Customized Modular Multi-Material Mouthguard and Method of Making the Same

Abstract

There is described a mouthguard comprising an externally exposed impact protective region defined by a first material property and configured to cover a front tooth, an internally exposed occlusional cushioning region defined by a second material property and configured to cover a molar tooth, and an internally exposed intermediate region defined by a third material property and configured to be located between the occlusional cushioning region and the impact protective region, wherein said first, second and third material properties are different. A corresponding method of fabricating a mouthguard is also described.

What is claimed is: 
     
         1 - 15 . (canceled) 
     
     
         16 . A mouthguard for protecting teeth of a dental arch from impact while also promoting biting-induced neck muscle activation, thus providing protection against brain injury, said mouthguard comprising:
 an externally exposed impact protective region defined by a first material property and configured to cover a front tooth of said dental arch;   an internally exposed occlusional cushioning region defined by a second material property and configured to cover a molar tooth of said dental arch; and   an internally exposed intermediate region defined by a third material property and configured to be located between the occlusional cushioning region and the impact protective region;   wherein said first, second and third material properties are different;   wherein the externally exposed impact protective region is the only part of the mouthguard to comprise the material of the externally exposed impact protective region.   
     
     
         17 . The mouthguard of  claim 16 , wherein said externally exposed impact protective region does not cover a molar tooth of said dental arch; and
 wherein said internally exposed occlusional cushioning region does not cover a front tooth of said dental arch.   
     
     
         18 . The mouthguard of  claim 17 , wherein the occlusional cushioning region is configured to cover two molar teeth of said dental arch; and
 wherein the impact protective region is configured to cover a central incisor tooth of said dental arch and a lateral incisor tooth of said dental arch and a canine tooth of said dental arch.   
     
     
         19 . The mouthguard of  claim 16 , wherein at least one interface between regions comprises a mechanical interlocking portion, wherein the mechanical interlocking portion comprises an interlocking feature;
 wherein the interlocking feature is configured to be positioned so as to reduce discomfort for the user;   wherein the interlocking feature is configured to be positioned over an area between a first tooth of said dental arch and a second tooth of said dental arch; and   wherein said at least one interface between regions comprising a mechanical interlocking portion is selected from a group comprising at least:
 a) an interface between the intermediate region and the occlusional cushioning region, and 
 b) an interface between the intermediate region and the impact protective region. 
   
     
     
         20 . The mouthguard of  claim 18 , wherein the intermediate region and the occlusional cushioning region comprise a material that can resist at least 70% tensile strain; and
 wherein said material that can resist at least 70% tensile strain is selected from a group comprising at least:
 a) an elastomeric material, 
 b) a rubber-like material, 
 c) a polymeric material, 
 d) a polymeric material made from thermoplastic polyurethanes, and 
 e) a polymeric material made from photosensitive resins. 
   
     
     
         21 . The mouthguard of  claim 20 , wherein the intermediate region and the occlusional cushioning region comprise the same material; and
 wherein the internal structure of the intermediate region is different to the internal structure of the occlusional cushioning region to provide said different material properties.   
     
     
         22 . The mouthguard of  claim 20 , wherein the hardness of the intermediate region is greater than the hardness of the occlusional cushioning region;
 wherein the hardness of the intermediate region is from 80 to 90 in Shore A scale; and   wherein the hardness of the occlusional cushioning region is from 55 to 75 in Shore A scale.   
     
     
         23 . The mouthguard of  claim 20 , wherein the hardness of the occlusional cushioning region is from 60 to 80 in Shore A scale and a compressive stiffness of the occlusional cushioning region is from 8 to 20 Mpa; and
 wherein the hardness of the intermediate region is from 70 to 95 in Shore A scale and a compressive stiffness of the intermediate region is from 15 to 40 Mpa.   
     
     
         24 . The mouthguard of  claim 23 , wherein the Young's modulus of the impact protective region is from 1 to 3 GPa and the impact protective region comprises a material selected from a group comprising at least:
 a) a thermoplastic material, and   b) a thermoset material.   
     
     
         25 . The mouthguard of  claim 18 , wherein the impact protective region comprises a stress concentration feature. 
     
     
         26 . The mouthguard of  claim 19 , wherein the impact protective region is a first impact protective region that is configured to be detachable from another region of the mouthguard; and
 wherein the first impact protective region is interchangeable with a second impact protective region.   
     
     
         27 . The mouthguard of  claim 18 , wherein the mouthguard further comprises a gap region in an anterior portion of the mouthguard, wherein said gap region comprises a gap of at least 1 millimetre;
 wherein the gap region is configured to be over a front tooth of said dental arch, said font tooth selected from a central incisor tooth, a lateral incisor tooth, and a canine tooth; and   wherein said gap exists between the interface of the impact protective region and the intermediate region.   
     
     
         28 . A mouthguard for a dental arch, said mouthguard being for protecting teeth of said dental arch from impact while also promoting biting-induced neck muscle activation, thus providing protection against brain injury, said mouthguard comprising:
 an externally exposed impact protective region defined by a first material property and configured to cover a front tooth of said dental arch; and   an internally exposed occlusional cushioning region defined by a second material property and configured to cover a molar tooth of said dental arch;   wherein said first and second material properties are different;   wherein said externally exposed impact protective region does not cover a molar tooth of said dental arch.   
     
     
         29 . The mouthguard of  claim 28 , wherein at least one interface between regions comprises a mechanical interlocking portion, wherein the mechanical interlocking portion comprises an interlocking feature;
 wherein the interlocking feature is configured to be positioned so as to reduce discomfort for the user; and   wherein the interlocking feature is configured to be positioned over an area between a first tooth of said dental arch and a second tooth of said dental arch.   
     
     
         30 . The mouthguard of  claim 28 , wherein the occlusional cushioning region comprises a material selected from an elastomeric material, a rubber-like material and a polymeric material; and
 wherein the occlusional cushioning region comprises a material that can resist at least 70% tensile strain;   wherein the thickness of the occlusional cushioning region is from 2.0 to 5.0 millimetres; and   wherein the hardness of the occlusional cushioning region is from 70 to 90 in Shore A scale.   
     
     
         31 . The mouthguard of  claim 30 , wherein the impact protective region comprises a material selected from a thermoplastic material and a thermoset material;
 wherein the Young's modulus of the impact protective region is from 1 to 3 GPa;   wherein the impact protective region comprises a stress concentration feature; and   wherein the thickness of the impact protective region is from 0.9 to 2.0 millimetres.   
     
     
         32 . The mouthguard of  claim 31 , wherein the mouthguard is configured to be anteriorly offset from a front tooth of said dental arch by at least 1 millimetre; and
 wherein said front tooth of said dental arch from which the mouthguard is configured to be anteriorly offset is selected from a central incisor tooth, a lateral incisor tooth and a canine tooth.   
     
     
         33 . The mouthguard of  claim 32 , wherein the occlusional cushioning region is configured to cover two molar teeth of said dental arch; and
 wherein the impact protective region is configured to cover two incisor teeth of said dental arch.   
     
     
         34 . A 3D printed mouthguard, comprising:
 a first mouthguard piece; and   a second mouthguard piece;   wherein said first and second mouthguard pieces are configured to mechanically interlock and/or chemically bond.   
     
     
         35 . The 3D printed mouthguard of  claim 34 , wherein said first mouthguard piece is detachable from said second mouthguard piece.