Source: https://patents.google.com/patent/US7600999B2/en
Timestamp: 2019-07-19 03:02:26
Document Index: 682023660

Matched Legal Cases: ['arts 1', 'art 1', 'art 2', 'art 1', 'art 2', 'art 3', 'art 4']

US7600999B2 - Systems and methods for fabricating a dental template - Google Patents
Systems and methods for fabricating a dental template Download PDF
US7600999B2
US7600999B2 US10/794,325 US79432504A US7600999B2 US 7600999 B2 US7600999 B2 US 7600999B2 US 79432504 A US79432504 A US 79432504A US 7600999 B2 US7600999 B2 US 7600999B2
US10/794,325
US20040253562A1 (en
Peter G. Knopp
2003-02-26 Priority to US10/375,223 priority Critical patent/US20040166462A1/en
2004-03-04 Application filed by Align Technology Inc filed Critical Align Technology Inc
2004-03-04 Priority to US10/794,325 priority patent/US7600999B2/en
2004-03-04 Assigned to ALIGN TECHNOLOGY reassignment ALIGN TECHNOLOGY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KNOPP, PETER G.
2004-07-21 Priority claimed from ES04254358T external-priority patent/ES2714375T3/en
2004-12-16 Publication of US20040253562A1 publication Critical patent/US20040253562A1/en
2009-10-13 Publication of US7600999B2 publication Critical patent/US7600999B2/en
2011-01-21 Priority claimed from JP2011011431A external-priority patent/JP2011120928A/en
2024-10-18 Adjusted expiration legal-status Critical
A dental template to position an object on a patient's tooth includes digitizing the patient's tooth; adding virtual objects to predetermined three-dimensional positions on the digitized tooth; and fabricating the dental template to locate the object at the predetermined 3D position on the patient's tooth. The template can be used for etching or for positioning brackets on teeth.
The present invention relates generally to the field of orthodontics.
Orthodontic brackets are often bonded directly to the patient's teeth. Typically, a small quantity of adhesive is placed on the base of each bracket and the bracket is then placed on a selected tooth. Before the adhesive is set, the bracket is maneuvered to a desired location on the tooth. Once the adhesive has hardened, the bracket is bonded to the tooth with sufficient strength to withstand subsequent orthodontic forces as treatment progresses. One shortcoming with this technique is the difficulty in accessing the optimal surface for bracket placement on severely crowded teeth or in teeth where the bonding surface is obstructed by teeth in the opposing arch during jaw closure. With posterior teeth, the treatment provider may have difficulty seeing the precise position of the bracket relative to the tooth surface. The amount of time needed to carry out the bonding procedure may be a nuisance both to the patient as well as to the treatment provider. Also, the necessity of minimizing moisture contamination from the patient's saliva can prolong the procedure and also unduly impair the accuracy of placement of the brackets on the teeth. All of these factors increase the chance that the ultimate adhesive bond will not have sufficient strength to retain the brackets on the teeth during treatment. One way to overcome some of the limitations of direct bracket placement is with indirect bonding. Typically, an impression of each of the patient's dental arches is taken and a replica plaster or “stone” model is made from each impression and sealed. Brackets are bonded to the sealed stone models using a temporary cement. A transfer tray is then made by placing matrix material over both the model and the brackets on the model. For example, a heated plastic sheet matrix material may be placed over the model and brackets and then under pressure. The plastic sheet material then assumes a configuration that precisely matches the shape of the replica teeth of the stone model with the brackets in the desired position. The plastic material is then allowed to cool and harden to form a tray. The temporary adhesive is removed, and permanent adhesive is placed on the base of each bracket in the tray, and the tray with the embedded brackets then placed over matching portions of the patient's dental arches. Since the configuration of the interior surface of the tray closely matches the respective portions of the patient's dental arches, each bracket is ultimately positioned on the patient's teeth at precisely the same location that corresponds to the previous location of the same bracket on the stone model. The adhesive is hardened and the matrix material removed, leaving the brackets in the desired positions. This method however, is labor intensive. An additional problem with the indirect method is that brackets may become dislodged during the removal of the matrix from the dental arches. The problem of proper access to tooth surfaces for optimal placement in the event of severely crooked teeth or teeth which interfere with the opposing arch such that brackets cannot be placed is also not addressed.
