Abstract:
An apparatus of the present disclosure has a dental tray cup filled with a silicone elastomer and elastomeric sheeting covering the silicone elastomer in the dental tray cup. A method of the present disclosure comprises the steps of providing a dental tray, filling the dental tray with an elastomeric material, covering the elastomeric material in the dental tray with a sheeting.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 61/070,390, entitled “Custom Fit Dental Tray and Method for Making Same,” filed on Mar. 21, 2008, U.S. Provisional Patent Application Ser. No. 61/123,123, entitled “Custom Fit Dental Tray and Method for Making Same,” filed on Apr. 4, 2008, and U.S. Provisional Patent Application Ser. No. 61/099,235, entitled “Custom Fit Dental Tray and Method for Making Same,” filed on Sep. 23, 2008, all which are fully incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the field of dentistry. In particular, the present invention relates to a custom fit dental tray and method for making same. 
     BACKGROUND OF THE INVENTION 
     In dentistry, impressions are oftentimes made of a patient&#39;s teeth. To make an impression of a patient&#39;s teeth, polyvinyl siloxane (PVS), a silicone elastomer, is poured into a cup of a dental impression tray. The dental impression tray is then pressed onto the patient&#39;s teeth, causing the PVS to ooze through a plurality of holes in the dental impression tray and an impression of the patient&#39;s teeth is made in the PVS as the residual PVS escapes. 
     The cup and PVS are then removed from the patient&#39;s teeth, and after some time the impression made of the patient&#39;s teeth in the PVC hardens. This hardened impression can then be used in various ways, including making dental trays. 
     To create custom fit dental trays from the hardened impressions, a technique using a vacuuforming machine is used to create the custom fit dental trays from a model made from the impressions. This process is time consuming and may not result in a custom fit dental tray having a uniform thickness. 
     Custom fit dental trays dental trays may also be made of ethylene-vinyl acetate (EVA) material and are created using a boil-and-bite method. Such boil-and-bite type trays are used in sports to protect teeth; however, the material that is used is very thick thereby limiting their utility. 
     Custom fit dental trays are used in a variety of ways. For example, custom fit dental trays are used for teeth bleaching, treatment of periodontal disease, desensitizing teeth, remineralizing teeth, treatment of tooth decalcification, breath freshening, root caries treatment, among others. Solutions of various chemical compositions are placed into the custom formed mouth tray and the tray is placed over the teeth of the user to allow such chemicals to have intimate contact with dental structures undiluted by oral fluids. 
     SUMMARY 
     An apparatus in accordance with an embodiment of the present disclosure comprises a dental tray cup filled with a silicone elastomer and elastomeric sheeting covering the silicone elastomer in the dental tray cup. 
     A method in accordance with an embodiment of the present disclosure comprises the steps of filling a dental tray with an elastomeric material, heating a sheeting of elastomeric material, and placing the heating sheeting over the elastomeric-filled dental tray. The method further comprises pressing the elastomeric-filled dental tray and sheeting over teeth, removing the tray and sheeting from the teeth, and removing the sheeting from the dental tray. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the left-most digit(s) of a reference number identifies the drawing in which the reference number first appears. 
         FIG. 1  is an exploded view of an exemplary apparatus in accordance with an embodiment of the present disclosure illustrating a method in accordance with an embodiment of the present disclosure. 
         FIG. 2  is a dental impression tray of  FIG. 1  filled with polyvinyl siloxane (PVS). 
         FIG. 3  depicts the dental impression tray of  FIG. 2  filled with polyvinyl siloxane (PVS) and overlaid with a sheeting of ethylene-vinyl acetate (EVA). 
         FIG. 4  is a bottom view of the dental tray of  FIG. 1  after an impression has been made in the sheeting. 
         FIG. 5  is a top view of the dental tray of  FIG. 1  after an impression has been made in the sheeting. 
         FIG. 6  depicts the sheeting after it has been removed from the PVS-filled dental tray depicted in  FIG. 5 . 
         FIG. 7  depicts a custom fit dental tray after excess sheeting has been removed from the sheeting of  FIG. 6 . 
         FIG. 8  is an exemplary hinged dental tray in accordance with another embodiment of the present disclosure shown in an open position. 
         FIG. 9  is the hinged dental tray of  FIG. 9  shown in a closed position. 
