U.S. patent application number 14/795764 was filed with the patent office on 2016-04-07 for tooth attachment placement device.
This patent application is currently assigned to ORAMETRIX, INC.. The applicant listed for this patent is Phillip Getto, Friedrich Riemeier, Rohit Sachdeva, Frank Witte. Invention is credited to Phillip Getto, Friedrich Riemeier, Rohit Sachdeva, Frank Witte.
Application Number | 20160095670 14/795764 |
Document ID | / |
Family ID | 55631941 |
Filed Date | 2016-04-07 |
United States Patent
Application |
20160095670 |
Kind Code |
A1 |
Witte; Frank ; et
al. |
April 7, 2016 |
TOOTH ATTACHMENT PLACEMENT DEVICE
Abstract
In a preferred embodiment of the invention, tooth attachment
placement (TAP) device or for assisting a user in placing one or
more appliances or attachments on one or more teeth is disclosed.
The TAP device comprises single tooth jigs connected through
splines. The geometry of the device is automatically designed in
the treatment planning unified workstation, thereby generating a
digital STL file. Then the device is created from a non-flexible
biocompatible material by a 3D printer in accordance with the
digital STL file. Appliance, for example, may be a bracket or a
bracket shim; and the attachment may be an aligner attachment or a
pad. Different embodiments of the TAP device are disclosed. Methods
for verifying the accuracy of the placements of the brackets on the
teeth using the TAP device are disclosed.
Inventors: |
Witte; Frank; (Berlin,
DE) ; Riemeier; Friedrich; (Berlin, DE) ;
Sachdeva; Rohit; (Plano, TX) ; Getto; Phillip;
(Dallas, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Witte; Frank
Riemeier; Friedrich
Sachdeva; Rohit
Getto; Phillip |
Berlin
Berlin
Plano
Dallas |
TX
TX |
DE
DE
US
US |
|
|
Assignee: |
ORAMETRIX, INC.
Richardson
TX
|
Family ID: |
55631941 |
Appl. No.: |
14/795764 |
Filed: |
July 9, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62061130 |
Oct 7, 2014 |
|
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Current U.S.
Class: |
433/3 ;
433/24 |
Current CPC
Class: |
B33Y 80/00 20141201;
A61C 7/002 20130101; A61C 7/146 20130101 |
International
Class: |
A61C 7/14 20060101
A61C007/14; A61C 7/00 20060101 A61C007/00 |
Claims
1. A method for indirect bonding orthodontic brackets on a
patient's teeth, comprising the steps of: a) obtaining a virtual
model comprising the dentition of a patient in a current stage and
placement locations of virtual orthodontic brackets on the
dentition in said current stage, including type and dimensions of
said virtual orthodontic brackets; b) defining the geometry of a
bracket placement tray; wherein the geometry is derived basically
from the inverse shape of virtual the model with orthodontic
brackets on; c) wherein said bracket placement tray is designed for
a plurality of real teeth of said patient based on said virtual
model; d) said bracket placement tray having features for placement
of real orthodontic brackets thereby enabling bonding of said real
orthodontic brackets to said real teeth at desired locations; e)
wherein said bracket placement tray is manufactured using
generative manufacturing technologies (3D printing, 3D laser
sintering, etc.); f) wherein the real brackets will be put into the
holding features of the indirect bonding tray; g) bonding said real
orthodontic brackets on said patient's real teeth using said
bracket placement tray;
2. Method according to claim 1, where the transfer tray consists
from separate transfer jigs for each single tooth connected to each
other by structures like one or more splines or other connecting
geometries.
3. Method according to claim 2, where the rigidity of the complete
tray, the jigs and/or the connectors is adjusted by different
material properties or geometries at different locations of the
transfer tray (thickness, diameter and shape of connectors,
etc.)
4. Method according to claim 3, where the features holding the
brackets are optimized by geometries acting like a spring, having
prominent ridges, using snap fit mechanisms or other geometries to
better hold the brackets or allow for using adhesive in addition
(like silicon) to hold the brackets in the transfer tray.
5. Method according to claim 4, where the transfer jig(s) for at
least one tooth that cannot be bonded due to crowding or missing
eruption are already designed and manufactured with this tray, but
positioned outside of but connected to the transfer tray area that
will be used intra-orally, so that it can be cut to be used at a
later point in time. ("cut off jigs")
6. Method according to claim 5, where the geometry of the "cut off
jigs" comprises a significantly larger surface area covering the
respective tooth for more accurate placement of a bracket with that
separate "cut off jig".
7. Method according to claim 2, where the connecting geometries
comprise features of easy separation like constrictions or
notches.
8. Method according to claim 2, where the separate transfer jigs
are as narrow as possible to allow for better placement.
9. Method according to claim 1, wherein the placement of the
virtual brackets is based on jig heights.
10. Method according to claim 1, wherein the placement of the
virtual brackets is based on a virtual setup.
11. Method according to claims 9 and 10, wherein the geometry of
the transfer tray is calculated automatically in a format allowing
for using a generative manufacturing method to produce the real
transfer tray.
12. Method according claim 1, scanning the dentition of said
patient after bonding of said real orthodontic brackets is
complete;
13. Method according claim 12, verifying positions of said real
orthodontic brackets on said patient's real teeth.
14. A tooth attachment placement device, comprising: (a) single
tooth jigs; and (b) an upper spline and a lower spline; wherein
said single tooth jigs are interconnected by said upper spline and
said lower spline; wherein each jig is designed to hold a bracket
to be placed on a tooth; wherein said upper spline and said lower
spline is made in tubular form for carrying ultra violet rays for
curing pads attached to said brackets; wherein said tooth placement
device is made from translucent material; wherein said tooth
placement device is created with generative manufacturing
technologies.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional application
corresponding to the provisional application Ser. No. 62/061,130,
filed Oct. 7, 2014, pending. This application is related to the
U.S. Pat. Nos. 6,554,613, 6,905,337, 6,918,761, 7,013,191,
7,252,509, 7,590,462 and 7,699,606 issued to OraMetrix and their
related patent applications, the entire contents of each of these
patents and corresponding applications are fully incorporated by
reference herein.
BACKGROUND OF THE INVENTION
[0002] A. Field of the Invention
[0003] This invention relates generally to the field of
orthodontics and dentistry. More particularly, the invention
relates to templates that are applied to teeth and which provide a
locating mechanism for a variety of purposes, including
localization of treatments on a tooth, and accurately placing
brackets, bracket bonding pads, and other orthodontic appliances on
teeth.
[0004] B. Description of Related Art
[0005] In orthodontics, a patient suffering from a malocclusion is
typically treated by bonding brackets to the surface of the
patient's teeth. The brackets have slots for receiving an archwire.
The bracket-archwire interaction governs forces applied to the
teeth and defines the desired direction of tooth movement.
Typically, the bends in the wire are made manually by the
orthodontist. During the course of treatment, the movement of the
teeth is monitored. Corrections to the bracket position and/or wire
shape are made manually by the orthodontist.
[0006] In conventional orthodontics, accurate placement of the
brackets on the teeth is important to ensure that the tooth is
moved over the course of treatment to the desired finish position.
The proper location of brackets on the teeth is part of treatment
planning for the patient performed by the orthodontist. Desired
bracket position can be determined in a variety of ways, including
mathematical calculation (see Lemchen, U.S. Pat. No. RE 35,169 and
Andreiko et al., U.S. Pat. Nos. 5,431,562 and 5,683,243), using
interactive orthodontic treatment planning software (see published
PCT application of OraMetrix, Inc., WO 01/80761), using wax set-ups
from a model of the malocclusion, and by the orthodontist mentally
visualizing the bracket placement on the tooth.
[0007] Once the desired bracket position is determined using any of
these means, the actual placement of the bracket on the teeth can
be carried out directly by bonding the bracket to the teeth, either
with or without some bracket placement aids. Bracket placement
aids, in the form of customized machined bracket placement jigs and
thermoplastic bracket transfer trays, are known in the art. See the
above-cited patents to Andreiko, Cohen et al. U.S. Pat. No.
3,738,005 and Cleary et al., U.S. Pat. No. 6,123,544.
