Orthodontic article having partially hardened composition and related method

Abstract

An orthodontic article is provided for bonding to a tooth structure comprising an orthodontic appliance, a layer of partially hardened hardenable composition adjacent the appliance, and a bonding adhesive adjacent the partially hardened hardenable composition. A method of making an orthodontic article for orthodontic bonding is provided, comprising partially hardening a hardenable composition adjacent the base of an orthodontic appliance.

What is claimed is: 
     
         1 . A method of making an article for orthodontic bonding comprising:
 a) applying a hardenable composition to the base of an orthodontic appliance; and   b) partially hardening the hardenable composition to provide a partially hardened hardenable composition;   
       wherein at least one of the base or a surface of the partially hardened hardenable composition has a contour of a negative replica of at least a portion of a tooth structure. 
     
     
         2 . The method of  claim 1 , wherein the partially hardened hardenable composition is less than 95 percent cured. 
     
     
         3 . The method of  claim 1 , wherein the step of partially hardening the hardenable composition comprises directing actinic radiation to the hardenable composition. 
     
     
         4 . The method of  claim 1  further comprising the step of providing a positive replica of a tooth structure, wherein the partially hardened hardenable composition is between the base and the replica. 
     
     
         5 . The method of  claim 4  wherein at least one of the replica and the orthodontic appliance transmits actinic radiation. 
     
     
         6 . The method of  claim 5 , wherein the step of partially hardening the hardenable composition comprises directing actinic radiation to the hardenable composition. 
     
     
         7 . The method of  claim 6 , wherein the directing of actinic radiation to the hardenable composition comprises directing at least a portion of the actinic radiation through at least one of the replica and the orthodontic appliance. 
     
     
         8 . The method of  claim 5 , further comprising the step of forming a transfer apparatus over at least a portion of the replica, and wherein the transfer apparatus holds the appliance. 
     
     
         9 . The method of  claim 8 , further comprising the step of detaching the partially hardened hardenable composition from the replica. 
     
     
         10 . The method of  claim 9 , wherein the detaching step comprises removing the transfer apparatus from the replica. 
     
     
         11 . A packaged orthodontic assembly comprising:
 a container including a recess;   an orthodontic appliance received in the recess, the appliance comprising   a) a base for bonding to tooth structure;   b) a partially hardened hardenable composition adjacent and extending across the base; and   c) a bonding adhesive adjacent and extending across the partially hardened hardenable composition;   
       wherein the partially hardened hardenable composition has a tooth-facing surface contour of a negative replica of at least a portion of the tooth structure. 
     
     
         12 . The packaged orthodontic assembly of  claim 11 , wherein the partially hardened hardenable composition is less than 95 percent cured. 
     
     
         13 . The packaged orthodontic assembly of  claim 12 , wherein the partially hardened hardenable is 27 to 94 percent cured. 
     
     
         14 . The packaged orthodontic assembly of  claim 11 , wherein the container further comprises a release surface. 
     
     
         15 . The packaged orthodontic assembly of  claim 11 , wherein the appliance is an orthodontic bracket. 
     
     
         16 . The packaged orthodontic assembly of  claim 11 , and further comprising a transfer apparatus disposed in the container. 
     
     
         17 . The packaged orthodontic assembly of  claim 16 , wherein the appliance is positioned in the transfer apparatus. 
     
     
         18 . The packaged orthodontic assembly of  claim 17 , wherein the transfer apparatus is a transfer tray. 
     
     
         19 . The packaged orthodontic assembly of  claim 18 , wherein the tray comprises rapid prototyping material. 
     
     
         20 . An orthodontic article for bonding to a tooth surface structure comprising:
 a) an orthodontic appliance having a base;   b) a partially hardened hardenable composition adjacent and extending across the base, the partially hardened hardenable composition being less than 95 percent cured; and   c) a bonding adhesive adjacent and extending across the partially hardened hardenable composition;   wherein the partially hardened hardenable composition has a tooth-facing surface contour of a negative replica of at least a portion of the tooth structure at a time prior to the appliance being bonded to the tooth structure.