         FIG. 10  is an exemplary hinged dental tray in accordance with another embodiment of the present disclosure shown in an open position. 
         FIG. 11  is the hinged dental tray of  FIG. 11  shown in a closed position. 
         FIG. 12  is a flowchart depicting an exemplary method for making a custom fit dental tray in accordance with an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is an exploded view depicting an exemplary process for creating a custom dental tray (not shown) in accordance with an embodiment of the present disclosure.  FIG. 1  depicts a dental impression tray  100 , polyvinyl siloxane (PVS)  101 , a sheeting  102  of ethylene-vinyl acetate (EVA), and a person&#39;s upper set of teeth  103 . 
     The dental impression tray  100  comprises a cup  104  and a handle  105 . Formed in the cup  104  is a plurality of openings  106 . During the process, the cup  104  receives the PVS  101 , and the openings  106  allow the PVS  101  to escape from the cup  104  when an impression is being made of a patient&#39;s teeth, which is illustrated further herein. 
     Note that the dental impression tray  100  can be various sizes, e.g., small, medium, and large. In addition, they may come in a maxillary and mandibular configuration. The size and type of the dental impression tray  100  used in the method described herein depends upon the size of the patient&#39;s mouth. 
     Further note that the sheeting  102  is comprised of EVA, which is the copolymer of ethylene and vinyl acetate. The sheeting  102  is a soft, flexible material, not unlike elastomeric materials. In one embodiment, the sheeting  102  is heat formable and exhibits a melting point compatible with a patient&#39;s temperature sensitivity. In such an embodiment, the sheeting  102  is molten at a temperature above body temperature but not so hot that it runs tissues. Thus, in such an embodiment the sheeting  102  melts between 100 and 180 degrees Fahrenheit or between 110 and 145 degrees Fahrenheit. Further, the sheeting  102  is between 0.030 and 0.040 inches in thickness. 
     During the process of creating the custom dental tray, the PVS  101  is placed within the cup  104  of the dental impression tray  100 .  FIG. 2  depicts the dental impression tray  100  and the cup  104  filled with the PVS  101 . 
     The sheeting  102  is heated and is placed so as to overlay the PVS  101 .  FIG. 3  depicts the dental impression tray  100 , the cup  104  filled with the PVS  101 , and the PVS  101  overlaid with the heated sheeting  102 . 
     With reference to  FIG. 1 , a user (not shown) grasps the handle  105  of the custom dental tray  100  that is filled with the PVS  101  and covered with the sheeting  102 . The user presses the dental tray  100  against the teeth  103  such that the teeth  103  fit within the cup  104  of the dental impression tray  100 . 
     In one embodiment, the sheeting  102 , PVS  101 , and the dental impression tray  100  may be sold as a unitary product, which is described further herein. In such an embodiment, the tray  100 , the PVS  101 , and the sheeting  102  may be heated as a unit, as depicted in  FIG. 3 . In another embodiment, the sheeting  102  may be separately heated so that it is deformable. The tray  100  may then be loaded with PVS  101 , and the heated sheeting  102  placed over the PVS  101  prior to being placed and pressed over the teeth  103  ( FIG. 1 ) as described. 
       FIG. 4  depicts a bottom view of the dental impression tray  100  after the dental impression tray  100  has been firmly pressed against the teeth  103  ( FIG. 1 ). As the tray  100  is being pressed against the teeth  103 , the sheeting  102  deforms to the topography of the teeth  103 , which is described further with reference to  FIG. 5 . Further, as the dental tray  100  is pressed against the teeth  103 , excess PVS  101  escapes from the cup  104  ( FIG. 1 ) of the dental impression tray  100  through the openings  106  as the sheeting  102  deforms. 
       FIG. 5  depicts a top view of the dental impression tray  100  after the dental impression tray  100  has been firmly pressed against the teeth  103  ( FIG. 1 ) and removed from the teeth  103 . In  FIG. 5 , the tray  100  filled with the PVS  101  that is overlaid with the sheeting  102  is depicted so that the sheeting  102  is shown as the front layer. 
     Once the dental impression tray  100  is removed from the teeth  103 , an impression  500  has been formed in the sheeting  102 . In this regard, the heated sheeting  102  deforms corresponding to the topography of the teeth  103  thereby creating the impression  500  of the patient&#39;s teeth  103  in the sheeting  102 . 