[0008] The present invention provides device or tooth templates for
a variety of possible purposes, including precisely locating
brackets on teeth. The devices or templates represent a less
costly, easier to use approach to bracket placement than the jigs
and transfer trays described above. Moreover, the manufacturing of
the templates, at least in some embodiments, does not require any
specialized equipment such as milling machines or stereolithography
machines. The templates can also be used for a variety of other
dental uses besides the bracket placement, including locating
mechanisms for specific procedures on teeth such as varnishing and
etching, treatment of cavities, root canals and other treatments
and placement of attachments for aligners or pads on the teeth.
SUMMARY OF THE INVENTION
[0009] In a preferred embodiment of the invention, tooth attachment
placement (TAP) device for assisting a user in placing one or more
appliances or attachments on one or more teeth is disclosed. The
TAP device comprises single tooth jigs connected through splines or
other elements of different configuration(s). The geometry of the
TAP device is automatically designed in the treatment planning
unified workstation, thereby generating a digital file of the TAP
device design, preferably in the STL format, or in any other
suitable format such as STEP. Then, the TAP device is created
preferably from a non-flexible biocompatible material by a
generative manufacturing apparatus, such as a 3D printer, in
accordance with the digital file of the TAP device design. One
skilled in the art would appreciate that the TAP device can also be
created from semi flexible or flexible material, or from a hybrid
combination of flexible and non-flexible materials. Appliance, for
example, may be a bracket or a bracket shim; and the attachment may
be an aligner attachment or a pad. A bracket shim is an
intermediary structure with opposed surfaces, one facing the tooth
and the other facing the bracket base, providing a shim between the
tooth surface and the bracket base to accurately position the
bracket, and in particular the slot of the bracket, in
three-dimensional space. The device or the template comprises
single tooth jigs connected through splines. The device is produced
in labial and lingual versions and provides better fit compared to
conventional deep-drawn Indirect Bonding Trays (IDBs). Bonding of
all brackets can be achieved in one step. If needed, the device can
be cut into segments in certain malocclusions. Additionally,
re-bonding of a single tooth can be done by using only one cut out
jig. Jigs can be included for later bonding of teeth that cannot be
bonded initially (because the tooth may not be erupted, or require
rotation, or for any other treatment reasons). The geometry of the
device is automatically designed in the treatment planning
workstation, and does not require any manual interaction of an
operator to generate the STL File for producing the device from a
biocompatible material, which is not flexible, using a 3D printer.
The device is produced at a very reasonable cost.
[0010] In one embodiment, the jig designed to hold the appliance
(or the attachment) has one or more marks indicating the location
and orientation of where the appliance is to be placed on the at
least one tooth. The device or the template, in some embodiments,
is temporarily adhered to the surface of the tooth. In use, after
the device or template is generated, the user removes the mark
indicating the location of the appliance, creating a void in the
template at that location. Alternatively, the void can be formed in
the template during manufacturing process of the template. The
template is then applied to the tooth. The void provides an
aperture in the template enabling the user to directly bond a
bracket to the tooth surface at that location, or, alternatively
the shim. The mark may optionally provide orientation features
which assist the user in the proper placement of the bracket on the
tooth.
[0011] The template can take the form for placing brackets on a
plurality of teeth for an upper or lower arch of the patient.
Alternatively, the template can take the form of a single tooth
template for placing a bracket on a single tooth. Other alternative
constructions of the templates are contemplated, such as templates
that provide a feature which can be activated after the template is
applied to the tooth or teeth to make a physical bracket locating
mark on the tooth surface directly.
[0012] In another preferred aspect, a method is provided for
verifying the accuracy of the placement of an orthodontic template
on the teeth of a patient, comprising the steps of: a) creating a
design of an orthodontic template through treatment planning using
a computer containing a three-dimensional virtual model of the
teeth of a patient and the location of virtual appliances on the
three-dimensional virtual model; b) generating the orthodontic
template using the design of the orthodontic template; indicating
the outline of the teeth and marks indicating the position and
orientation of the appliance on each tooth; c) applying the
template to the surface of the actual teeth of the patient; d)
verifying the accuracy of the placement of the template on the
actual teeth of the patient using the computer; and e) adjusting
the placement of the template on the actual teeth of the patient
until the desired or acceptable placement of the template is
achieved. In order to verify the accuracy of the placement of the
template on the teeth of the patient, an image of the dentition of
the patient with the template placed upon the teeth is taken and
stored in the computer; then digitally compared with the template
design placed on the virtual three-dimensional model of the teeth
of the patient. If there is a discrepancy between the actual
placement of the template on the teeth and the desired placement of
the template, then the actual placement is adjusted until the
desired or acceptable placement is achieved. The image of the
dentition of the patient with the template placed upon the actual
teeth is taken using an in-vivo scanning device or with digital
photographs or by other similar means.
[0013] In another aspect, a method is provided for placing a
bracket on a tooth, comprising the steps of: a) generating a
template for positioning a bracket on a tooth, the template
comprising a a mark indicating the position and orientation of an
appliance on the tooth and a void in the template; c) placing the
template on the surface of the tooth; d) placing a bracket on the
tooth at the location of the void in the template; e) bonding the
bracket or bracket shim to the tooth; and f) removing the template.
In one possible embodiment, prior to the step of bonding the
bracket to the tooth, the orthodontist may use the void in the
template as a means for accurately applying a chemical composition,
such as an acid or sealant, to the tooth surface, or for placing a
mask for laser etching of the tooth surface.
[0014] In still another aspect, a template is provided for use in
applying a treatment to a tooth. The template is sized and shaped
so as to be place able onto at least one tooth of a set of teeth of
a patient. The template has a void at the location and orientation
of where a treatment is to occur on the at least one tooth. The
template has a tooth-facing surface adapted to be adhered to the
surface of the tooth in a reference position wherein the void
accurately indicates the location of wherein the treatment is to
occur. The treatment could be any possible treatments, for example,
varnishing, etching, cleaning, locating a dental prosthetics e.g.,
crown or filling, root canal, or of course bracket placement.
[0015] The templates of this invention can be used directly on the
tooth for direct bonding of the bracket, or they can be used with a
model of the teeth and used to fabricate a more conventional
indirect bonding bracket placement jig, as discussed in detail
below.
[0016] In another preferred aspect, a method of making an
orthodontic template for a patient for use in assisting a user in
placing an appliance on a designated tooth void of an appliance
whereas each of a plurality of the remaining teeth has an appliance
attached thereto is disclosed. The method comprises the steps of:
(a) obtaining a three-dimensional virtual model of a patient
comprising a designated tooth void of an appliance and the
remaining teeth wherein each of a plurality of the remaining teeth
has an appliance attached thereto; (b) storing the
three-dimensional virtual model in a computer, the computer having
instructions foe treatment planning and a library of virtual
appliances; (c) positioning a virtual appliance on the designated
tooth through treatment planning using the three-dimensional
virtual model, wherein the virtual appliance is selected from the
library of virtual appliances; (d) creating a design of an
orthodontic template using the positioning of the virtual appliance
on the designated tooth using the computer; (e) generating said
orthodontic template directly with 3D printing using the design of
the orthodontic template; the template indicating the outline of
the designated tooth; the template having one or more marks
indicating the location and orientation of where the appliance is
to be placed on the designated tooth; the template having a
tooth-facing surface adapted for positioning on the surface of said
designated tooth in a reference position wherein the one or more
marks accurately indicate the proper location for said appliance.
The method is particularly useful where the designated tooth was
previously only partially erupted and therefore unable to receive
an appliance. The virtual three-dimensional model is created using
images obtained through in-vivo scanning the patient. The images
include the patient's teeth as well as existing appliances on the
remaining teeth.
[0017] These and still other aspects of the invention will be more
apparent from the following detailed discussion of presently
preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Presently preferred embodiments of the invention are
described below in reference to the appended drawings, wherein like
reference numerals refer to like elements in the various views, and
in which:
[0019] FIG. 1 is block diagram of a system for creating a
three-dimensional virtual patient model and for diagnosis and
planning treatment of the patient.
[0020] FIG. 2 shows the in-vivo scanned digital dentition model of
a patient with teeth and gingiva in the malocclusion state.
