedded into the tooth. Tooth moving components, accessible through the gum casting, are mounted on each post to selectively provide for left-right, fore-aft, and rotational tooth movements. In its operation, the system involves selectively orienting individual teeth in the teeth casting, to prepare a series of sequentially useable appliances that will straighten teeth in accordance with a pre-planned procedure.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention pertains generally to systems and devices for straightening teeth. More particularly, the present invention pertains to systems that involve preparing a series of sequentially useable appliances that will straighten teeth in accordance with a pre-planned procedure. The present invention is particularly, but not exclusively, useful as a plurality of articulating tools that can be selectively manipulated to respectively move individual teeth in a prosthetic dental structure for subsequent manufacture of an appliance that helps straighten teeth.  
       BACKGROUND OF THE INVENTION  
       [0002]     It is a fact that not all persons are born with beautifully straight teeth. Nevertheless, for both health and beauty reasons, it is desirable that a person have a dental structure that is characterized by properly aligned (i.e. straight) teeth. Consequently, much effort is endured by many people to achieve this goal.  
         [0003]     Heretofore, the use of braces has been widely accepted as a means for straightening teeth. Though effective for this purpose, braces necessitate many repeat visits to the dentist&#39;s office. Specifically, this happens because the dentist needs to gradually tighten the braces, rather than enforce a complete change in one sitting. That could be really painful. More recently, however, computer-generated systems have been developed that are intended to be used without requiring repeat visits to the dentist&#39;s office. Typically, these systems will include a series of appliances that are to be used sequentially, in a progression, to thereby incrementally and gradually align the teeth as desired. For example, U.S. Pat. No. 5,975,893, which issued to Chishti et al. for an invention entitled “Method and System for Incrementally Moving Teeth” discloses such a computer-generated system. Because they are computer-generated, however, such systems do not have the flexibility to selectively align individual teeth in a dental structure. More particularly, this cannot be done in a way that will remedy the specific dental alignment needs of a particular patient.  
         [0004]     In light of the above, it is an object of the present invention to provide a mechanical device for reconfiguring a model dental structure, where each individual tooth in the dental structure can be selectively realigned, individually or collectively with other teeth in the structure. Another object of the present invention is to provide a system for reconfiguring a model dental structure that creates a series of teeth straightening appliances that are customized to incrementally remedy the specific dental alignment needs of a particular patient. Still another object of the present invention is to provide a mechanical device for reconfiguring a model dental structure that is easy to use, relatively simple to manufacture and commercially cost effective.  
       SUMMARY OF THE INVENTION  
       [0005]     In accordance with the present invention, a device for reconfiguring a model dental structure includes a casting that comprises a plurality of teeth. Specifically, the teeth casting is made of a rigid material to provide an accurate physical replication of a patient&#39;s dental structure. Preferably, the rigid material is a hard durable urethane. Further, the device also includes a casting of the gum that is positioned in contact with the teeth casting. In contrast to the teeth casting, however, the gum casting is made of a relatively flexible material, such as a polyurethane elastomer. In addition to the teeth casting, and the gum casting, the device of the present invention also includes a support casting that is made of the same rigid material that is used for the teeth casting. In combination, the support casting is positioned in contact with the gum casting, with the gum casting positioned between the teeth casting and the support casting.  
         [0006]     A plurality of elongated posts are individually embedded in the gum casting, and into a respective tooth in the teeth casting. More specifically, each elongated post has a first end and a second end, with the first end of the post being embedded in a respective tooth of the teeth casting. The second end of the post is distanced from the tooth, and extends into the gum casting.  
         [0007]     A plurality of articulating tools is also provided for the device of the present invention. In particular, each articulating tool is respectively engaged with the second end of a post. Each articulating tool is also held in contact with the support casting to thereby stabilize the plurality of posts on the device. As intended for the present invention, each articulating tool can be accessed through the gum casting and manipulated to selectively, and individually, orient its respective tooth. Thus, the patient&#39;s original dental structure can be sequentially reconfigured to create a series of appliances that will successively realign and straighten the dental structure of a patient.  
