Abstract:
A system and method for custom molding dental trays is disclosed. The system includes a hot air source and heat chamber, wherein a thermoformable dental tray is placed within the heat chamber and heated to the appropriate temperature. The heat chamber may include air escape holes to allow for uniform heating. Furthermore, the heat chamber may incorporate a fan or other air removal device to improve uniform heating.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. provisional application Ser. No. 60/838,239, filed Aug. 17, 2006, and which is incorporated by reference herein. 
     
     BACKGROUND OF THE DISCLOSURE 
       [0002]    This disclosure generally relates to customized dental trays which can be used as protective mouthpieces or for dental treatments. In particular, the present disclosure relates to a system and process for custom molding dental trays. 
         [0003]    The need for custom fitted oral appliances is well known. Protective mouthpieces or mouthguards are used by athletes to protect against injury. Dental trays are also used for bleaching, administration of fluoride, or application of other medicines. Various custom fitted dental trays including mouthguards are known in the art. One of the most common products on the market today is the “boil and bite” dental tray, which is made out of a thermoformable plastic such as ethyl vinyl acetate (“EVA”) or polyethylene. A customized tray is created by heating the plastic in boiling water causing it to melt at a biologically acceptable temperature, and then placing it directly over an individual&#39;s teeth where it cools and retains its new shape. 
         [0004]    The “boil and bite” method is very convenient and simple as it eliminates the expensive and lengthy process of creating an impression of the teeth, which is used to fabricate a model over which a thermoformed plastic tray is formed. However, a limitation of the “boil and bite” method is that a source and reservoir of boiling water is required to soften the dental tray material and make it moldable. An improvement in the art involves creating a method which does not require boiling water and which is able to evenly soften a thermoformable, universal fitted, blank dental tray such that it can be molded and permanently adapted to the teeth of an individual user. 
       SUMMARY OF THE DISCLOSURE 
       [0005]    The present disclosure recognizes and addresses various of the foregoing limitations and drawbacks, and others, concerning the system and process of creating a custom fitted dental tray. Therefore, the present disclosure is directed to a system and process that satisfies this need. 
         [0006]    It is, therefore, a principle object of the subject disclosure to provide a system which is able to evenly soften a thermoformable dental tray through the use of hot air and without any boiling water such that it can be molded and permanently adapted to the teeth of an individual user. 
         [0007]    It is a further object of this present disclosure to provide a process for evenly softening a thermoformable dental tray through the use of hot air and without any boiling water so that it can be molded and permanently adapted to the teeth of an individual user. 
         [0008]    The process of using heat transferred through air is advantageous because a source and reservoir of boiling water would no longer be needed. Also, the system which heats the dental tray is advantageous because it can be produced as a small portable unit that can be stored and used in professional offices or by the user. There would no longer be a need to keep water boiling or to wait for it to boil. The unit could easily begin generating hot air within a short period of time. 
         [0009]    Additional objects and advantages of the disclosure are set forth in, or will be apparent to those of ordinary skill in the art from, the detailed description as follows. Also, it should be further appreciated that modifications and variations to the specifically illustrated and discussed features and materials hereof may be practiced in various embodiments and uses of this disclosure without departing from the spirit and scope thereof, by virtue of present reference thereto. Such variations may include, but are not limited to, substitutions of the equivalent means, features, and materials for those shown or discussed, and the functional or positional reversal of various parts, features, or the like. 
         [0010]    Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of this disclosure, may include various combinations or configurations of presently disclosed features, elements, or their equivalents (including combinations of features or configurations thereof not expressly shown in the figures or stated in the detailed description). 
         [0011]    These and other features, aspects and advantages of the present disclosure will become better understood with reference to the following descriptions. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the disclosure and, together with the descriptions, serve to explain the principles of the disclosure. 