A dental template is disclosed to support positioning an object on a patient's tooth oriented in such a way that all the objects as a whole are lined up to a user defined ideal arrangement. Also, a method is disclosed for fabricating the template. The method includes digitizing the patient's teeth; adding virtual objects to predetermined locations on the digitized teeth; and fabricating the dental template to locate the object on the patient's teeth. The dental template is designed to locate each object at a predetermined inclination or a predetermined angulation on the patient's tooth. The template can be used for etching or for positioning brackets on teeth.
FIG. 1 shows an exemplary method or process to fabricate a dental template to position an object on a patient's tooth.
FIG. 1 shows an exemplary method or process to fabricate a dental template to position an object on a patient's tooth. First, the process digitizes the patient's tooth (10). Next, virtual objects are added to pre-determined locations on the digitized tooth (12). Finally, the process fabricates the dental template to locate the object on the patient's tooth (14). One detailed implementation of FIG. 1 is described in FIGS. 3A and 3B below.
Scale the teeth to values likely within the range 105-150%.
Co-locate the original (100%) teeth and the scaled teeth in the same 3D space
Place a virtual bracket or other appropriate geometry at a specific location and in a specific orientation on each tooth to be treated.
Cavity the original teeth and the brackets in the scaled teeth.
Remove from the resulting template or body those aspects that would be below the gingival line. Remove the portions of the resultant body buccal and gingival to the brackets remove a substantial portion or all of the lingual aspect of the resultant body.
Convert this computer model to a real part, likely through the use of a rapid prototyping method (e.g. Fused Deposition Modeling, 3-D Printing, and stereolithography).
If indirect fabrication is to be done, the following operations are done using an arch model:
Form an Aligner-like appliance or template over an arch model that has brackets or other appropriate geometries properly located on the teeth.
Convert this computer model to a real part, likely through the use of a rapid prototyping method (e.g. Fused Deposition Modeling, 3-D Printing, and sterolithography).
Form an Aligner-like appliance or template over an arch model that has brackets or other appropriate geometries properly located on the teeth
Remove from the Aligner or template those aspects that would be below the gingival line or in direct interproximal contact with adjacent teeth. Remove the portions of the Aligner buccal and gingival to the bracket. Remove a substantial portion or all of the lingual aspect of the Aligner.
FIG. 4A shows one embodiment of a dental template 220 or appliance formed over a mold 210. The template looks like a removable appliance; however, it has openings 222 or “port-holes” approximating the footprint, key portions of the footprint, and/or possibly other geometrical features of a bracket to guide the precise placement of the bracket on its respective tooth. The template 220 with the openings 222 or “port-holes” may also be a guide for enamel etching or adhesive placement.
More information on the fabrication of the dental template or appliance is disclosed in U.S. Pat. No. 6,499,997 “Manipulable dental model system for fabrication of a dental appliance”; U.S. Pat. No. 6,497,574 “Modified tooth positioning appliances and methods and systems for their manufacture”; U.S. Pat. No. 6,488,499 “Methods for correcting deviations in preplanned tooth rearrangements”; U.S. Pat. No. 6,485,298 “System and method for releasing tooth positioning appliances”; U.S. Pat. No. 6,471,511 “Defining tooth-moving appliances computationally”; U.S. Pat. No. 6,463,344 “Efficient data representation of teeth model”; U.S. Pat. No. 6,457,972 “System for determining final position of teeth”; U.S. Pat. No. 6,454,565 “Systems and methods for varying elastic modulus appliances”; U.S. Pat. No. 6,450,807 “System and method for positioning teeth”; U.S. Pat. No. 6,409,504 “Manipulating a digital dentition model to form models of individual dentition components”; U.S. Pat. No. 6,406,292 “System for determining final position of teeth”; U.S. Pat. No. 6,398,548 “Method and system for incrementally moving teeth”; U.S. Pat. No. 6,394,801 “Manipulable dental model system for fabrication of dental appliances”; U.S. Pat. No. 6,390,812 “System and method for releasing tooth positioning appliances”; U.S. Pat. No. 6,386,878 “Systems and methods for removing gingiva from teeth”; U.S. Pat. No. 6,386,864 “Stress indicators for tooth positioning appliances”; U.S. Pat. No. 6,371,761 “Flexible plane for separating teeth models”; U.S. Pat. No. 6,318,994 “Tooth path treatment plan”; U.S. Pat. No. 6,309,215 “Attachment devices and method for a dental appliance”; U.S. Pat. No. 6,299,440 “System and method for producing tooth movement”; U.S. Pat. No. 6,227,851 “Manipulable dental model system for fabrication of a dental appliance”; U.S. Pat. No. 6,227,850 “Teeth viewing system”; U.S. Pat. No. 6,217,325 “Method and system for incrementally moving teeth”; U.S. Pat. No. 6,210,162 “Creating a positive mold of a patient's dentition for use in forming an orthodontic appliance”; and U.S. Pat. No. 5,975,893 “Method and system for incrementally moving teeth,” the contents of which are hereby incorporated by reference.
