U.S. patent application number 13/700264 was filed with the patent office on 2013-12-12 for high performance mouthguard.
The applicant listed for this patent is William Cook, Mark H. Herman. Invention is credited to William Cook, Mark H. Herman.
Application Number | 20130327343 13/700264 |
Document ID | / |
Family ID | 44201370 |
Filed Date | 2013-12-12 |
United States Patent
Application |
20130327343 |
Kind Code |
A1 |
Cook; William ; et
al. |
December 12, 2013 |
HIGH PERFORMANCE MOUTHGUARD
Abstract
Described herein is a high performance mouthguard. Generally,
the mouthguard includes a base that includes at least one facial
wall, at least one lingual structure extending from the base such
that the base, the facial wall, and the lingual structure define a
trough having an inner surface, a heat-softenable material disposed
in the inner surface, defining a channel, and at least one
protrusion that includes a heat-softenable material projecting into
the channel from the heat-softenable material disposed on the inner
surface of at least one of the at least one facial wall and the at
least one lingual structure.
Inventors: |
Cook; William; (Lakeville,
MN) ; Herman; Mark H.; (Minneaplis, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cook; William
Herman; Mark H. |
Lakeville
Minneaplis |
MN
MN |
US
US |
|
|
Family ID: |
44201370 |
Appl. No.: |
13/700264 |
Filed: |
May 31, 2011 |
PCT Filed: |
May 31, 2011 |
PCT NO: |
PCT/US11/38532 |
371 Date: |
August 29, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61350327 |
Jun 1, 2010 |
|
|
|
Current U.S.
Class: |
128/862 |
Current CPC
Class: |
A63B 71/085
20130101 |
Class at
Publication: |
128/862 |
International
Class: |
A63B 71/08 20060101
A63B071/08 |
Claims
1. A mouthguard comprising: a base comprising at least one facial
wall; at least one lingual structure extending from the base such
that the base, the facial wall, and the lingual structure define a
trough having an inner surface; a heat-softenable material disposed
in the inner surface, defining a channel; and at least one
protrusion comprising a heat-softenable material projecting into
the channel from the heat-softenable material disposed on the inner
surface of at least one of: the at least one facial wall and the at
least one lingual structure.
2. The mouthguard of claim 1 wherein the heat-softenable material
of the protrusion is positioned so that, when the heat-softenable
material is softened and the mouthguard is fitted over a user's
dentition, the heat-softenable material of the protrusion
infiltrates space between the user's teeth.
3. The mouthguard of claim 1 wherein at least one of the base, the
at least one lingual wall, and at least one facial wall comprises a
heat-softenable material.
4. The mouthguard of claim 1 wherein a plurality of protrusions
project from the heat-softenable material disposed on the inner
surface of the facial wall.
5. The mouthguard of claim 1 wherein at least one protrusion
comprises a rounded surface facing toward the channel.
6. The mouthguard of claim 1 wherein the heat-softenable material
of at least one protrusion is greatest near the base and tapers as
the protrusion extends along the wall.
7. The mouthguard of claim 1 wherein the base comprises one or more
recesses positioned to accept one or more cusps of one or more of a
user's teeth.
8. The mouthguard of claim 1 wherein the facial wall comprises: a
labial portion comprising a thickness; and a lateral portion
comprising a thickness; wherein the thickness of the labial portion
of the facial wall is greater than the thickness of the lateral
portion of the facial wall.
9. The mouthguard of claim 1 wherein the facial wall comprises: a
labial portion comprising a thickness; and a posterior portion
comprising a thickness; wherein the thickness of the labial portion
of the facial wall is greater than the thickness of the posterior
portion of the facial wall.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 61/350,327, filed Jun. 1, 2010, which is
hereby incorporated by reference in its entirety.
BACKGROUND
[0002] A number of mouthguards currently exist in the art for
protecting the teeth and for reducing the chance of shock,
concussions, and other injuries as a result of high impact
collisions and blows during athletic competition. Mouthguards
generally are characterized as being non-personalized, universal
and stock model type, or are formed to have direct upper jaw
tooth-formed contact. These are customizable mouthguards.
[0003] Additionally, the mouthguards may be tethered or untethered.