[0021] FIG. 3 shows the digital model of the patient in FIG. 2 with
teeth and gingiva wherein the teeth are set-up in a target state
using the treatment planning instructions provided in the system of
FIG. 1.
[0022] FIG. 4A shows front view of the upper jaw and lower jaw and
facial bone with modeled teeth, all obtained from the volume scan
of the patient.
[0023] FIG. 4B shows left bucal view of the upper jaw and lower jaw
and facial bone with modeled teeth, all obtained from the volume
scan of the patient.
[0024] FIG. 5A shows modeling of teeth obtained from surface
scanning of the dentition of a patient. While tooth crowns are
displayed in the model, tooth roots and jaw bones are missing.
[0025] FIG. 5B shows teeth with roots in malocclusion. The roots
are obtained through scanning the patient's dentition and bones
using a CBCT device and integrating the CBCT digital data with the
data obtained through in-vivo scanning.
[0026] FIG. 6 shows patient's crowns with roots at a target
stage.
[0027] FIG. 7 shows the digital target set-up model of the patient
in FIG. 3 with the brackets placed on the teeth. Gingiva is also
present in this figure.
[0028] FIG. 8 shows the digital target set-up model of the patient
with the brackets placed on the teeth of FIG. 7 with a plane of
reference for the brackets. Again, gingiva are also present in this
figure.
[0029] FIG. 9 shows the digital target set-up model of the patient
of FIG. 8 with the brackets repositioned by using the plane of
reference for the brackets as a guide.
[0030] FIG. 10 shows the patient model of FIG. 7 with an individual
bracket repositioned as shown on the tooth.
[0031] FIGS. 11A, 11B and 11C show examples of bracket positioning
on a tooth.
[0032] FIGS. 12A and 12B show additional examples of bracket
positioning on a tooth.
[0033] FIG. 13 shows the digital malocclusion model of the patient
of FIG. 2 with the brackets placed on the teeth in accordance with
the bracket-positions on the teeth in the target positions per FIG.
9. FIG. 13 shows the target placement of the brackets on the teeth
which will be used to design the TAP device in accordance with the
invention disclosed herein.
[0034] FIG. 14 shows the preferred embodiment of the invention,
namely the design of the TAP (Tooth Attachment Placement) device
created by the system described in FIG. 1 in accordance with the
placement of the brackets on the teeth as shown in FIG. 13.
[0035] FIGS. 15-19 show various applications of the TAP device as
described below.
[0036] FIG. 15 shows a lingual TAP device. Jig is skipped in this
case.
[0037] FIG. 16 shows a labial TAP device for a lower jaw, including
jigs, splines and patient identifier.
[0038] FIG. 17 shows a labial TAP device for an upper jaw.
[0039] FIG. 18 shows a lingual TAP device placed on the physical
model of a jaw. Jig for a tooth is skipped in this case since the
tooth is in a rotated position so that the jig cannot be used in
this state.
[0040] FIG. 19 shows a lingual TAP device placed on the physical
model of the jaw as shown in FIG. 18, and additionally with a
patient identification link.
[0041] FIGS. 20-32 show various details of the TAP device design as
described below.
[0042] FIG. 20 shows the bracket holding geometry of the TAP device
including the jig or the holder, the splines, and the bracket.
[0043] FIG. 21 shows another view of the bracket holding geometry
of the TAP device shown in FIG. 20 including the bracket base.
[0044] FIG. 22 shows stabilizing the TAP device by closing the
teeth.
[0045] FIG. 23 shows another example of stabilizing the TAP device
by closing the teeth.
[0046] FIG. 24 shows another example of stabilizing the TAP device
by closing the teeth.
[0047] FIG. 25 shows a section of the TAP device showing side view
of a counter shaped slot.
[0048] FIG. 26 shows the sane section of the TAP device of FIG. 25,
showing front view of the counter shaped slot.
[0049] FIG. 27 shows a section of the TAP device showing hollow
tubes.
[0050] FIG. 28 shows a section of the TAP device showing an example
of the distance between the bracket surface and the tooth
surface.
[0051] FIG. 29 shows a section of the TAP device showing another
example that there is no distance between the bracket surface and
the tooth surface.
[0052] FIG. 30 shows a section of the TAP device showing a snap
fit.
[0053] FIG. 31 shows a section of the TAP device showing an example
of the form-fitting elements.
[0054] FIG. 32 shows another embodiment of the invention showing a
design of another type of TAP device based upon the brackets placed
on the patient's malocclusion.
[0055] FIG. 33 shows design of another type of TAP device shown in
FIG. 33 with clips inserted in the clip holder.
[0056] FIG. 34 shows the design of the TAP device shown in FIG. 33
with orientation plane of each bracket.
[0057] FIG. 35 shows a variation of the TAP device previously shown
in FIG. 32 placed on the teeth.
[0058] FIG. 36A shows the components of the TAP device for a single
tooth, namely cap, metal bracket holder, O-ring and bracket.
[0059] FIG. 36B shows the tooth number, for which the particular
jig is designed, placed on the front of the cap.
[0060] FIG. 37 shows configuration of the TAP device where the jigs
are removed for the teeth.
[0061] FIGS. 38A-38H display the steps of the process of preparing
a jig, bonding a bracket to a tooth, and subsequently removing the
cap and the bracket holder.
[0062] FIGS. 38A and 38B display how to position bracket
holder.
[0063] FIG. 38C displays how to place Jig on the tooth.
[0064] FIG. 38D displays how to fix the Jig before light
hardening.
[0065] FIGS. 38E and 38F display how to remove cap.
[0066] FIG. 38G displays how to open the bracket door.
[0067] FIG. 38H displays how to remove the metal bracket
holder.
[0068] FIG. 39 shows separated jigs designed for two specific
teeth. Tooth number is engraved on the jig.
[0069] FIG. 40 shows a spline joining the separated two jigs shown
in FIG. 39.
[0070] FIG. 41 shows a TAP device and a malocclusion model of the
dentition of a patient and the brackets are bonded on a quadrant of
the malocclusion model in order to determine the accuracy of the
placements of the brackets.
[0071] FIG. 42 shows the TAP device with the brackets.
[0072] FIG. 43 shows the brackets bonded to the teeth.
[0073] FIG. 44 shows the in-vivo scanned image of the dentition
after the brackets were bonded to the teeth using a customized TAP
device. This image enables verification of the accuracy of the
placement of the brackets on the teeth.
[0074] FIG. 45 shows archwire placement through the bonded brackets
for verification of the accuracy of the placement of the brackets
on the teeth.
[0075] FIG. 46 shows a jig with the bracket portion cutout. Such a
jig can be placed on a patient's tooth and the cutout portion
marked to see where the bracket will be attached. The marked area
then can be cleaned. Also, the marked area can be used to verify
the accuracy of the placement of the bracket on the tooth.
[0076] FIG. 47 shows an attachment different from a bracket, such
as an attachment to be placed on a tooth for an aligner, placed on
the jig of a TAP device.
[0077] FIG. 47A shows the attachment in more detail.
[0078] FIG. 47B shows the attachment mounted on the tooth.
[0079] FIG. 48 shows a cotton roll attached to the shim of the TAP
device. The cotton roll will absorb the saliva of a patient when
the TAP device is used to place the brackets or other attachments
on the teeth of a patient.
[0080] FIG. 49 shows a different configuration of the bracket
holder which makes it easier to remove the TAP device jig after the
bracket is placed and bonded to a tooth.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0081] In a preferred embodiment of the invention, tooth attachment
placement (TAP) device or for assisting a user in placing one or
more appliances or attachments on one or more teeth is disclosed.
The TAP device comprises single tooth jigs connected through
splines or other elements of different configuration(s). The
geometry of the TAP device is automatically designed in the
treatment planning unified workstation, thereby generating a
digital file of the TAP device design, preferably in the STL
format, or in any other suitable format including STEP or VDA. Then
the TAP device is created from a non-flexible biocompatible
material by a generative manufacturing apparatus, such as a 3D
printer in accordance with the digital file of the TAP device
design. One skilled in the art would appreciate that the TAP device
can also be created from semi flexible or flexible material, or
from a hybrid combination of flexible and non-flexible materials.