         [0012]    One embodiment of the present disclosure is a process for evenly heating a thermoformable dental tray to make it moldable with hot air. The process provides a lid with air escape holes from which the blank thermoformable dental tray is suspended. This lid is placed on one end of a heat chamber which also contains air escape holes. A hair dryer or similar hot air source is then placed on the opposite end of the heat chamber and generates a hot air flow. This hot air flow heats the dental tray until it is moldable. 
         [0013]    Another embodiment of the present disclosure is a process for evenly heating a thermoformable dental tray with hot air, further including a fan for removing the hot air from the system. The air removal fan can either be located on the side of the heat chamber or on top of the lid, and it helps to more efficiently and evenly heat the dental tray by increasing the turbulent air flow in the system. This increased air flow also prevents the system from overheating. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    A full and enabling description of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
           [0015]      FIG. 1  is a perspective view of a blank, thermoformable dental tray which is to be custom fitted to an individual&#39;s teeth; 
           [0016]      FIG. 2  is a perspective exploded view of an exemplary system for custom molding dental tray such as is depicted in  FIG. 1 ; 
           [0017]      FIG. 3  is a top view of the lid of the system depicted in  FIG. 2 ; 
           [0018]      FIG. 4  is a perspective view of the assembled system for custom molding dental trays as depicted in  FIG. 2 ; 
           [0019]      FIG. 5  is a perspective exploded view of another exemplary system for custom molding dental trays, further including an air removal fan. 
           [0020]      FIG. 6  is a perspective view of the assembled system as depicted in  FIG. 5 . 
           [0021]      FIG. 7  is a front view of the air removal fan of the system depicted in  FIG. 5 . 
       
    
    
       [0022]    Repeat use of reference characters throughout the present specification and appended drawings is intended to represent the same or analogous features or elements of the disclosure. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0023]    Reference will now be made in detail to embodiments of the disclosure, examples of which are fully represented in the accompanying drawings. Such examples are provided by way of an explanation of the disclosure, not limitation thereof. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure, without departing from the spirit and scope thereof. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Still further, variations in selection of materials and/or characteristics may be practiced, to satisfy particular desired user criteria. Thus, it is intended that the present disclosure cover such modifications and variations as come within the scope of the present features and their equivalents. 
         [0024]    As disclosed above, the present disclosure is particularly concerned with custom fitted dental trays. In one aspect, the disclosure relates to the process of evenly heating a thermoformable dental tray with air, making it moldable so it can be placed over an individual&#39;s teeth where it will cool and permanently adapt to that new shape. In another aspect, the disclosure relates to a system which evenly heats a thermoformable dental tray with hot air, making it moldable so it can be placed on an individual&#39;s teeth and permanently adapt to its new shape as it cools. The resulting trays can be used as protective mouthguards or for dental treatment, such as bleaching, fluoride treatments, and antimicrobial treatments. Reference is now made to the drawings. 
         [0025]      FIG. 1  depicts a preformed, blank dental tray  101  that may be used to manufacture a customized dental tray by heating the dental tray  101 . In this regard, the dental tray  101  may be heated according to the process of the present disclosure, and then placed over the individual&#39;s teeth. 
         [0026]    Once it is cooled, and the dental tray  102  will permanently adapt to the shape of the individual&#39;s teeth. In one embodiment, the dental tray  101  is attached to a detachable handle  102 . The detachable handle  102  is described further herein with reference to  FIG. 2 . The dental tray  101  can be made of any appropriate thermoformable material which softens at a temperature that is greater than body temperature. 
         [0027]      FIG. 2  depicts a system  200  in accordance with an embodiment of the present disclosure for heating a thermoformable dental tray  101 . The system  200  comprises a lid  201 , and a heat chamber  204 . In one embodiment, the system  200  further comprises a hot air source  206 . 
         [0028]    As stated hereinabove, the dental tray  101  may be attached to a detachable handle  102 . In such an embodiment, the handle  102  couples with a slot  210  of the lid  201 . As an example, the detachable handle  102  is inserted in a slot  211  in the lid  201 . In an alternative embodiment, the dental tray  101  may be suspended in the heat chamber  204  through any other suitable method. The lid  201  further has air escape holes  202  to allow for the circulation of air. With reference to  FIG. 3 , the slot  211  and air escape holes  202  are disclosed. As will be shown with reference to  FIG. 4 , The lid fits securely on an end  209  of the heat chamber  204  in order to withstand forces placed upon it from air from the hot air source  201 . 