Mouthguards may be tethered to a fastening point, such as a helmet
or face guard, to prevent the chance of the mouthguard from being
lost as well as to prevent swallowing of the mouthguard or choking
on the mouthguard by the user.
[0004] The lack of a mouthguard or the use of an improperly fitted
mouthguard have been found to be responsible for illnesses and/or
injuries resulting from impacts, collisions, or blows that occur to
the jaw structure of an athlete. Such injured athletes are
susceptible to headaches, presence of earaches, ringing in the
ears, clogged ears, vertigo, concussions and dizziness. The cause
of these types of health problems and injuries are generally not
visible by inspection of the mouth or the jaw but more particularly
relate to the temporomandibular joint (TMJ) and surrounded tissues
where the lower jaw is connected to the skull in the proximity
where the auriculo-temporalis nerves and supra-temporo arteries
pass from the neck into the skull to the brain.
[0005] In addition to protection of the teeth and the TMJ, athletes
clench their teeth during exertion, which can result in hundreds of
pounds of compressed force exerted from the lower jaw onto the
upper jaw. Such clenching can result in headaches, muscle spasms,
damage to teeth, injury to the TMJ, and pain in the jaw.
Furthermore, clenching of the teeth makes breathing more difficult
during physical exercise.
[0006] Most importantly, many problems exist with prior
mouthguards. Mouthguards with a rigid labial or buccal walls may
not readily accept wide teeth, were bulky, and/or have sharp edges.
When the custom appliances were placed in hot water to soften for
fitting, the mouthguards tended to collapse and permit portions to
touch and stick together upon removal from the hot water, thus
creating problems fitting such mouthguards. Delamination and
chewing destruction caused short life of the mouthguards.
SUMMARY OF THE INVENTION
[0007] The present invention provides a mouthguard. Generally, the
mouthguard includes a base that includes at least one facial wall,
at least one lingual structure extending from the base such that
the base, the facial wall, and the lingual structure define a
trough having an inner surface, a heat-softenable material disposed
in the inner surface and thereby defining a channel, and at least
one protrusion that includes a heat-softenable material projecting
into the channel from the heat-softenable material disposed on the
inner surface of at least one of the at least one facial wall and
the at least one lingual structure.
[0008] In some embodiments, the heat-softenable material of the
protrusion is positioned so that, when the heat-softenable material
is softened and the mouthguard is fitted over a user's dentition,
the heat-softenable material of the protrusion infiltrates space
between the user's teeth.
[0009] In some embodiments, at least one of the base, the at least
one lingual wall, and at least one facial wall comprises a
heat-softenable material.
[0010] In some embodiments, a plurality of protrusions project from
the heat-softenable material disposed on the inner surface of the
facial wall.
[0011] In some embodiments, at least one protrusion comprises a
rounded surface facing toward the channel.
[0012] In some embodiments, the heat-softenable material of at
least one protrusion is greatest near the base and tapers as the
protrusion extends along the wall.
[0013] In some embodiments, the base comprises one or more recesses
positioned to accept one or more cusps of one or more of a user's
teeth.
[0014] In some embodiments, the thickness of the labial portion of
the facial wall is greater than the thickness of the lateral or
posterior portion of the facial wall.
[0015] The above summary of the present invention is not intended
to describe each disclosed embodiment or every implementation of
the present invention. The description that follows more
particularly exemplifies illustrative embodiments. In several
places throughout the application, guidance is provided through
lists of examples, which examples can be used in various
combinations. In each instance, the recited list serves only as a
representative group and should not be interpreted as an exclusive
list.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIG. 1 illustrates a top perspective view of an exemplary
embodiment of a mouthguard.
[0017] FIG. 2 illustrates a top view of an exemplary embodiment of
a mouthguard.
[0018] FIG. 3 illustrates a rear view of an exemplary embodiment of
a mouthguard.
[0019] All Figures are illustrated for ease of explanation of the
basic teachings of the present invention only; the extensions of
the Figures with respect to number, position, relationship and
dimensions of the parts to form the embodiment will be explained or
will be within the skill of the art after the following description
has been read and understood. Further, the exact dimensions and
dimensional proportions to conform to specific force, weight,
strength, and similar requirements will likewise be within the
skill of the art after the following description has been read and
understood.