Appliance, for example, may be a bracket or a bracket shim; and the
attachment may be an aligner attachment or a pad.
[0082] Before describing the features of this invention in detail,
an overview of the unified workstation will be set forth initially.
The workstation provides software features that create two
dimensional and/or three-dimensional virtual model of a patient on
a computer, which can be used for purposes of communication,
diagnosis, treatment planning and designing orthodontic devices or
templates for assisting users in placing one or more appliances or
attachments on one or more teeth, or other orthodontic customized
appliances.
[0083] The essence of the unified workstation described herein is
the ability to capture images from various sources that provide
volumetric images, surface images that are 3-D or 2-D in nature,
and may be static or dynamic, such as from CBCT, CAT, MRI, fMIRI,
ultrasound device, cameras that provide still photos, white light
and laser based surface scanners, video cameras providing video
images, tracking devices and digital cameras. Images from these
sources are combined as needed to create a unified simulation model
of the craniofacial and dental facial complex, for facilitating
diagnosis, communication, treatment planning, and design of
appliances for treating craniofacial and dentofacial problems. With
these images a composite structure of the face can be constructed
with dynamic or static behavioral properties. One can also track
function or jaw movement and simulate the functional movements,
e.g., smile movement of the lower jaw etc.
[0084] The global positioning of the entire face with respect to
its surroundings can be set by the user for planning purposes. In
addition, the relative position of each of the structural elements,
such as the upper jaw and its teeth when captured independently,
can be oriented with respect to any other structure such as the
soft tissue face by using specific anatomical land marks or user
defined reference planes, either in 2-D or 3-D space. Furthermore,
the relationship of the lower jaw and its accompanying teeth can be
registered with respect to the upper jaw using a combination of
registration techniques. For instance, the bite registration can be
recorded by taking an intraoral surface scan of the teeth together
and using it as a template to register the relationship of the
upper jaw and the lower jaw from a CBCT volumetric scan.
[0085] Most importantly from volumetric data, one can extract three
dimensional structural data which may include crowns and roots of
teeth, bone, soft tissue, e.g., gingiva and facial soft tissue and
appliances attached to any of these structures, such as orthodontic
brackets, implants, etc. Each of these structural elements can be
independently manipulated in three-dimensional space to construct a
treatment plan, and design the appropriate device for correction of
a problem. Furthermore, the interdependencies of the treatment
between these various structural components can be modeled to
design a holistic treatment plan. Specific relationships between
the various structural components can be defined by choosing an
appropriate reference plane and capturing the spatial relationships
between specific structures. The treatment design may include
repositioning, restoring, replacing of any of the structural
elements in 2-D or 3-D space. Also function can be simulated or
modeled based upon captured data to achieve the desired goals,
e.g., the teeth with their roots can be appropriately positioned in
the bone to withstand the stresses of jaw movement or the position
of the jaw joint, i.e., the condyle is in harmony with the position
of the teeth to prevent any source of dysfunction or breakdown of
the structural elements. Mechanical analysis, such as finite
element method, may also be used to better understand the nature of
stresses and strains imposed on the structural elements to design
better treatment. All changes may be measured with respect to
defined planes of reference to provide numerical output to design a
variety of customized treatment devices, such as orthodontic
brackets, orthodontic archwires, surgical bite splints, surgical
fixation plates, implants, condylar prosthesis, bone screws,
periodontal stents, mouth guards, bite plates, removable
orthodontic appliances, crowns, bridges, dentures, partial
dentures, obturators, temporary anchorage devices from either
natural or synthetic substances using generative manufacturing
apparatus--such as SLA or milling or robotic manufacturing. Any
type of dental, orthodontic, restorative, prosthodontic or surgical
device which may be tissue borne, dental borne, osseous borne, can
be designed in combination, or singularly in serial or in parallel,
e.g., indirect bonding trays that allow bonding of brackets, and
are also designed to guide implant insertion. Furthermore, if the
patient requires surgery, splints, fixation plates, boney screws
may all be designed and manufactured simultaneously. The numerical
output of the treatment plan can be used to drive navigational
systems for performing any procedure. Simulations can be used to
train and build skills or examine proficiency. The numerical output
of the treatment design can be used to drive robots to perform
surgical procedures. Furthermore this output can be used to create
a solid model representation of the treatment plan using generative
manufacturing techniques or milling techniques.
[0086] Template data or normative data stored in memory can be used
to plan any of the structural changes or design of the devices. In
addition, reference data from the non-affected structural elements
may be used as templates to provide design parameters to plan and
correct the affected side.
[0087] One can also replace or remove any of the structures to
achieve the desired goal, e.g., extraction of teeth, root
amputation, sinus lift, veneers, inter-proximal reduction, etc. The
codependency of movement of one object and its effect on another
can also be simulated for all three tissue types, e.g., when the
tooth moves how does it affect the gum soft tissue, when the tooth
moves where does the root move in reference to the bone, or how
does the bone change, how does the face change when the bones move.
All types of planning can be executed by different modalities or
professionals in an interactive manner asynchronously or
synchronously.
[0088] In summary, the unified workstation provides the ability to
plan crowns with roots thereby optimizing the planning by changing
the root position so that the crown planned is designed such that
axial forces are transmitted to the roots to add to the stability
of the crown minimizing aberrant forces that can lead to root
fracture, crown fracture, and breakdown of the periodontium or
bone. Similarly, for surgical patients one can plan root positions
so that the surgeon can cut between the roots and prevent damage
besides planning the movement of the bones. Similarly for implants,
one can move the roots in a desirable location so that the implant
when inserted doesn't damage the roots. The user can also size the
implants correctly so that they don't encroach on root space. All
this planning would be impossible if the roots were not made
separate objects that could move. Finally one can move the roots
preferentially to create bone. As one extrudes a root one can
create bone. Similarly one can change the gum tissue architecture
by moving roots and for orthodontic movement one can avoid moving
roots where there is no bone or selectively move teeth to prevent
root collision or move roots away from areas where there is lack of
bone into the areas where there is bone as one plans to move them
towards their final destination. Again, not only can one plan tooth
movement but bone movement and soft tissue gum and face as well to
achieve the goals. One can, alter the spatial position of all the
objects which are extracted, change their shape form and volume to
restore and or reconstruct. One can sculpt or remove selectively
any region gum soft issue bone dentition. Although one can use a
fusion technique, the preference is to extract the data from the
CBCT for bone and dentition with roots at a minimum. One can take
partial intramural scans where distortion is expected, e.g., large
metal crowns or fillings, or one can scan an impression in those
areas or plaster limited to the region of interest.
[0089] The images of the roots can be taken with CBCT and affixed
to crowns taken by scanning intramural impressions or models. The
preferred process does not require fusing a model of the dentition
into the crank facial structure. All needed information can be
captured in one shot and extract individual features. The unified
workstation captures the dental and osseous and soft tissue as one
and segregates them in to individual components for planning
treatment. The optimization of the treatment plan can be achieved
by using different approaches, e.g., correcting crowding by
minimizing tooth movement and planning veneers or minimizing tooth
preparation for veneer construction by positioning the teeth
appropriately. This can be said for any structure and the decision
can be driven by the patients need, time constraints, cost risk
benefit, skill of operator, etc.
[0090] Many of the details and computer user interface tools which
a practitioner may use in adjusting tooth position, designing
appliance shape and location, managing space between teeth, and
arriving at a finish tooth position using interaction with a
computer storing and displaying a virtual model of teeth are set
forth in the prior application Ser. No. 09/834,412 filed Apr. 13,
2001, and in published OraMetrix patent application WO 01/80761,
the contents of which are incorporated by reference herein.
[0091] General Description
[0092] A unified workstation environment and computer system for
diagnosis, treatment planning and delivery of therapeutics,
especially adapted for treatment of craniofacial structures, is
described below. In one possible example, the system is
particularly useful in diagnosis and planning treatment of an
orthodontic patient with other craniofacial disorders or conditions
requiring surgery, prosthodontic treatment, restorative treatment,
etc.
[0093] As depicted in FIG. 1, the overall system 50 includes a
general-purpose computer system 10 having a processor (CPU 12) and
a user interface 14, including screen display 16, mouse 18 and
keyboard 20. The system is useful for planning treatment for a
patient 34.
