Systems and methods for orthodontic devices

Abstract

Embodiments presented herein provide apparatus and methods for forming and coupling an attachment device onto one or more teeth. A system comprises a template including a shell having a cavity defining a shape that is operable to receive one or more teeth. The template comprises an aperture at one or more predetermined locations. The aperture defines an aperture perimeter. The system further comprises one or more attachment molds. Each attachment mold comprises a mold bore therethrough. The attachment mold further includes a mold perimeter surface that defines a predetermined shape, wherein each of the aperture perimeters being operable to receive and cooperate with the mold perimeter surface of one of the attachment molds. Each mold bore being operable for providing a mold for forming an attachment device coupled to a tooth of a desired shape and orientation from curable material that may be disposed within the mold bore.

1 . A system for forming and coupling an attachment device onto one or more teeth, comprising:
 a template comprising a shell having a cavity defining a shape operable to receive one or more teeth, the template including a template inner surface and a template outer surface opposite the template inner surface, the template further comprising an aperture at one or more predetermined locations that extends from the template inner surface to the template outer surface therethrough, the aperture defining an aperture perimeter; and   one or more attachment molds, each attachment mold comprising a mold first surface and a mold second surface opposite the mold first surface, the attachment mold includes a mold bore having a bore surface extending from the mold first surface to the mold second surface therethrough, the attachment mold further includes a mold perimeter surface that defines a predetermined shape, wherein each of the aperture perimeters being operable to receive and cooperate with the mold perimeter surface of one of the attachment molds, wherein each mold bore being operable for providing a mold for forming an attachment device of a desired shape and orientation from curable material that may be disposed within the mold bore.   
     
     
         2 . The system of  claim 1 , wherein the attachment mold further comprises an adhesive layer disposed on the mold first surface, the adhesive layer being operable for removably coupling the attachment mold to a tooth surface. 
     
     
         3 . The system of  claim 2 , wherein the adhesive layer provides a means to conform the mold first surface to an irregular tooth surface upon which it may be removably coupled. 
     
     
         4 . The system of  claim 3 , wherein the means to conform the mold first surface is selected from a list consisting of: elastic properties of the adhesive layer; pressure-sensitivity of the adhesive layer; a foam matrix within the adhesive layer, the resiliency of the attachment mold; and combinations thereof. 
     
     
         5 . The system of  claim 3 , wherein the adhesive layer is operable to provide a sealing engagement with a tooth surface so as to resist the infiltration of contaminants onto a tooth surface exposed by the mold bore. 
     
     
         6 . The system of  claim 3 , wherein the adhesive layer is operable to resist the migration of curable material under the mold first surface that may be disposed within the mold bore prior to curing the curable material forming an attachment device. 
     
     
         7 . The system of  claim 3 , wherein the adhesive layer is opaque to those light frequencies associated with curing curable material which is curable by exposure to light-curing radiation, the adhesive layer operable to block light-curing radiation from illuminating between the mold first surface and the tooth surface and therefore resists the curing of any curable material that may unintentionally migrate between the mold first surface and the tooth surface. 
     
     
         8 . The system of  claim 3 , wherein the attachment mold further comprises an opaque layer disposed between the mold first surface and the adhesive layer, the opaque layer comprising a material which is opaque to those light frequencies associated with curable material which is curable by exposure to light-curing radiation, the opaque layer being operable to substantially block light-curing radiation from illuminating under the attachment mold and therefore resist the curing of any curable material that may unintentionally migrate between the mold first surface and the tooth surface. 
     
     
         9 . The system of  claim 3 , wherein the attachment mold comprises an opaque material operable to block light-curing radiation from illuminating between the mold first surface and the tooth surface when coupled to a tooth surface. 
     
     
         10 . The system of  claim 3 , wherein the attachment mold comprises a transparent material so as to allow light-curing radiation to illuminate curable material that may be within the mold bore through the attachment mold. 
     
     
         11 . The system of  claim 3 , further comprising a cover plate including a plate inner surface and a plate outer surface opposite the plate inner surface, the cover plate being operable to be placed upon the mold second surface and cover the mold bore, the cover plate being operable for the compression of curable material that may be within the mold bore to affect intimate contact between the curable material and the tooth surface and minimize voids within the curable material. 
     