[0020] Where a numeral is used in various Figures of the drawings,
the numeral designates the same or similar parts in the various
Figures in which it is used.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0021] The present invention provides a mouthguard that may be
fitted particularly to the upper teeth of an individual. It has
been discovered that prior custom fittable mouthguards do not
optimally fit a user's teeth. As a result, certain characteristics
of the mouthguard such as, for example, fit, performance,
durability, and/or comfort may be compromised. Thus, the mouthguard
described herein can provide a better, more complete, and more
customized fit than prior mouthguards and, therefore, provide
better comfort, fit, durability, and/or performance.
[0022] Generally, the mouthguard described herein includes
heat-softenable material in addition to the heat softenable
material provided by existing custom fittable mouthguards. The
additional heat-softenable material can infiltrate spaces between
teeth that are not infiltrated by existing mouthguards, which lack
the additional heat-softenable material.
[0023] As used herein, the following terms shall have the indicated
meanings:
[0024] "Heat-softenable" refers to materials that soften and become
moldable when heated to a temperature within a glass transition
temperature range of from about 120.degree. F. to about 200.degree.
F.
[0025] "Non-softenable" refers to materials that do not soften and
become moldable when heated to a temperature of 200.degree. F. or
less.
[0026] The term "and/or" means one or all of the listed elements or
a combination of any two or more of the listed elements.
[0027] The terms "comprises" and variations thereof do not have a
limiting meaning where these terms appear in the description and
claims.
[0028] Unless otherwise specified, "a," "an," "the," and "at least
one" are used interchangeably and mean one or more than one.
[0029] Also herein, the recitations of numerical ranges by
endpoints include all numbers subsumed within that range (e.g., 1
to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).
[0030] Furthermore, when the terms "top," "bottom," "right,"
"left," "forward," "rearward," "front," "rear," "first," "second,"
"inside," "outside," "upper," "lower," "inferior," "superior,"
"anterior," "posterior," "proximal," "distal," "facial," "buccal,"
"labial," "oral," "lingual," "palatal," "mesial," and similar
positional and/or relative terms are used, the terms should be
understood to refer to structures shown in the drawings as they
will typically be utilized by one skilled in the art or otherwise
as would be recognized by one skilled in the art.
[0031] The present invention generally provides a mouthguard that
may be custom fit to the dentition of a user. The mouthguard
generally includes a heat-softenable material shaped to fit over
the teeth of the maxillary arch. In use, the heat-softenable
material may be heated sufficiently to soften the material so that
the heat-softenable material is moldable around the teeth of the
maxillary arch. The heat-softenable material may be placed over the
teeth of the maxillary arch and then molded to the dentition of the
user and then allowed to cool to produce a mouthguard custom fit to
the user. The molding of the softened heat-softenable material may
be performed by the user forcing the maxillary teeth into the
softened heat-softenable material.
[0032] Custom fitting the mouthguard can involve immersing the
mouthguard into water that has been heated to or above the glass
transition temperature of the heat-softenable material. In some
cases, the water may be boiling. In other cases, however, the water
may be heating to a sub-boiling temperature and still be warm
enough to soften the heat-softenable material.
[0033] After the heat-softenable material has been softened, the
mouthguard can be inserted into the mouth and registered with the
maxillary arch. The user then exerts a force pressing the maxillary
teeth into the softened heat-softenable material, thereby causing
the heat-softenable material to conform to the contours of at least
a portion of the user's maxillary teeth and, optionally, at least a
portion of the user's gums. The user may exert the force by
providing a biting force to the mouthguard. Alternatively, the user
may exert the force by pressing the mouthguard upwardly into the
maxillary teeth with the tongue or a finger.
[0034] Turning now to the Figures, a mouthguard 10 is generally
depicted in FIG. 1. The mouthguard includes a base 12 that includes
a facial wall 14. A lingual structure 16 extends from the base 12
opposite the facial wall 12. Together, the base 12, facial wall 14,
and lingual structure 16 define a trough 18 having an inner surface
20.
[0035] Each of the base 12, facial wall 14, and lingual structure
16 may independently of one another be formed from either a
heat-softenable material or a non-softenable material.
Heat-softenable materials and non-softenable materials are
described in detail below.
[0036] A heat-softenable material is disposed on the inner surface
20 of the trough 18. The heat-softenable material defines a channel
22 sized and shaped to accept at least a portion of a user's
maxillary teeth.