[0094] The system 50 includes a computer storage medium or memory
22 accessible to the general-purpose computer system 10. The memory
22, such as a hard disk memory or attached peripheral devices,
stores two or more sets of digital data representing patient
craniofacial image information. These sets include at least a first
set of digital data 24 representing patient craniofacial image
information obtained from a first imaging device and a second set
of digital data 26 representing patient craniofacial image
information obtained from a second image device different from the
first image device. The first and second sets of data represent, at
least in part, common craniofacial anatomical structures of the
patient. At least one of the first and second sets of digital data
normally would include data representing the external visual
appearance or surface configuration of the face of the patient.
[0095] In a representative and non-limiting example of the data
sets, the first data set 24 could be a set of two dimensional color
photographs of the face and head of the patient obtained via a
color digital camera 28, and the second data set is
three-dimensional image information of the patient's teeth,
acquired via a suitable scanner 30, such as a hand-held optical 3D
scanner, or other type of scanner. The memory 22 may also store
other sets 27 of digital image data, including digitized X-rays,
MRI or ultrasound images, CT scanner, CBCT scanner, jaw tracking
device, scanning device, video camera, etc., from other imaging
devices 36. The other imaging devices need not be located at the
location or site of the workstation system 50. Rather, the imaging
of the patient 34 with one or other imaging devices 36 could be
performed in a remotely located clinic or hospital, in which case
the image data is obtained by the workstation 50 over the Internet
37 or some other communications medium, and stored in the memory
22.
[0096] The system 50 further includes a set of computer
instructions stored on a machine-readable storage medium. The
instructions may be stored in the memory 22 accessible to the
general-purpose computer system 10. The machine-readable medium
storing the instructions may alternatively be a hard disk memory 32
for the computer system 10, external memory devices, or may be
resident on a file server on a network connected to the computer
system, the details of which are not important. The set of
instructions, described in more detail below, comprise instructions
for causing the general computer system 10 to perform several
functions related to the generation and use of the virtual patient
model in diagnostics, therapeutics and treatment planning.
[0097] These functions include a function of automatically, and/or
with the aid of operator interaction via the user interface 14,
superimposing the first set 24 of digital data and the second set
26 of digital data so as to provide a composite, combined digital
representation of the craniofacial anatomical structures in a
common coordinate system. This composite, combined digital
representation is referred to herein occasionally as the "virtual
patient model," shown on the display 16 of FIG. 1 as a digital
model of the patient 34. Preferably, one of the sets 24, 26 of data
includes photographic image data of the patient's face, teeth and
head, obtained with the color digital camera 28. The other set of
data could be intra-oral 3D scan data obtained from the hand-held
scanner 30, CT scan data, X-Ray data, MRI, etc. In the example of
FIG. 1, the hand-held scanner 30 acquires a series of images
containing 3D information and this information is used to generate
a 3D model in the scanning node 31, in accordance with the
teachings of the published PCT application of OraMetrix, PCT
publication no. WO 01/80761, the contents of which are incorporated
by reference herein. Additional data sets are possible, and may be
preferred in most embodiments. For example the virtual patient
model could be created by a superposition of the following data
sets: intra-oral scan of the patient's teeth, gums, and associated
tissues, X-Ray, CT scan, intra-oral color photographs of the teeth
to add true color (texture) to the 3D teeth models, and color
photographs of the face, that are combined in the computer to form
a 3D morph-able face model. These data sets are superimposed with
each other, with appropriate scaling as necessary to place them in
registry with each other and at the same scale. The resulting
representation can be stored as a 3D point cloud representing not
only the surface on the patient but also interior structures, such
as tooth roots, bone, and other structures. In one possible
embodiment, the hand-held in-vivo scanning device is used which
also incorporates a color CCD camera to capture either individual
images or video.
[0098] The software instructions further includes a set of
functions or routines that cause the user interface 16 to display
the composite, combined digital three-dimensional representation of
craniofacial anatomical structures to a user of the system. In a
representative embodiment, computer-aided design (CAD)-type
software tools are used to display the model to the user and
provide the user with tools for viewing and studying the model.
Preferably, the model is cable of being viewed in any orientation.
Tools are provided for showing slices or sections through the model
at arbitrary, user defined planes. Alternatively, the composite
digital representation may be printed out on a printer or otherwise
provided to the user in a visual form.
[0099] The software instructions further include instructions that,
when executed, provide the user with tools on the user interface 14
for visually studying, on the user interface, the interaction of
the craniofacial anatomical structures and their relationship to
the external, visual appearance of the patient. For example, the
tools include tools for simulating changes in the anatomical
position or shape of the craniofacial anatomical structures, e.g.,
teeth, jaw, bone or soft tissue structure, and their effect on the
external, visual appearance of the patient. The preferred aspects
of the software tools include tools for manipulating various
parameters such as the age of the patient; the position,
orientation, color and texture of the teeth; reflectivity and
ambient conditions of light and its effect on visual appearance.
The elements of the craniofacial and dental complex can be analyzed
quickly in either static format (i.e., no movement of the
anatomical structures relative to each other) or in an dynamic
format (i.e., during movement of anatomical structures relative to
each other, such as chewing, occlusion, growth, etc.). To
facilitate such modeling and simulations, teeth may be modeled as
independent, individually moveable 3 dimensional virtual objects,
using the techniques described in the above-referenced OraMetrix
published PCT application, WO 01/80761.
[0100] The workstation environment provided by this invention
provides a powerful system and for purposes of diagnosis, treatment
planning and delivery of therapeutics. For example, the effect of
jaw and skull movement on the patient's face and smile can be
studied. Similarly, the model can be manipulated to arrive at the
patient's desired feature and smile. From this model, and more
particularly, from the location and position of individual
anatomical structures (e.g., individual tooth positions and
orientation, shape of arch and position of upper and lower arches
relative to each other), it is possible to automatically back solve
for or derive the jaw, tooth, bone and/or soft tissue corrections
that must be applied to the patient's initial, pre-treatment
position to provide the desired result. This leads directly to a
patient treatment plan.
[0101] These simulation tools, in a preferred embodiment, comprise
user-friendly and intuitive icons 35 that are activated by a mouse
or keyboard on the user interface of the computer system 10. When
these icons are activated, the software instruction provide pop-up,
menu, or other types screens that enable a user to navigate through
particular tasks to highlight and select individual anatomical
features, change their positions relative to other structures, and
simulate movement of the jaws (chewing or occlusion). Examples of
the types of navigational tools, icons and treatment planning tools
for a computer user interface that may be useful in this process
and provide a point of departure for further types of displays
useful in this invention are described in the patent application of
Rudger Rubbert et al., Ser. No. 09/835,039 filed Apr. 13, 2001, the
contents of which are incorporated by reference herein.
[0102] The virtual patient model, or some portion thereof, such as
data describing a three-dimensional model of the teeth in initial
and target or treatment positions, is useful information for
generating customized orthodontic appliances for treatment of the
patient. The position of the teeth in the initial and desired
positions can be used to generate a set of customized brackets, and
customized flat planar archwire, and customized bracket placement
jigs as disclosed herein. Alternatively, the initial and final
tooth positions can be used to derive data sets representing
intermediate tooth positions, which are used to fabricate
transparent aligning shells for moving teeth to the final position,
as described in the above-referenced Chisti et al. patents. The
data can also be used to place brackets and design a customized
archwire as described in the previously cited application Ser. No.
09/835,039.
[0103] To facilitate sharing of the virtual patient model among
specialists and device manufacturers, the system 50 includes
software routines and appropriate hardware devices for transmitting
the virtual patient model or some subset thereof over a computer
network. The system's software instructions are preferably
integrated with a patient management program having a scheduling
feature for scheduling appointments for the patient. The patient
management program provides a flexible scheduling of patient
appointments based on progress of treatment of the craniofacial
anatomical structures. The progress of treatment can be quantified.
The progress of treatment can be monitored by periodically
obtaining updated three-dimensional information regarding the
progress of treatment of the craniofacial features of the patient,
such as by obtaining updated scans of the patient and comparison of
the resulting 3D model with the original 3D model of the patient
prior to initiation of treatment.