     
         12 . The system of  claim 11 , the cover plate comprising a material that is translucent to those light frequencies associated with curable material which is curable by exposure to light-curing radiation. 
     
     
         13 . The system of  claim 11 , the cover plate further comprising a plate aperture extending from the plate inner surface to the plate outer surface therethrough, the plate aperture being operable for allowing any excess curable material to extrude from the mold bore under pressure created as the cover plate is pressed against the mold second surface and any curable material disposed within the mold bore. 
     
     
         14 . The system of  claim 2 , wherein each of the attachment molds has one of a predetermined unique shape of the mold perimeter surface that is complementary with a predetermined unique shape of a corresponding aperture perimeter, the unique shape of the mold perimeter surface being operable to prevent the use of an attachment mold that may not be intended for an attempted location defined by the aperture on the template. 
     
     
         15 . The system of  claim 14 , wherein the unique shape of a corresponding aperture perimeter defines a keyway for a corresponding mold perimeter surface identifying a complementary shape operable to receive the keyway, the keyway being operable to ensure that the attachment mold is disposed at a predetermined orientation on the tooth surface. 
     
     
         16 . The system of  claim 14 , wherein a particular unique shape of the mold perimeter surface being associated with a particular unique shape of an attachment mold bore. 
     
     
         17 . The system of  claim 2 , wherein the mold bore comprises a first portion adjacent the mold first surface having a first diameter and a second portion adjacent the mold second surface having a second diameter that is larger than the first portion. 
     
     
         18 . The system of  claim 1 , wherein the template comprises frangible portions operable to provide for preferentially breaking apart so as to facilitate removal of the template from the teeth and any attachment devices. 
     
     
         19 . The system of  claim 2 , wherein the attachment mold is provided with means to facilitate removal of the attachment mold from an attachment device. 
     
     
         20 . The system of  claim 2 , wherein the attachment mold comprises an elastic material operable to be readily stretched and peeled from the tooth and attachment device. 
     
     
         21 . The system of  claim 2 , wherein the attachment molds are disposed within and removably coupled to respective apertures, the attachment molds being held within the respective aperture recessed from the template inner surface. 
     
     
         22 . A system for forming and coupling an attachment device onto one or more teeth, comprising:
 one or more attachment molds, each attachment mold comprising a mold first surface and a mold second surface opposite the mold first surface, the attachment mold includes a mold bore having a bore surface extending from the mold first surface to the mold second surface therethrough, each mold bore being operable for providing a mold for forming an attachment device of a desired shape from curable material that may be disposed within the mold bore, the attachment mold further comprising an adhesive layer disposed on the mold first surface, the adhesive layer being operable for removably coupling the attachment mold to a tooth surface.   
     
     
         23 . The system of  claim 22 , wherein the adhesive layer provides a means to conform the mold first surface to an irregular tooth surface upon which it may be removably coupled. 
     
     
         24 . The system of  claim 23 , wherein the attachment mold further comprises an opaque layer disposed between the mold first surface and the adhesive layer, the opaque layer comprising a material which is opaque to those light frequencies associated with curable material which is curable by exposure to light-curing radiation, the opaque layer being operable to substantially block light-curing radiation from illuminating under the attachment mold and therefore resist the curing of any curable material that may unintentionally migrate between the mold first surface and the tooth surface. 
     
     
         25 . The system of  claim 22 , further comprising a cover plate including a plate inner surface and a plate outer surface opposite the plate inner surface, the cover plate being operable to be placed upon the mold second surface and cover the mold bore, the cover plate being operable for the compression of curable material that may be within the mold bore to affect intimate contact between the curable material and the tooth surface and minimize voids within the curable material. 
     
     
         26 . The system of  claim 25 , the cover plate further comprising a plate aperture extending from the plate inner surface to the plate outer surface therethrough, the plate aperture being operable for allowing any excess curable material to extrude from the mold bore under pressure created as the cover plate is pressed against the mold second surface and any curable material disposed within the mold bore. 
     
     
         27 . The system of  claim 22 , wherein the mold bore comprises a first portion adjacent the mold first surface having a first diameter and a second portion adjacent the mold second surface having a second diameter that is larger than the first portion.