[0037] In embodiments in which at least one of the base 12, facial
wall 14, and lingual structure 16 are formed from a non-softenable
material, the heat-softenable material and the component formed
from the non-softenable material may be attached, affixed, adhered,
or otherwise assembled to one another in any suitable manner. FIG.
3 illustrates an exemplary embodiment in which the base 12, facial
wall 14, and lingual structure 16 are formed from a non-softenable
material so that the trough 18 and the heat-softenable material
that defines the channel 22 are readily distinguishable.
[0038] In alternative embodiments, however, one or more of the base
12, facial wall 14, and lingual structure 16 may be formed from a
heat-softenable material. In such embodiments, the heat-softenable
material forming the inner surface 20 of the trough 18 may also be
considered to be the heat-softenable material "disposed" on the
inner surface 20 of the trough 18 even though no additional layer
of heat-softenable material is present. Thus, in some embodiments,
a portion of trough 18 may be structurally indistinguishable from a
portion of the heat-softenable material that defines the channel
22.
[0039] One or more protrusions 24 of heat-softenable material
project into the channel 22 from the heat-softenable material
disposed on the inner surface 22 of the trough 18. The
heat-softenable material of each protrusion 24 may independently of
one another, and independently of the heat-softenable material
disposed on the inner surface 20 of the trough 18, be formed from
the same heat-softenable material or different heat-softenable
materials. Each protrusion 24 may, independently of one another,
project from the heat-softenable material disposed on the inner
surface 20 of the facial wall 14 or the inner surface 20 of the
lingual structure 16, or project into the channel 22 from the inner
surface 20 of both the facial wall 14 and the lingual structure 16.
In embodiments in which protrusions 24 project into the channel 22
from the inner surface 20 of both the facial wall 14 and the
lingual structure 16, the contours of the maxillary dentition may
be more completed enveloped, thereby providing a more thorough
fitting of the mouthguard 10.
[0040] When the mouthguard is being fitted, the heat-softenable
material of the protrusions 24 can infiltrate the spaces between a
user's teeth to a greater degree than is possible for mouthguards
that lack this additional heat-softenable material. The presence of
additional heat-softenable material provides more material to
infiltrate spaces and provide more complete filling of the contours
of the user's maxillary teeth and gums. Moreover, the protrusions
24 may be positioned to optimize infiltration of the protrusion
heat-softenable material into spaces between teeth. Finally, the
protrusions 24 may be formed from different heat-softenable
material than the heat-softenable material disposed on the inner
surface 20 of the trough 18. In some embodiments, the protrusion 24
heat-softenable material may, when heated and softened, be less
viscous and, therefore, infiltrate spaces between teeth more
readily than is possible for the heat-softenable material disposed
on the inner surface 20 of the trough 18. As noted above in the
Background, when mouthguards are formed from less viscous
heat-softenable materials, which may promote more complete fitment,
the walls of the mouthguard may collapse, thereby making proper
fitting of the mouthguard more difficult. Providing sources of less
viscous heat-softenable material in structures--i.e., as
protrusions 24--that are not required to maintain the general
integrity of the mouthguard can introduce the relatively more
flowable heat-softenable materials into the mouthguard 10 in a way
that does not compromise the integrity of the form of the
mouthguard 10 as a whole during the custom fitting process.
[0041] The protrusions 24 may be provided having any suitable
geometry or, alternatively, may be provided with no consistent
shape. Moreover, when a plurality of protrusions 24 are provided,
each of the plurality of protrusions 24 may be of identical,
similar, or dissimilar shape. Certain shapes, however, may be
preferred in certain embodiments.
[0042] For example, as shown in FIGS. 1-3, one or more protrusions
24 may include a rounded surface facing toward the channel 22. In
such embodiments, the rounded surface can improve comfort while the
mouthguard 10 is being fitted. In some embodiments, a protrusion 24
may be generally semi-conical, possessing more heat-softenable
material near the base 12 and tapering as the protrusion 24 extends
upward along the wall 14. In such embodiments, the rounded surface
may provide comfort while the mouthguard 10 is being fitted. In
addition, the relatively greater amount of heat-softenable material
near the base can provide optimal fit in an area where the total
volume of fillable recesses between teeth and in the cusps of the
teeth may be greatest.