Orthodontic brackets are designed and produced with a fixed base profile for a given manufacturer prescription, and usage. The bracket base is that surface that is the interface with the tooth. Since a patient's tooth morphologies are unique, the bracket base and its underlying tooth may not mate well. Typically, a gap exists between the bracket base and the tooth surface. This gap needs to be filled to form a “Custom Base”. The custom base may involve adjusting the angulation and/or inclination of the bracket base when it is applied to the tooth.
In the case of using the model tooth, the model could be a shell that has hole(s) 412 to access the back of the bracket 402. Also, the customized base could be formed by pressing one model into another while the bracket is spatially fixed by the template 400. In this case, the outer ‘model’ would be a structure similar to the template, but more rigid and covers more of the teeth's surfaces. The inner ‘model’ would represent the actual teeth. The base gap would have been first filled with a bonding medium (e.g. adhesive). When the two models are fit together, the bonding medium is compacted into the gap and any excess flash around the bracket is removed. Yet another method would have a hollow model to represent the teeth, a template over this to fix the brackets in space, and a second model that nests in the first hollow model. When this latter is pressed into the hollow model, adhesive is forced through holes in the hollow model that are located behind the brackets' bases. After curing the adhesive, the two models are removed so the brackets and their custom bases remain in the template.
1. A digital representation of a tooth is acquired through scanning or other digitization means.
2. This tooth file is opened in a computer application that allows a user to alter it or that itself alters the file.
3. The tooth is enlarged to a scale greater than 100%—typically in the range of 105 to 150%; and saved as a separate file.
The original tooth file (i.e. 100% scales) is co-located within the scaled tooth.
The original tooth's geometry is subtracted from that of the scaled tooth to leave a hollowed or shelled body.
The root and other sub-gingival aspects are removed from this body. The removal can be performed through the use of additional bodies or surfaces that cut, cavity, or are subtracted from the body to be kept.
Adjacent tooth cavity method A.
Solid (not hollow), scaled versions of adjacent teeth are subtracted from this body where the bodies overlap or intersect.
Adjacent tooth cavity method B.
The geometry common to the object tooth and adjacent teeth is subtracted from this body. This step is best performed before the hollowing of the object tooth.
4. All teeth in the target arch which are to be part of the template are then brought together in their proper relative positions and orientations to form the template for this arch.
5. Exterior interproximal regions are filled in, as needed, to join the tooth shell segments together. This ‘buttressing’ process has numerous possibilities, among them:
Add a solid body that extends beyond the teeth's buccal surfaces and re-cavity it where it would otherwise collide with the teeth.
Individually fill the interproximal regions between adjacent teeth outward from the buccal surfaces of the 100% and/or scaled teeth.
Add another, larger-scaled tooth over each respective tooth and re-cavity it where it would otherwise collide with the underlying tooth.
Allow the interproximal regions to be disjoint, but connect the individual teeth by applying a solid body on and into the incisal/occlusal surfaces. Re-cavity this as necessary.
6. Any unwanted or interfering geometries are removed. This may include the positions for brackets or other orthodontic or dental components. As noted above, the removal can be performed through the use of additional bodies or surfaces that are used to cut, cavity, or subtract from the kept body/bodies.
7. If necessary, the resultant file is converted to a format required by the rapid-prototyping method.
FIGS. 20-27 show various diagrams illustrating an overlaid cavities embodiment. In FIG. 20, a block 550 is used as an arbitrary body and a 100% scaled tooth model 552 has been placed inside that body. In FIG. 21, the same block 550 with the same dimensions in every aspect as the body of block 550 in FIG. 20 contains a scaled tooth 554 (such as a 140% scaled tooth model). In each case, the body fully encompasses the original and scaled tooth models. In FIG. 22, the 100% tooth has been cavitied or hollowed from the block 550, and in FIG. 23, the 140% scaled tooth model 554 is cavitied from the block 550. In FIG. 24, the cavitied block 550 that contained the 100% tooth model 552 is co-located with the cavitied block 550 that contained the 140% tooth model 554 so that the model 552 is inside the model 554.