     Note that the sheeting  102  can be heated in any suitable manner now known or future-developed. As examples, an electric heating element, boiling water, hot air blower or any other means may be used to bring the temperature of the sheeting  102  to a melting point, yet keep it below the temperature that would cause tissue damage or discomfort for the patient. 
       FIG. 6  depicts the sheeting  102  after the sheeting  102  has been removed from the PVS  101  ( FIG. 1 ) and the tray  100  ( FIG. 1 ). Once the sheeting  102  is removed, it retains the impression  500  of the teeth  103  ( FIG. 1 ). Around the impression  500  is excess sheeting  600 . This excess sheeting  600  can be cut away, for example with a pair of scissors (not shown). 
       FIG. 7  depicts a custom fit dental tray  700  formed when the excess sheeting  600  ( FIG. 6 ) is cut away from the impression  500  ( FIG. 6 ). Note that the excess sheeting  600  may be cut away in a variety of configurations depending upon the final use. For example, the excess sheeting  600  may be trimmed away from the impression  500 , as shown, thereby leaving the custom dental tray  700 . In addition, however, the excess sheeting  600  may also be trimmed at the margin of the teeth  103  ( FIG. 1 ) and gingival tissues (not shown) such that the finished tray  700  touches the gingival tissues. 
     Note that the tray  700  has a uniform thickness, and the tray  700  is fabricated within the mouth of the patient with one sitting technique that equals or exceeds a laboratory fabricated custom molded tray that requires much more time and expense to produce. Further note that the rigid impression tray  100  and the PVS  101  provide support for the soft molten sheeting  102  that is overlaid on the PVS  101 . 
       FIG. 8  is a perspective view of an EVA-hinged dental tray  900  in accordance with an embodiment of the present disclosure. The dental tray  900  comprises an impression tray  901  and a hinged upper component  902 . The impression tray  901  comprises a handle  903  and a cup  904 . A plurality of openings  905  are formed in the cup  904 . 
     The openings  905  allow putty material  906 , e.g., polyvinyl siloxane (PVS), to escape from the cup  904  when an impression is being made of a patient&#39;s teeth (not shown). The impression tray  904  can be various sizes, e.g., small, medium, and large. In addition, they may come in a maxillary and mandibular configuration. The size and type of the dental impression tray  904  used in the process described herein depends upon the size of the patient&#39;s mouth. 
     The hinged component  902  comprises a sheeting  907  of a polymer material, e.g., ethylene-vinyl acetate (EVA). Note that EVA is the copolymer of ethylene and vinyl acetate, as described hereinabove. 
     In one embodiment, the sheeting  907  is rigid such that the sheeting  907  is hingedly coupled to the handle  903  of the impression tray  904 . The hinged component  902  further comprises a wire frame  908 , and the sheeting  907  is affixed to the wire frame  908 . In such an embodiment, the hinged wire frame  908  forms a handle  909 , and the handle  909  is hingedly coupled to the handle  903  of the impression tray  901  via a hinge mechanism  910 . The hinge mechanism  910  can be a type of hinge known in the art or future-developed. As examples, the hinge mechanism  910  may be a butt hinge or a butterfly hinge. 
     Note that the wire frame  908  is shown in the exemplary embodiment in  FIG. 8 . However, in other embodiments, the wire frame  908  may not be necessary. As an example, the sheeting  907  may consist of a material that is rigid such that the handle  909  can be directly coupled to the handle  903  without the presence of the wire frame  908 . 
     A user (not shown) actuates the hinge mechanism  910  such that the hinged component  902  pivots about the hinge mechanism  910  in a direction indicated by reference arrow  911 . Note that  FIG. 8  depicts the dental tray  900  in an open position. The term “open position” refers to when the hinged component  902  is separated from the PVA-filled impression tray  901 . When the dental tray  900  is in the open position, the sheeting  907  can be heated on both sides. When the dental tray  900  is in the open position, the sheeting  907  can be heated with hot air and/or hot liquid. 
     Once the sheeting  907  has been heated, the user actuates the hinge mechanism  910  in a direction indicated by reference arrow  912  such that the hinged component  902  is in a closed position, as depicted in  FIG. 9 . The term “closed position” refers to that position of the dental tray  900  such that the dental tray  900  can be inserted into a patient&#39;s mouth (not shown) and an impression made of the patient&#39;s teeth (not shown). 