[0043] As shown in FIG. 1 and FIG. 2, the base 12 can include one
or more recesses 26 positioned to accept one or cusps of one or
more teeth. Each recess 26 may be formed in heat-softenable
material so that, upon fitting, the heat softenable material
defining the recess 26 can fill spaces between teeth and/or the
spaces in the cusps of the teeth. This, too, can improve fit and,
therefore, comfort of the mouthguard 10 for the user.
Alternatively, each recess 26 may be formed in non-softenable
material. In such embodiments, the area including and surrounding
the recesses 26 may be better constructed to withstand wear and/or
destruction from biting and/or chewing forces and, therefore, offer
greater durability.
[0044] The presence of one or more recesses 26 and/or
heat-softenable material of the protrusions 24 can provide certain
benefits. One benefit is a more complete and individualized fit for
the mouthguard 10. A more complete and individualized fit can
result in increased comfort for the user, which can increase the
likelihood that a user will wear the mouthguard 10 as designed and,
therefore, enjoy that maximum performance and/or protective benefit
of using the mouthguard 10. Better fit also improves the likelihood
that the mouthguard 10 will remain in the intended, proper position
when in use. This, too, increases the likelihood that the user can
enjoy the maximum performance and/or protective benefit of using
the mouthguard 10. Another consequence of the mouthguard 10
remaining in its intended, proper position is that the mouthguard
10 may be less exposed to the user removing and chewing on the
mouthguard 10, which can promote delamination of mouthguard
components and/or premature destruction of the mouthguard 10.
[0045] Another benefit that may be provided by the protrusions 24
includes addition material providing performance benefits such as,
for example, impact absorption. Impact force may originate from,
for example, impacts, collisions, and/or blows associated with
athletic competition and/or clenching stress. Regardless of the
source of the impact force, additional impact absorption capacity
provided by additional heat-softenable material can improve the
performance and/or protection offered by the mouthguard 10 and,
therefore, improve the performance of the user.
[0046] In some embodiments, the thickness of the facial wall 14 may
vary. This feature can improve fitting and comfort for the user.
FIG. 2 illustrates that the labial portion of the facial wall 30
is, generally, the front portion of the mouthguard 10, the portion
that, in use, may fit over the incisors. Likewise, the lateral
portion of the facial wall 32 is shown as the portion of the
mouthguard 10 that, in use, may fit generally over the bicuspids
(or premolars). The posterior portion of the facial wall 34 is
shown as the portion of the mouthguard 10 that, in use, may fit
over the molars, particularly the second molar.
[0047] The labial thickness 31 may have a minimum thickness of at
least 3 mm such as for example, at least 4 mm, at least 5 mm, or at
least 6 mm. The labial thickness 31 may have a maximum thickness of
no more than 8 mm such as, for example, no more than 7 mm, no more
than 6 mm, no more than 5 mm, or no more than 4 mm. In various
embodiments, the labial thickness 31 may be within a range defined
by any combination of minimum labial thickness and maximum labial
thickness. In certain embodiments, the labial thickness 31 may be,
for example, about 4 mm, about 5 mm, or about 6 mm. In one
particular embodiment, the labial thickness 31 may be about 5
mm.
[0048] The lateral thickness 33 may have a minimum thickness of at
least 1 mm such as for example, at least 1.5 mm, at least 2 mm, at
least 2.5, at least 3, or at least 3.5 mm. The lateral thickness 33
may have a maximum thickness of no more than 4 mm such as, for
example, no more than 3.5 mm, no more than 3 mm, no more than 2.5
mm, no more than 2, or no more than 1 mm. In various embodiments,
the lateral thickness 33 may be within a range defined by any
combination of minimum lateral thickness and maximum lateral
thickness. In certain embodiments, the lateral thickness 33 may be,
for example, about 2.5 mm, about 3 mm, or about 3.5 mm. In one
particular embodiment, the lateral thickness 33 may be about 3
mm.