[0104] Thus, it is contemplated that system described herein
provides a set of tools and data acquisition and processing
subsystems that together provides a flexible, open platform or
portal to a variety of possible therapies and treatment modalities,
depending on the preference of the patient and the practitioner.
For example, a practitioner viewing the model and using the
treatment planning tools may determine that a patient may benefit
from a combination of customized orthodontic brackets and wires and
removable aligning devices. Data from the virtual patient models is
provided to diverse manufacturers for coordinated preparation of
customized appliances. Moreover, the virtual patient model and
powerful tools described herein provide a means by which the
complete picture of the patient can be shared with other
specialists (e.g., dentists, maxilla-facial or oral surgeons,
cosmetic surgeons, other orthodontists) greatly enhancing the
ability of diverse specialists to coordinate and apply a diverse
range of treatments to achieve a desired outcome for the patient.
In particular, the overlay or superposition of a variety of image
information, including 2D X-Ray, 3D teeth image data, photographic
data, CT scan data, and other data, and the ability to toggle back
and forth between these views and simulate changes in position or
shape of craniofacial structures, and the ability to share this
virtual patient model across existing computer networks to other
specialists and device manufacturers, allows the entire treatment
of the patient to be simulated and modeled in a computer.
Furthermore, the expected results can be displayed beforehand to
the patient and changes made depending on the patient input.
[0105] Treatment Planning
[0106] Various treatment planning steps are explained through FIGS.
2-13.
[0107] FIG. 2 shows the in-vivo scanned digital dentition model of
a patient with teeth 110 and gingiva 112 in the malocclusion state.
The in-vivo scanning is performed using a hand held, white light
scanner. Alternately, the scanning can be done through other
scanning devices including a monochrome light scanner or a laser
scanner. Also, a similar model can be obtained through scanning an
impression of the dentition or a physical model of the dentition
created from the impression.
[0108] FIG. 3 shows the digital model of the patient in FIG. 2 with
teeth and gingiva 112 wherein the teeth 120 are set-up in a target
state using the treatment planning instructions provided in the
system of FIG. 1. This can be achieved through treatment planning
simulations to realize the target set-up. The target set-up may be
the final desired state or an intermediate state depending on the
treatment plan chosen for the patient.
[0109] Alternately, the treatment planning can be done using the
dentition models without gingiva, as explained in FIGS. 4A, 4B, 5A,
5B and 6.
[0110] FIG. 4A shows front view of the upper jaw 52 and lower jaw
54 and facial bone 56 with modeled teeth 58, all obtained from the
volume scan of the patient.
[0111] FIG. 4B shows left bucal view of the upper jaw 60 and lower
jaw 62 and facial bone 64 with modeled teeth 66, all obtained from
the volume scan of the patient.
[0112] FIG. 5A shows modeling of teeth obtained from surface
scanning of the dentition of a patient. While tooth crowns 70 are
displayed in the model, tooth roots and jaw bones are missing.
[0113] FIG. 5B shows teeth 72 with roots in malocclusion. The roots
are obtained through scanning the patient's dentition and bones
using a CBCT device and integrating the CBCT digital data with the
data obtained through in-vivo scanning.
[0114] FIG. 6 shows patient's crowns with roots 74 at a target
stage.
[0115] FIG. 6 shows the digital model of the patient in FIG. 5B
set-up in a target state by taking into account the positions of
the roots using the treatment planning instructions provided in the
system of FIG. 1. The advantage of this approach is that the root
positions are taken into consideration while planning the target
set-up thereby avoiding any teeth movements that may not be
feasible due to root positions.
[0116] FIG. 7 shows the digital target set-up model of the patient
in FIG. 3 with the brackets 130 placed on the teeth 120. Gingiva
112 are also present in this figure. The brackets 130 may be
automatically selected from a bracket library and automatically
placed at desired locations on the teeth by the instructions in the
system of FIG. 1. Alternately, the brackets may be selected by an
operator and placed at locations selected by the operator. If the
brackets are automatically placed by the instructions in the system
of FIG. 1, then one or more of them can be selected and moved to a
different location by the operator.
[0117] FIG. 8 shows the digital target set-up model of the patient
with the brackets 130 placed on the teeth 120 of FIG. 7 with a
plane of reference 140 for the brackets. Again, gingiva 112 is also
present in this figure. With the plane of reference, all the
brackets can be moved to a different position globally.
[0118] FIG. 9 shows the digital target set-up model of the patient
of FIG. 8 with the brackets 132 repositioned by using the plane of
reference for the brackets as a guide. Teeth 120 and gingiva 112
are also present in this figure.
[0119] FIG. 10 shows the patient model of FIG. 7 with an individual
bracket 134 repositioned as shown on tooth 122. Such repositioning
of one or more brackets is done when desired.
[0120] FIGS. 11A, 11B and 11C show examples of bracket positioning
on a tooth. FIG. 11A shows the bracket 136 touching at a single
point 136a on the surface of the tooth 124 thereby creating a gap
136b between the base of the bracket 136 and the surface of the
tooth 124; FIG. 11B shows the bracket 137 not touching the surface
of the tooth 124 at all and thereby creating a gap 137a between the
base of the bracket 137 and the surface of the tooth 124; and FIG.
11C shows the bracket 138 touching the surface of the tooth 124 at
two points 138a and 138b thereby leaving no gap between the base of
the bracket 138 and the surface of the tooth 124. The operator can
thus modify the positioning of the base of any bracket on the
surface of a tooth as desired in order to realize the treatment
goals. The shape of the gap between the base of a bracket and the
surface of the corresponding tooth dictates the shape of the pad
necessary to properly bond the bracket to the tooth.
[0121] FIGS. 12A and 12B show additional examples of bracket
positioning on a tooth. FIG. 12A shows the bracket 142 touching at
one point 142a on the tooth 126; and FIG. 12B shows the bracket 144
touching at the opposite point 144a on the tooth 126.
[0122] Thus, different bracket placements are designed with respect
to the tooth surface in order to realize different forces, such as
torque, angulation and/or translational or rotational movements of
the tooth in the desired directions.
[0123] FIG. 13 shows the digital malocclusion model of the patient
of FIG. 2 with the brackets placed 150 on the teeth 120 in
accordance with the bracket-positions on the teeth in the target
positions per FIG. 9. FIG. 13 shows the target placement of the
brackets on the teeth which will be used to design the TAP device
in accordance with the invention disclosed herein.
[0124] One skilled in the art would appreciate that the target
set-up can be done either automatically or manually by an operator
or a combination of the two can be used as well.
[0125] TAP Device Design & Manufacturing
[0126] FIG. 14 shows the preferred embodiment of the invention,
namely the design of the TAP device created by the system described
in FIG. 1 in accordance with the placement of the brackets on the
teeth as shown in FIG. 13. The TAP device 200 consists of single
tooth jigs 210 interconnected through splines 300 and 310. Each jig
210 has a specific tooth number 320 engraved on it indicating the
particular tooth associated with the jig. Each jig is designed to
hold an attachment or a bracket to be placed on a tooth.
Additionally, there are over mold retention pegs 322 attached to
the spline 310. Geometry of the TAP device is automatically
designed by the system described in FIG. 1, without requiring any
manual interaction of an operator. The design is created in the
form of a digital STL File for exporting it to an apparatus for
manufacturing the TAP device.
[0127] The spline is made with unique width in a small shape from
rigid material. This design helps in keeping the elements of the
TAP device in the desired position. The cross section of the spline
can be different for each spline and designed to carry the UV rays
as well as provide the snap points to break the sections apart when
needed.
[0128] The distances between the jigs on the spline can vary
depending upon the geometry of the dentition, and for providing
enough space to effectively place the jigs, and thereby the
brackets or the attachments on the teeth.
[0129] The Tap device can be designed to serve the upper jaw and
the lower jaw together.
[0130] Bracket placement within the TAP device jigs can be made
either manually or with a robot.
[0131] The TAP device can be designed for a single tooth, multiple
teeth or the full arch. The TAP device can be designed in segments
as well.
[0132] The TAP device can be made locally at an orthodontist's
practice or remotely at a manufacturing facility.