3. A body that more than encompasses the space occupied by all the teeth is created or opened in the application. This is Block 550 in the images. Alternately, encompassing bodies may be created for an individual tooth or groups of teeth. These bodies would later be brought together into one template file (FIG. 20).
4. Preferentially, all object teeth are moved into this file into their proper positions and orientations. The body is then cavitied with the teeth. Alternately, the body could be successively cavitied by individual teeth. The resultant body is saved.
5. Each tooth is then enlarged to a scale greater than 100%—typically in the range of 105 to 150%; and saved as a separate file.
6. A second, identical, all-encompassing body (550) is created or opened in the application (FIG. 21).
7. Step 4 is repeated for Block 550 (FIG. 21) with the difference being that the scaled teeth of Step 5 are used. Alternately, it is not required to create and use scaled teeth. Rather, the original teeth may be cavitied in Block 550 at a larger than 100% scale.
8. Block 550 of FIG. 20 and Block 550 of FIG. 21 are co-located in one of their files or in a new file that preferentially contains only these two objects.
9. Block 550 of FIG. 21 is subtracted from Block 550 of FIG. 20. This leaves one or more shelled bodies—the exterior surfaces defined by the scaled teeth and the interior surfaces by the original, unsealed teeth.
10. The roots and sub-gingival aspects are removed from the body/bodies. The removal can be performed through the use of additional bodies or surfaces that cut, cavity, or are subtracted from the body to be kept.
11. Successively or contemporaneously, the geometry common to an object tooth and its adjacent teeth is subtracted from the body/bodies.
12. Exterior interproximal regions are filled in, as needed, to join the tooth shell segments together. This ‘buttressing’ process has numerous possibilities:
Individually fill the interproximal regions between adjacent teeth outward from the buccal surfaces.
The buttressing can be placed or enacted on the scaled teeth prior to, at the same time as, or subsequent to Steps 7 and/or 8. It is preferentially performed prior to Step 9.
13. Any unwanted or interfering geometries are removed, e.g. internal interproximal regions. This removal may include the positions for brackets or other orthodontic or dental components. The removal can be effected as described above.
14. If necessary, the resultant file is converted to a format required by the rapid-prototyping method.
FIG. 28 illustrates another embodiment for scaling a tooth model. In this embodiment, the original tooth model surface is off-set (565) using a predetermined mathematical formula or predetermined points or constraints. The embodiment offsets numerous surfaces to show alternative methods to enlarging the tooth model or creating a surface that bounds the same shape but in a large scale of the tooth model. FIG. 29 thickens the surface (565) from FIG. 28 inward towards the tooth to form body 567. FIG. 30 is that same surface (565) but now thickening it outward away from the tooth, and FIG. 31 is showing thickening both inward and outward at the same time.
3. The orthodontic or dental component is placed on the tooth in its intended position. Alternately, the plate is placed with respect to where it is known the component will be placed.
4. A body is placed on, into, and/or over the tooth so it abuts the component with contact sufficient to limit its degrees of freedom as desired. This body may be a standardized shape or customized relative to tooth type or specifically to a given patient's tooth or teeth. At minimum, this body will have these characteristics or features: a buccolingual thickness greater than approximately half the this dimension of the component, but generally less than the sum of the thicknesses of the component and its respective tooth; a mesiodistal length that may be greater than, less than, or equal to the tooth's mesiodistal width; and an occlusogingival height that may be greater than, less than, or equal to the height of the tooth. The body could be simply rectalinear or as complex as the tooth or mouth morphology and could also include a mating cavity for the orthodontic component. Or the component could subsequently be cavitied in the body when the latter is merely approximately positioned.
5. After all teeth have been ‘plated’, the plates are merged, connected, or joined where there are gaps and cut, trimmed, or shaped where they are undesirably protrusive. An incisal/occlusal element could also be merged into the plates at this time.
6. If necessary the tooth bodies are subtracted from the body comprised of the plates and any incisal/occlusal element.
7. Any unwanted or interfering geometries are removed. This may include the positions for brackets or other orthodontic or dental components. See above for methods of removal.
8. If necessary, the resultant file is converted to a format required by the rapid-prototyping method.
FIGS. 38 and 39 show another embodiment of the surface off-set method. In this embodiment, two surfaces 590 and 592 are used rather than just one surface. In FIG. 38, one surface 592 is offset at or near the tooth. A second surface 590 is offset at a distance larger than the distance from surface 592 resulting in two surfaces that are essentially congruent but located at a different distance. FIG. 39 shows the two surfaces 590 and 592 bounding a solid body. The solid body can be specified in a number of ways. For example, one surface can be extruded towards the other surface alternatively, the edges (591) where the surfaces gap can be closed.