         [0008]     In greater structural detail, each articulating tool includes a main shaft that defines an axis. A first component is mounted at the distal end of the main shaft to provide for back and forth movement relative to the axis, in a first radial direction. After the first component has been so moved, it can then be held in a predetermined position. There is also a second component that is mounted more distally on the first component, for back and forth movement in a second radial direction. In this case, the second radial direction is substantially perpendicular to the first radial direction. Like the first component, after the second component has been moved, it can also then be held in a predetermined position. Along with this combination, the second end of the post is mounted on the second component for universal rotation thereon. Also, there is a clamping means on the articulating tool for holding the second end of the post on the second component in a fixed manner. With the coordinated operation and manipulation of the first component, the second component, and the clamp, the articulating tool is able to spatially orient the prosthetic tooth, as desired. Preferably, the first component is moved by the action of a lead screw, while the second component is moved by a rack and pinion. Alternatively, the second component can be moved by the action of a lead screw, while the first component is moved by a rack and pinion. In either case, it is desirable that both the first component and the second component of the articulating tool be accessible for manipulation from the same direction.  
         [0009]     In the manufacture and operation of the device of the present invention, a plurality of articulating tools in combination with their respective elongated posts, are positioned in an impression of the patient&#39;s dental structure. The teeth casting is then made such that an end of each elongated post is embedded in an individual tooth of the teeth casting. Next, the gum casting is made and, finally, the support casting is made. As mentioned above, the articulating tool will be embedded within the gum casting. Importantly, for the purposes of manipulating the first and second components and for the purpose of clamping the post, each articulating tool should be accessible through the front of the gum casting.  
         [0010]     In order to use the device described herein, in preparation for the teeth being straightened, an original dental structure is created to replicate the actual dental structure of a patient. Based on this original dental structure, a user can then orient individual teeth in the teeth casting, as desired, to create a new interim dental structure. An appliance is then made of this new interim dental structure. The device can then be reconfigured, as desired, to create a subsequently different interim dental structure. Again, an appliance is made. In practice, the most recent interim dental structure is used as a new interim dental structure, and the reconfiguration process is repeated as many times as necessary. Specifically, appliances can be made for each interim dental structure until an appliance for a final dental structure is formed. Together, the various appliances create a series of differential shapes for dental structures that can be sequentially used by the patient to realign and straighten his/her teeth. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]     The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:  
         [0012]      FIG. 1  is a perspective view of an articulating tool engaged with a prosthetic tooth in accordance with the present invention;  
         [0013]      FIG. 2  is a side elevation view of the articulating tool;  
         [0014]      FIG. 3  is a front view of the articulating tool with portions shown in cross-section as seen along the line  3 - 3  in  FIG. 1 ;  
         [0015]      FIG. 4  is a perspective view of a dental impression tray with a plurality of articulating tools positioned therein, where portions of the tray have been removed for clarity; and  
         [0016]      FIG. 5  is a front view showing a plurality of articulating tools in combination with a teeth casting, a gum casting and a support casting, in accordance with the present invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0017]     Referring initially to  FIG. 1 , an articulating tool in accordance with the present invention is shown and designated  10 . There it will be seen that the articulating tool  10  includes a main shaft  12  that defines an axis  14 . Further, the tool  10  includes a component  16  that is mounted at the distal end of the shaft  12 . For purposes of this disclosure, the proximal direction is taken to be in a positive z-direction (see  FIG. 1 ), and the distal direction is therefore in the negative z-direction. As shown, the tool  10  also includes another component  18  that is mounted distally from the component  16 . More specifically, a structural interconnect  20  is provided between the component  16  and the component  18 . Additionally, the tool  10  includes a socket  22  that is integrally mounted distally on the component  18 .  
         [0018]     In  FIG. 2 , it can be clearly seen that the component  16  is associated with a lead screw  24  that is associated with the interconnect  20 . With this connection, an appropriate rotation of the lead screw  24  will cause the component  16  to move back and forth in radial directions relative to the axis  14  (i.e. alternatively in the x-directions indicated by arrows  28  and  26 ). By cross-referencing  FIG. 2  with  FIG. 3 , it will also be seen that the component  18  includes a pinion  30  that interacts with a saw-tooth rack  32  formed on the interconnect  20 . With this connection, an appropriate rotation of the pinion  30  will cause the component  18  to move back and forth in radial directions relative to the axis  14  (i.e. alternatively in the y-directions indicated by arrows  34  and  36 ). Accordingly, movements of the component  16  will be perpendicular to the movements of the component  18 .  