[0133] The bracket holder in a jig in a TAP device can have two
walls, three walls or four walls for properly holding the
bracket.
[0134] The TAP device is made from a non-flexible, biocompatible
material using an additive manufacturing process apparatus such as
a 3D printer. Properties of the preferred biocompatible material
are listed in Table 1. The preferred material for making the TAP
device is in the liquid form; however materials in the powder form
or any other form suitable for 3D printing apparatus can also be
used.
[0135] The TAP device is preferably made from clear/transparent or
translucent material. The splines are made in the form of tubes.
Such a design enables the spline to carry ultra-violate light or
rays for curing the bracket pads attached to the teeth surfaces;
thereby enabling firm attachments of the brackets to the teeth once
the brackets are placed on the teeth using the TAP device.
[0136] There are marks placed on the splines so that the splines
can be broken at those points in order to remove the jigs or the
holders once the brackets are bonded to the teeth.
[0137] The TAP device described above can be used for attaching
other types of attachments, such as aligner attachments, to the
teeth as well.
[0138] The TAP devices are packaged in ultra-violate resistance
boxes for storage and shipping purposes.
[0139] There are many advantages of the TAP device over the
conventional similar devices. The TAP device is created in labial
and lingual versions. It provides better fit compared to the
conventional deep-drawn Indirect Bonding (IDB) Trays. Bonding of
all brackets can be achieved in one step. If needed, the TAP device
can be cut into segments for certain malocclusions. Re-bonding of a
single tooth can be achieved by using only one cut-out jig. TAP
device can be designed to include jigs for later bonding of teeth
that cannot be bonded initially (because the tooth is not erupted,
or requires rotation, etc.). The cost of producing a customized TAP
device is low compared to commercially available IDB Trays.
[0140] In summary, as disclosed before, (a) the single tooth jigs
of a TAP device are connected through splines or other elements of
different configuration(s); (b) the TAP device design is stored in
a digital file, preferably in the STL format, or in any other
suitable format including STEP or VDA; (c) the TAP device is
created from a non-flexible biocompatible material, or from semi
flexible or flexible material, or from a hybrid combination of
flexible and non-flexible materials; and (d) the TAP device is
produced by a generative manufacturing apparatus, such as a 3D
printer in accordance with the digital file of the TAP device
design.
[0141] FIGS. 15-19 show various applications of the TAP device as
described below.
[0142] FIG. 15 shows a lingual TAP device 220. Jig at the location
221 is skipped in this case since the corresponding tooth is in
position so that the jig cannot be used along with the other jigs.
So, an additional jig 222 is added for a later use. The figure
shows the patient identifier link 324. The patient identifier link
324 as well as the additional jig 222 can be detached from the TAP
device before bonding the brackets on the teeth using the TAP
device. Every jig can be broken apart at points 224 on the splines
after bonding. The jig 222 can be used at a later appropriate time
for bonding a bracket on the particular tooth at the position 221
that was initially skipped.
[0143] The calculation of how much occlusal surface to cover on
each tooth is a critical parameter. In crowded cases it is tricky
to create enough space between the jigs to allow for the bends in
the splines. The TAP device design disclosed herein, which aims at
effectively creating a TAP device with spaces in between is indeed
unique. The jigs are attached by one or more splines of various
potential shape. Varying the width trades flexibility (thinner
jigs) of the TAP device against stability (wider jigs). Stability
can be offset by bonding multiple teeth at once or by going to a
single jig with full occlusal coverage in situations where the
tooth is hard to get to at the same time as bonding the adjacent
teeth. Having the space will also reduce the printing cost which is
calculated by material needed.
[0144] FIG. 16 shows a labial TAP device 230 for a lower jaw,
including jigs 234, splines 236 and 238 and patient identifier
326.
[0145] Similarly, FIG. 17 shows a labial TAP device 240 for an
upper jaw.
[0146] FIG. 18 shows a lingual TAP device 250 placed on the
physical model 260 of a jaw. Jig for tooth 261 is skipped in this
case since the tooth is in a rotated position so that the jig
cannot be used in this state.
[0147] FIG. 19 shows a lingual TAP device 250 placed on the
physical model 260 of the jaw as shown in FIG. 18, and additionally
with a patient identification link 270. In this view also the jig
for tooth 261 is skipped in this case since the tooth is in a
rotated position so that the jig cannot be used in this state.
[0148] FIGS. 20-32 show various details of the TAP device design as
described below.
[0149] FIG. 20 shows the bracket holding geometry of the TAP device
including the jig or the holder 400, the splines 410 and 412, and
the bracket 420.
[0150] FIG. 21 shows another view of the bracket holding geometry
of the TAP device shown in FIG. 20 including the bracket base
422.
[0151] FIG. 22 shows stabilizing the TAP device by closing the
teeth. This figure shows the lower teeth 430, the jig or the holder
432, the spline 434, the bracket 436, the spline breaking point 438
and bite 440.
[0152] FIG. 23 shows another example of stabilizing the TAP device
by closing the teeth. The lingual view is shown. This figure shows
the lower teeth 430, the jig or the holder 432, the bracket 436 and
the upper teeth 450.
[0153] FIG. 24 shows another example of stabilizing the TAP device
by closing the teeth. The labial view is shown. This figure shows
the lower teeth 430, the jig or the holder 432, the spline 434, the
bracket 436 and the upper teeth 450.
[0154] FIG. 25 shows a section of the TAP device showing side view
of a counter shaped slot. This figure shows the jig or the holder
432, the spline 434, the bracket 436 and the pad 437.
[0155] FIG. 26 shows the sane section of the TAP device of FIG. 25,
showing front view of the counter shaped slot. This figure shows
the jig or the holder 432, the spline 434, the bracket 436 with the
base 439.
[0156] FIG. 27 shows a section of the TAP device showing hollow
tubes. This figure shows the tooth 430, the jig or the holder 432,
the spline 434 and the bracket 436. It should be noted that the
splines are made of hollow tubes. They are translucent and designed
to carry light to cure the bracket pads for attaching the brackets
to the teeth.
[0157] FIG. 28 shows a section of the TAP device showing an example
of the distance between the bracket surface and the tooth surface.
This figure shows the tooth 430, the jig or the holder 432, the
spline 434, the bracket 436 and the pad 437 filling the distance
between the surface of the tooth 430 and the base of the bracket
436.
[0158] FIG. 29 shows a section of the TAP device showing another
example that there is no distance between the bracket surface and
the tooth surface. This figure shows the tooth 430, the jig or the
holder 432, the spline 434 and the bracket 436. There is no
distance between the surface of the tooth 430 and the base of the
bracket 436. So, the bracket base has a thin layer of glue or
adhesive, not shown in the figure, for attaching the bracket to the
tooth.
[0159] FIG. 30 shows a section of the TAP device showing a snap
fit. The figure shows the jig or the holder 433, the spline or the
frame of the TAP device 435 and the bracket 436. the frame of the
TAP device 435 holds the jig 433 with the snap 460. Alternately,
this holding arrangement can be in the form of a ball and
socket.
[0160] FIG. 31 shows a section of the TAP device showing an example
of the form-fitting elements. The figure shows a portion of the
spline or frame 434 and an over mold 462 performing the form
fitting in to the frame 434.
[0161] One skilled in the art would appreciate that other designs
of the TAP device are possible.
[0162] FIG. 32 shows another embodiment of the invention showing a
design of another type of TAP device based upon the brackets placed
on the patient's malocclusion. The figure shows teeth 600, clip
holder 602, retention peg 604 and bracket 608.
[0163] FIG. 33 shows design of another type of TAP device shown in
FIG. 32 with clips 606 inserted in the clip holder 602. The figure
also shows teeth 600, retention peg 604 and bracket 608.
[0164] FIG. 34 shows the design of the TAP device shown in FIG. 33
with orientation plane 610 of each bracket. The figure also shows
teeth 600, clip holder 602, retention peg 604, the clip 606 and
bracket 608.