1. A digital representation of a tooth is acquired through scanning or other digitization means
3. The surface(s) of the tooth is offset to a desired distance.
4. This surface is thickened in a radially outward direction if the offset distance is greater than zero. The surface is thickened in a radially inward or inward and outward if the distance is greater than zero. The inwardly directed thickness preferentially does not penetrate the surface of the tooth. However, if it does, the tooth body could be subsequently subtracted from the solid created by thickening the offset surface(s).
5. Any unwanted or interfering geometries are removed. These may include the interproximal areas as well as the positions for brackets or other orthodontic or dental components. See above for removal methods.
6. If necessary, the resultant file is converted to a format required by the rapid-prototyping method.
Pseudo-code for Multiple Surface Off-setting is as follows:
3. The surface(s) of the tooth is offset to a desired first distance.
4. The surface(s) of the tooth is offset to a second desired distance, preferentially greater or less than the first distance.
5. The volume between the first and second surfaces is then filled to create a solid body.
6. If one of the offset distances sets the corresponding surfaces inside the tooth body, the solid body can be cavitied with the original tooth body.
7. Any unwanted or interfering geometries are removed. These may include the interproximal areas as well as the positions for brackets or other orthodontic or dental components. See above for removal methods.
FIGS. 40 and 41 show one embodiment of template cutting. A cutting body 593 partially encompasses the underlying bracket 572 to create a ‘window’ in the template wherein the bracket can be positioned and affixed while still allowing for subsequent removal of the template. In one embodiment, the cutting body 593 has a simple geometry. Other shapes could encompass more or less of the underlying orthodontic or dental component based on need or intent. Further, the shape of the body 593 could be more complex to create additional benefits such as a partial lock to hold the component ‘hands free’ in place, cause a seam along which the template is readily broken for removal, or allow for easier access for bonding or curing. In this example, the encompassing body 593 continues lingual to the template's buccal surface to cause a sharp-edged thin area 594 along whose buccal edge it is made easier to break the template.
US10/794,325 2003-02-26 2004-03-04 Systems and methods for fabricating a dental template Active 2024-10-18 US7600999B2 (en)
US10/375,223 US20040166462A1 (en) 2003-02-26 2003-02-26 Systems and methods for fabricating a dental template
US10/794,325 US7600999B2 (en) 2003-02-26 2004-03-04 Systems and methods for fabricating a dental template
ES04254358T ES2714375T3 (en) 2004-03-04 2004-07-21 Systems and methods for the manufacture of a dental template
DK04254358.7T DK1570803T3 (en) 2004-03-04 2004-07-21 Systems and methods for making a dental template
EP10179634.0A EP2266494B1 (en) 2004-03-04 2004-07-21 Orthodontic bonding template
EP04254358.7A EP1570803B1 (en) 2004-03-04 2004-07-21 Systems and methods for fabricating a dental template
ES10179634.0T ES2627430T3 (en) 2004-03-04 2004-07-21 Template binding orthodontic
EP18202114.7A EP3449865A1 (en) 2004-03-04 2004-07-21 Computer-implemented method of providing a digital representation of an orthodontic template for positioning an object on a patient's tooth
JP2004214985A JP4717390B2 (en) 2004-03-04 2004-07-22 Systems and methods for making dental template
CN 200410058321 CN1663540B (en) 2004-03-04 2004-08-10 Systems and methods for fabricating a dental template
HK05109721A HK1077727A1 (en) 2004-03-04 2005-11-01 Systems and methods for fabricating a dental template
JP2010137742A JP5196600B2 (en) 2004-03-04 2010-06-16 Systems and methods for making dental template
JP2011011431A JP2011120928A (en) 2004-03-04 2011-01-21 System and method for fabricating dental template
US10/375,223 Continuation-In-Part US20040166462A1 (en) 2003-02-26 2003-02-26 Systems and methods for fabricating a dental template
US20040253562A1 US20040253562A1 (en) 2004-12-16
US7600999B2 true US7600999B2 (en) 2009-10-13
ID=46300957
US10/794,325 Active 2024-10-18 US7600999B2 (en) 2003-02-26 2004-03-04 Systems and methods for fabricating a dental template
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