         [0029]    In an alternative embodiment, the lid  201  may be secured to the heat chamber by fasteners, clasps, or latches. Notably, the lid  201  may be secured to the chamber  204  via any method, mechanism or device now known or future-developed that would ensure that the lid  201  remains attached while air from the source  206  is heating the lid  201 . In one embodiment, the heat chamber  204  has air escape holes  212 . The holes  212  allow for the circulation of hot air which aids in the even heating of the dental tray  101 , as described further with reference to  FIG. 4 . In another embodiment, the heat chamber  204  is insulated and may be made from a standard soda can insulator or koozie, such as high density foam, neoprene, or any other suitable insulating material capable of withstanding the forces and heat placed upon it. Further, the heat chamber  204  may be coated with an insulating paint. 
         [0030]    The hot air source  206  depicted in  FIG. 2  is a standard hair dryer capable of generating a hot air flow of up to 200 degrees Fahrenheit. The hot air source  206  is placed on an end  210  of the heat chamber  204  opposite the end  209  coupled to the lid  201 . In one embodiment, the hot air source  206  is tapered to fit within the heat chamber  204  to promote the efficient operation of the system by ensuring all of the hot air from the hot air source is directed toward the dental tray  101 . When the hot air source  206  is activated, the hot air source  206  forces hot air through the heat chamber  204  toward the dental tray  101  in the direction shown by reference arrow  205 . The air escape holes  202  in the lid  201  and in the air escape holes  212  in the heat chamber  204  allow for the proper circulation of air and create a turbulent fluid flow which evenly heats the dental tray  101 . The air escape holes  202  further control the build-up of pressure in the heat chamber  204 . 
         [0031]      FIGS. 5 and 6  depict another embodiment of the present disclosure, in which an air removal fan  401  is located on the heat chamber  204  in order to adjust the circulation of air through the system  200 .  FIG. 6  displays the system  200  in which the fan  401  is securely fitted into a larger opening on the side of the heat chamber  204 . The fan  401  helps to evenly heat the dental tray  101  by maintaining a turbulent flow of air through the system  200 . In an alternative embodiment, the air removal fan  401  can be placed on top of the lid  201 , or incorporated into the lid  201  to accomplish the same result. 
         [0032]      FIG. 7  depicts a front plan view of the air removal fan  401  in operation. The number of blades  402  on the fan  401  can be varied in order to accomplish the desired results. 
         [0033]    The time the dental tray  101  remains in this system  200  is determined by the temperature produced by the hot air source  206  and the temperature maintained in the heat chamber  204 . The desired temperature of the heat chamber  204  will depend upon the material of the dental tray  101 . In one embodiment, the dental tray is made of EVA, and should be heated for 90 seconds once the heat chamber reaches 145 degrees Fahrenheit. 
         [0034]    Once the dental tray  101  reaches the desired temperature, it is placed over the user&#39;s teeth. The user bites down on the dental tray  101  and uses his tongue or finger to form the dental tray  101  to the shape of his or her teeth. Once the dental tray  101  has cooled to an appropriate temperature, it will retain shape of the user&#39;s teeth. 
         [0035]    In an alternative embodiment the hot air source  206  can be equipped with a variable temperature control device  213  which can be used to maintain the desired temperature in the heat chamber  204 . The temperature of the heat chamber  204  may be monitored by a thermostat (not pictured) and relayed to the hot air source  206  in order to maintain a desired temperature. 
         [0036]    Although an embodiment of the disclosure has been described using specific terms and devices, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present disclosure. In addition, it should be understood that aspects of various other embodiments may be interchanged either in whole or in part. Therefore, the spirit and scope of any appended claims should not be limited to the description of any embodiment contained herein.