[0049] The posterior thickness 35 may have a minimum thickness of
at least 0.25 mm such as for example, at least 0.5 mm, at least 1
mm, at least 1.5, or at least 2 mm. The posterior thickness 35 may
have a maximum thickness of no more than 3 mm such as, for example,
no more than 2.5 mm, no more than 2 mm, no more than 1.5 mm, or no
more than 1 mm. In various embodiments, the posterior thickness 35
may be within a range defined by any combination of minimum
posterior thickness and maximum posterior thickness. In certain
embodiments, the posterior thickness 35 may be, for example, about
0.5 mm, about 1 mm, or about 1.5 mm. In one particular embodiment,
the lateral thickness 33 may be about 1 mm.
[0050] In some embodiments, the labial thickness 31 may be greater
than the posterior thickness 35. In other embodiments, the labial
thickness 31 may be greater than the lateral thickness 33. In still
other embodiments, the labial thickness 31 may be greater than both
he lateral thickness 33 and posterior thickness 35.
[0051] In some embodiments, differences in thickness of the various
portions of the facial wall 14 may be expressed in absolute units,
in terms of being some percentage, ratio, or fold greater than
either or both of the lateral thickness 33 and posterior thickness
35, or in any other manner of comparing two values. Thus, in some
embodiments, the labial thickness 31 may be greater than the
lateral thickness 33 by, for example, 4 mm, 3.5 mm, 3 mm 2.5 mm, 2
mm, 1.5 mm, 1 mm, or 0.5 mm. Alternatively, in some embodiments,
the labial thickness 31 may be greater than the posterior thickness
35 by, for example, 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm,
or 5.5 mm. In other embodiments, the labial thickness 31 may be,
for example, 2-fold, 2.5-fold, 3-fold greater than the lateral
thickness 33. As used herein, a 2-fold increase reflects a 2:1
ratio such as one may find in an embodiment in which the lateral
thickness 33 is 2 mm and the labial thickness 31 is 4 mm. In other
embodiments, the labial thickness 31 may be expressed as being, for
example, 125%, 150%, 180%, 200% (i.e., the aforementioned 2:1 ratio
or being 2-fold greater), or 250% of the lateral thickness 33.
Similarly, in some embodiments, the labial thickness 31 may be, for
example, 2-fold, 3-fold, 4-fold, 5-fold, 6-fold, 7-fold, 8-fold,
9-fold, or 10-fold greater than the posterior thickness 35.
[0052] In some embodiments, the mouthguard can include one or more
components in addition to the components described in detail
herein. Such additional components may be mouthguard components
such as, for example, one or more components described in detail in
one or more of U.S. Pat. Nos. 6,505,626; 6,505,627; 6,505,628;
6,508,251; 6,510,853; 6,588,430; 6,675,806; 6,675,807; 6,691,710;
and 7,299,804.
Heat-Softenable Material
[0053] The heat-softenable material may be any suitable material
that softens and becomes moldable when heated to a temperature
between about 120.degree. F. and 200.degree. F. Suitable
heat-softenable materials can therefore be softenable within a
glass transition temperature range of as low as 120.degree. F. to
as high as about 200.degree. F. such as, for example, within a
glass transition temperature range of, for example, from about
140.degree. F. to approximately 185.degree. F. or 190.degree.
F.
[0054] Suitable materials include, for example, low melt
temperature ethylene vinyl acetate (EVA) thermoplastics. In some
embodiments, the heat-softenable material softens sufficiently for
deformation to receive the impression of teeth after being immersed
in water at a temperature range of approximately 140.degree. F. to
approximately 180.degree. F. for approximately two minutes.
[0055] In some embodiments, the heat-softenable material can
include a polycaprolactone such as, for example, polycaprolactone
CAPA 6500 (Perstorp UK, Ltd., Cheshire, UK) or TONE (P-767, Union
Carbide Corporation, Piscataway, N.J.). A polycaprolactone may be
used alone or, for example, in a mixture with EVA. In other
embodiments, the heat-softenable material can include a mixture of
polycaprolactone and a polyolefin elastomer such as, for example, a
copolymer of ethylene and octene-1 (e.g., ENGAGE, Dupont Canada,
Inc., Mississauga, Ontario). In other embodiments, the
heat-softenable material may be a thermoplastic olefin such as, for
example ADFLEX (LyondellBasell Industries N.V., Rotterdam,
Netherlands). In other embodiments, the heat-softenable material
may be a thermoplastic polyurethane having a low melt point (e.g.,
less than 160.degree. F.) such as, for example, certain TEXIN
thermoplastic polyurethanes (Bayer AG, Leverkusen, Germany). In
still other embodiments, the heat-softenable material may be a
thermoplastic polyolefin such as, for example, EXACT (ExxonMobil
Chemical Co., Houston, Tex.).