         [0019]     As best appreciated by cross-referencing  FIG. 1  with  FIG. 3 , the articulating tool  10  of the present invention is engageable with an elongated post  38  that is formed with a ball  40  at its proximal end.  FIG. 3  shows that the ball  40  of the post  38  is positioned in the socket  22  of the articulating tool  10 . Further, the tool  10  has a clamp screw  42  that can be rotated to tighten it against the ball  40 . This then will hold the post  38  in a stationary orientation on the tool  10 . Otherwise, as intended for the present invention, the ball  40  and socket  22  cooperate with each other to allow the post  38  to move in a universal rotation about a point at the center of the ball  40 . As indicated, however, the clamp screw  42  can be manipulated to prevent such rotation.  
         [0020]     At this point, it will be appreciated that the elongated post  38  can be selectively moved by the articulating tool  10  in several directions. In detail, translational movements of the post  38  can be made in radial directions, relative to the axis  14 . And, rotational movement of the post  38  can be made relative to the center of ball  40 . Specifically, a rotation of the lead screw  24  will move the interconnect  20 , component  18  and socket  22  with post  38  in an x-direction, perpendicular to the axis  14 . On the other hand, a rotation of the pinion  30  will move the component  18  and socket  22  with post  38  in a y-direction, also perpendicular to the axis  14 . Finally, a rotation of the clamp screw  42  can be made to hold the post  38  stationary in the joint between the ball  40  of post  38  and the socket  22  of the tool  10 .  
         [0021]     Referring now to  FIG. 4 , it will be seen that the articulating tool  10  is to be used together with other such tools  10 . The articulating tools  10   a - d  shown in  FIG. 4 , however, are only exemplary. In any event, as shown, it is envisioned that a plurality of tools  10  is properly positioned in a dental impression  44  that accurately replicates the dental structure of a patient (not shown) before corrective dental alignment procedures are taken. Specifically, the various tools  10  are held in the dental impression  44  by the holding wires  46   a  and  46   b  that interact with tie brackets  48  on the respective tools  10 . As shown, a tie bracket  48  is formed on each of the respective articulating tools  10  for this purpose. Importantly, and using the articulating tool  10   a  as an example, the elongated posts  38  that are associated with respective articulating tools  10  are positioned in the dental impression  44  so that the extreme distal end of the post  38  is positioned in an individual tooth impression  50 .  
         [0022]      FIG. 5  shows the result that is obtained when the articulating tools  10  are embedded in the various castings of the device of the present invention. Specifically,  FIG. 5  shows a teeth casting  52  that is made to replicate the individual teeth in the patient&#39;s dental structure. Preferably, the teeth casting  52  is made of a relatively rigid material, such as a hard durable urethane. As shown, the teeth casting  52  is made to cover and engage the distal end of the respective elongated posts  38 . Next, a gum casting  54  is made. Unlike the teeth casting  52 , the gum casting  54  is made of a relatively flexible material, such as a polyurethane elastomer. It needs to be noted here that most of the articulating tool  10  is actually embedded in the gum casting  54 . Importantly, the gum casting  54  needs to extend over a portion of the elongated posts  38 , and beyond the distal end of the articulating tool  10 , so that the flexible material of the gum casting  54  can allow individual teeth in the teeth casting  52  to be moved relative to the articulating tool  10 . Finally, there is a support casting  56 . As envisioned for the present invention, the support casting  56  is made of the same rigid material that is used for the teeth casting  52 . The import of the support casting  56  being to hold the various articulating tools  10  in a fixed relationship with each other.  
         [0023]     Once the elongated posts  38  have been joined to the teeth casting  52 , and the articulating tools  10  have been embedded in the gum casting  54  and are held by the support casting  56 , individual teeth (e.g. prosthetic tooth  58 ) in the teeth casting  52  can be selectively manipulated. Specifically, with reference to  FIG. 5 , and as disclosed above with reference to  FIGS. 1-3 , a rotation of the lead screw  24  will move the prosthetic tooth  58  in or out of the plane of  FIG. 5 , in an x-direction. A rotation of the pinion  30  will move the prosthetic tooth  58  left or right in the plane of  FIG. 5 , in an y-direction. And a rotation of the clamp screw  42  will hold the prosthetic tooth  58  in whatever rotational orientation is selected for the elongated post  38 . By selectively positioning each tooth in the teeth casting  52 , a user is able to customize the reconfiguration of a dental structure. Further, a series of such reconfigured dental structures can be made, and used for the manufacture of appliances (not shown). The appliances can then be sequentially worn by a patient, in accordance with instructions from a dentist, for the purpose of straightening teeth in the patient&#39;s dental structure.  
         [0024]     While the particular Method and Apparatus for Repositioning Teeth as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.