[0165] FIG. 35 shows a variation of the TAP device 620 previously
shown in FIG. 32 placed on the teeth 621. The TAP device 620
comprises single jigs to bond brackets indirectly to the lingual
surface of the teeth. There are several advantages of this TAP
device: (a) precise and fast bonding of the brackets on the teeth,
(b) single Jig positioning, (c) no deforming of the plastic cap and
(d) easy and precise re-bonding of the brackets is possible. The
TAP device 620 is manufactured using 3D printing apparatus. Further
details regarding the components of this TAP device are explained
in FIGS. 36A and 36B.
[0166] FIG. 36A shows the components of the TAP device 620 for a
single tooth, namely cap 622, metal bracket holder 624, O-ring 626
and bracket 628. The TAP device is mounted on the tooth 623. The
cap fits to the individual tooth and holds the assembly in place.
The metal bracket holder is assembled into the cap and holds the
bracket in place. The O-ring fixes the metal bracket holder to the
cap.
[0167] FIG. 36B shows the tooth number, for which the particular
jig is designed, 629 placed on the front of the cap 622.
[0168] In case of heavy crowding it is sometime needed to bond
brackets later in the treatment. Crowding, especially in the lower
jaw, makes it sometimes necessary to bond first alternating
bracket. In order to realize such a configuration of the TAP
device, the O-Ring, cap and metal bracket holder are removed for
selected teeth from the TAP device and bonded after the rest of the
brackets are bonded to the teeth. The reason for taking this
approach is that the caps sometimes do not fit side by side in case
of crowding.
[0169] FIG. 37 shows configuration of the TAP device 630 where the
jigs are removed for the teeth 631.
[0170] The process of preparing a jig, bonding a bracket to a
tooth, and subsequently removing the cap and the bracket holder
using the TAP device is as follows:
[0171] Step 1. Prepare Jigs [0172] a. Carefully remove the Jig from
the printed model. [0173] b. Clean the bonding surface of the
bracket. Make sure that no cleaning fluid like acetone or others
come in contact with the cap or O-Ring. [0174] c. Add glue to the
bonding surface of the bracket and make sure that the applied
amount of glue is in the right amount depending upon the type of
the glue and the size of the bracket base. Excessive amount of glue
may also bond the cap to the tooth, making removal of the cap
difficult later on. [0175] d. Prepare tooth surface. [0176] Note:
Light bond glue (light polymerization) is preferred to make sure
that there is enough time for a precise positioning of the jig.
[0177] Step 2. Bond Brackets [0178] a. Make sure that the bracket
holder is in position before placing the jig. See FIGS. 38A and 38B
to position the bracket holder. FIG. 38A shows the front view with
the cap 635, the bracket holder 636 and the bracket 637. FIG. 38B
shows the side view view of view with the cap 635', the bracket
holder 636' and the bracket 637'. [0179] b. Place the single jig on
the tooth and remove exceeding glue if needed. See FIG. 38C which
sows mounting the cap with the bracket on to the tooth. [0180] c.
Fix the Jig before light hardening. See FIG. 38D which shows
bonding the bracket to the tooth.
[0181] Step 3. Remove Cap and Bracket Holder [0182] a. Remove
O-ring. [0183] b. Remove the cap by swiveling the lower part of the
cap. as shown. Use a small tool to start the swiveling, See FIGS.
38E and 38F which show the steps of removing the cap after bonding
the bracket to the tooth. FIG. 38E shows moving the cap away from
the tooth; and then FIG. 38F shows lifting the cap upwards for
removing the cap. [0184] c. Open the bracket door (see FIG. 38G).
[0185] d. Remove the metal bracket holder from the bracket (see
FIG. 38H).
[0186] FIG. 39 shows separated jigs 640 and 642 designed for two
specific teeth. Tooth number 644 is engraved on the jig.
[0187] FIG. 40 shows a spline 646 joining the separated two jigs
shown in FIG. 39. The figure also shows the jigs 640 and 642 and
tooth number 644.
[0188] Although the preferred embodiment of the invention disclosed
above describes the design of the TAP device based upon the target
set-up determined through treatment planning, one would appreciate
that the TAP device can be designed simply based upon the placement
of the brackets on the dentition determined by any method, such as
placing the brackets by a practitioner on the malocclusion based on
gut-fill and experience or any other method including combination
of treatment planning and best judgment. Furthermore, the TAP
device can be made for bracket or other attachment placement at any
point during the treatment. In other words, the TAP device is not
limited for use only with the final stage of the treatment.
[0189] It should be noted that the TAP device can be used for
placement of any type of attachment, including brackets,
attachments for aligners, pad attachments or any other type of
attachment for placement on a patient's dentition.
[0190] Attachment Placement Verification
[0191] It is important to verify accuracy of the placement of the
attachments on the teeth using the TAP device. The placement
accuracy verification process is described below.
[0192] FIG. 41 shows a TAP device 652 and a malocclusion model 650
of the dentition of a patient and the brackets 654 are bonded on a
quadrant of the malocclusion model in order to determine the
accuracy of the placements of the brackets.
[0193] FIG. 42 shows the TAP device with the main spline 660, the
cut-off spline 662, the cap 664 and the bracket 666.
[0194] FIG. 43 shows the mold of the dentition taken from
impression with the brackets 672 placed on the teeth 670 using the
TAP device created for the patient. This method can be used to
evaluate the accuracy of the TAP device before actually using it to
place and bond the brackets to the teeth of the patient.
[0195] FIG. 44 shows the in-vivo scanned image 680 of the dentition
after the brackets were bonded to the teeth using a customized TAP
device. This image enables verification of the accuracy of the
placement of the brackets on the teeth The Fig. shows the deviation
between the planed and real bracket position.
[0196] FIG. 45 shows archwire 694 placement through the bonded
brackets 692 for verification of the accuracy of the placement of
the brackets on the teeth 690.
[0197] FIG. 46 shows a jig 700 with the bracket portion 704 cutout.
Such a jig can be placed on a patient's tooth and the cutout
portion marked to see where the bracket will be attached. The
marked area then can be cleaned. Also, the marked area can be used
to verify the accuracy of the placement of the bracket on the
tooth. Also shown is a portion of the spline 702.
[0198] FIG. 47 shows a bracket holder 710 with an attachment 714
different from a bracket, such as an attachment to be placed on a
tooth for an aligner, placed on the jig of a TAP device for placing
the attachment on a tooth 712. In this manner, the customized TAP
device can be used to place attachments on the teeth of a patient.
FIG. 47A shows the attachment 714 in more detail. The figure shows
pad 716 and staff 718.
[0199] FIG. 47B shows the attachment 714 mounted on the tooth
712.
[0200] FIG. 48 shows a cotton roll 724 attached to the shim 722
(???) of the TAP device. The cotton roll will absorb the saliva of
a patient when the TAP device is used to place the brackets or
other attachments on the teeth 720 of a patient. Although not shown
in this figure, a tongue blocker can also be attached to the shin
of the TAP device in order to prevent the tongue of the patient
from interfering with the placement of the TAP device on the
dentition of the patient.
[0201] FIG. 49 shows a different configuration of the bracket
holder which makes it easier to remove the TAP device jig after the
bracket is placed and bonded to a tooth. FIG. 49 shows lug 750 for
prying cap from the bracket after the bracket is bonded to the
tooth. Additionally the figure shows distal indicator 752, tooth
number 754 for which the bracket holder is designed, the bracket
holder cap 756 and the bracket 758.
[0202] Modifications to the illustrated embodiments are within the
scope of the invention. The scope is to be determined by reference
to the appended claims, interpreted in light of the foregoing
specification.
TABLE-US-00001 TABLE 1 Property ASTM Metric Imperial Tensile
Strength D-638-03 MPa 50-65 psi 7,250-9,450 Modulus of Elasticity
D-638-04 MPa 2,000-3,000 psi 290,000-435,000 Elongation at Break
D-638-05 % 10-25 % 10-25 Flexural Strength D-790-03 MPa 75-110 psi
11,000-16,000 Flexural Modulus D-790-04 MPa 2,200-3,200 psi
320,000-465,000 Izod Notched Impact D-256-06 J/m 20-30 ft lb/in
0.375-0.562 HDT at 0.45 MPa D-648-06 .degree. C. 45-50 .degree. F.
113-122 Water Absorption D570-98 24 Hr % 1.1-1.5 % 1.1-1.5
* * * * *