Non-Softenable Material
[0056] The non-softenable material may be any suitable material
that does not appreciably softens and remains substantially
unmoldable when heated to a temperature of about 200.degree. F.
Suitable non-softenable materials include thermoplastic materials
such as, for example, higher melt temperature thermoplastics
including, for example, certain EVA copolymer resins such as ELVAX
250 or ELVAX 260. In some embodiments, the non-softenable material
may have a Shore "A" hardness of approximately 82, which can
provide a durable, rubbery material.
[0057] In some embodiments, the non-softenable material can include
a mixture of styrene block copolymer and high-density polyethylene
(HDPE). More specifically, the styrene block copolymer may include
DYNAFLEX (part number G2780-0001 from GLS Corporation, McHenry,
Ill.) while the HDPE may include HD-6706 ESCORENE (ExxonMobile
Chemical Co., Houston, Tex.).
[0058] In another embodiment, the non-softenable material can
include a styrene block copolymer mixed with polyolefin elastomer,
which is a copolymer of ethylene and octene-1. A suitable copolymer
is available as ENGAGE (Dupont Canada, Inc., Mississauga,
Ontario).
[0059] In another embodiment, the non-softenable material can
include a mixture of thermoplastic rubber and a polyolefin
elastomer as described above. Suitably thermoplastic rubbers
include, for example, SANTOPRENE (ExxonMobile Chemical Co.,
Houston, Tex.) and KRATON Thermoplastic Rubber (Kraton Polymers
U.S. LLC, Houston, Tex.)
[0060] In other embodiments, the non-softenable material can
include a thermoplastic polyurethane having a relative high melt
point (e.g., greater than 180.degree. F.) and a durometer at or
above 90 A and/or 40 D. Thermoplastic polyurethanes suitable for
use as the non-softenable material include, for example, certain
TEXIN thermoplastic polyurethanes (Bayer AG, Leverkusen,
Germany).
[0061] In still other embodiments, the non-softenable material can
include a saturated elastomeric base styrenic (SEBS) such as, for
example, UNISOFT (United Soft Plastics, Inc., Lawrenceville,
Ga.).
[0062] Unless embodiments are mutually exclusive or unless
otherwise indicated, a mouthguard of the present invention can
include the features of any two or more embodiments described
herein.
[0063] For any method disclosed herein that includes discrete
steps, the steps may be conducted in any feasible order. And, as
appropriate, any combination of two or more steps may be conducted
simultaneously.
[0064] The complete disclosure of all patents, patent applications,
and publications, and electronically available material cited
herein are incorporated by reference in their entirety. In the
event that any inconsistency exists between the disclosure of the
present application and the disclosure(s) of any document
incorporated herein by reference, the disclosure of the present
application shall govern.
[0065] The foregoing detailed description and drawings have been
given for clarity of understanding only and represent merely
exemplary embodiments. Thus, no unnecessary limitations are to be
understood from the description and drawings. The invention is not
limited to the exact details shown and described, for variations
obvious to one skilled in the art will be included within the
invention defined by the claims.
[0066] Unless otherwise indicated, all numbers expressing
quantities of components, molecular weights, and so forth used in
the specification and claims are to be understood as being modified
in all instances by the term "about." Accordingly, unless otherwise
indicated to the contrary, the numerical parameters set forth in
the specification and claims are approximations that may vary
depending upon the desired properties sought to be obtained by the
present invention. At the very least, and not as an attempt to
limit the doctrine of equivalents to the scope of the claims, each
numerical parameter should at least be construed in light of the
number of reported significant digits and by applying ordinary
rounding techniques.
[0067] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the invention are approximations,
any numerical values set forth in the specific examples are
reported as precisely as possible. All numerical values, however,
inherently contain a range necessarily resulting from the standard
deviation found in their respective testing measurements.
[0068] All headings are for the convenience of the reader and
should not be used to limit the meaning of the text that follows
the heading, unless so specified.
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