     Moving the hinged component  910  in the direction of reference arrow  912  to the closed position as depicted in  FIG. 2 , places the sheeting  907  over the putty material  906  that is filled in the cup  904  of the dental impression tray  901 . Once the sheeting  907  is placed over the putty material  906 , the dental tray  900  can be placed in the patient&#39;s mouth and an impression made of the patient&#39;s teeth, such as described with reference to  FIG. 1 . 
       FIG. 10  is a perspective view of an EVA-hinged dental tray  1100  in accordance with another embodiment of the present disclosure. The EVA-hinged dental tray  1100  is substantially similar to the EVA-hinged dental tray  900  depicted in  FIG. 9  and described herein. 
     In this regard, the dental tray  1100  comprises an impression tray  1101  and a hinged upper component  1102 . The impression tray  1101  comprises a handle  1103  and a cup  1104 . A plurality of openings  1105  are formed in the cup  1104 . 
     The hinged component I  102  comprises a sheeting  1107  of a polymer material, e.g., EVA. The hinged component  1102  further comprises a wire frame  1108 , and the sheeting  1107  is affixed to the wire frame  1108 . In such an embodiment, the hinged wire frame  1108  forms a handle  1109 . 
     Note that the wire frame  1108  is shown in the exemplary embodiment in  FIG. 10 . However, in other embodiments, the wire frame  1108  may not be utilized. As an example, the sheeting  1107  may consist of a material that is rigid such that the handle  1109  can be directly coupled to the handle  1103  without the presence of the wire frame  908 . 
     In the embodiment depicted in  FIG. 11 , the handles  1103  and  1109  are transversely connected via a hinge pin  1110 . Note that  FIG. 11  depicts the dental tray  1100  in an open position. “Open position” refers to when the hinged component  1102  is separated from the PVA-filled impression tray  1101  by separating the handles  1103  and  1109  in directions indicated by reference arrows  1111  and  1112 , respectively. When the dental tray  1100  is in the open position, the sheeting  12  can be heated on both sides by submerging the sheeting  1107  in a hot air or hot liquid chamber (not pictured). 
     In order to close the dental tray  1100 , the user releases the handles  1103  and  1109  and the hinge pin  1110  forces the handles  1103  and  1109  together, thereby leaving the dental tray  1100  in a closed position, as depicted in  FIG. 12 . The “closed position” refers to that position of the dental tray  1100  such that the dental tray  1100  can be inserted into a patient&#39;s mouth (not shown) and an impression made of the patient&#39;s teeth (not shown) on the sheeting  1107 . 
     Releasing the hinge pin  1110  so that the dental tray  1100  is in the closed position as depicted in  FIG. 11 , places the sheeting  1107  over the putty material  1106  that is filled in the cup  1104  of the dental impression tray  1101 . Once the sheeting  1107  is placed over the putty material  1106 , the dental tray  1100  can be placed in the patient&#39;s mouth and an impression made of the patient&#39;s teeth in the Sheeting  1107 . 
       FIG. 12  depicts an exemplary method in accordance with an embodiment of the present disclosure. 
     In step  1300 , a user (not shown) fills a dental impression tray  100  ( FIG. 1 ) with PVS  101  ( FIG. 1 ). In step  1301 , the user heats a sheeting  102  ( FIG. 1 ). Heating can be done in a variety of ways as described herein. 
     In step  1302 , the user places the heated sheeting  102  over the PVS-filled dental impression tray  100 . In step  1303 , the user presses the sheeting  102  over a patient&#39;s teeth  103  ( FIG. 1 ). After some time, the user removes the tray  100  with the sheeting  102  from the patient&#39;s teeth, in step  1304 . In step  1305 , the user removes the sheeting  102  now exhibiting an impression  500  ( FIG. 5 ) from the PVS-filled dental impression tray  100 , thereby forming a custom fit dental tray  700  ( FIG. 7 ) fit for the patient&#39;s teeth. 
     Note that the excess EVA  600  ( FIG. 6 ) may be removed with scissors, as described with reference to  FIG. 6 . How much of the excess is removed depends upon how the custom fit dental tray  700  is intended to be used.