Cast orthodontic retainer system

Abstract

A cast orthodontic retainer system for reducing discomfort and improving durability. The cast orthodontic retainer system generally includes a palatal portion for positioning against the palate of a patient's mouth and a retention portion for extending across an anterior portion of the patient's teeth. The palatal portion of the present invention is fabricated of a cast metallic material, thus allowing for the palatal portion to be substantially thinner than the palatal portions of retainers in the prior art. In a preferred embodiment, the palatal portion of the present invention will be fabricated of a combination of cobalt, chromium and molybdenum (generally marketed under the trademark VITALLIUM). The palatal portion of the orthodontic retainer is preferably cast from the metallic material utilizing the “lost wax” technique of casting.

The invention claimed is: 
     
       1. A method of fabricating a palatal portion of an orthodontic retainer, comprising:
 providing a blocked out duplicate of a patient's palate and upper teeth; 
 providing a sheet of malleable material; 
 warming up said sheet of malleable material; 
 creating a palatal impression by pressing said warmed up sheet of malleable material against said blocked out duplicate of a patient's palate; 
 placing said palatal impression on a sprue tree; 
 enclosing said sprue tree and said palatal impression in a container; 
 creating a mold by pouring investment material around said sprue tree and said palatal impression within said container and allowing said investment material to dry; 
 creating a negative impression of said palatal impression within said mold by heating a hardened shell within a heating device to melt said palatal impression; 
 heating a metal material until said metal material is molten, wherein said metal material is comprised of cobalt, chromium and molybdenum; 
 inserting said molten metal material into said negative impression of said palatal impression within said mold; 
 cooling said mold to form a palatal portion formed from said metal material; and 
 removing said palatal portion from said hardened shell, wherein said palatal portion is comprised of a thickness between 0.20 millimeters and 0.30 millimeters. 
 
     
     
       2. The method of fabricating a palatal portion of an orthodontic retainer of  claim 1 , wherein said sheet of malleable material is comprised of a sheet of wax. 
     
     
       3. The method of fabricating a palatal portion of an orthodontic retainer of  claim 1 , wherein said metal material is comprised of a metal alloy. 
     
     
       4. A method of fabricating a palatal portion of an orthodontic retainer, comprising:
 casting a plate-like U-shaped member that consists of a metal alloy of cobalt, chromium, and molybdenum, wherein the plate-like U-shaped member is positionable against a palate of a patient's mouth;   wherein the plate-like U-shaped member is cast so as to have a front edge and a curved rear edge, the front edge is positionable adjacent lingual surfaces of a patient's teeth, and the front edge includes a plurality of indentations and projections, the indentations are sized and shaped to receive the lingual surfaces of the patient's teeth;   the plate-like U-shaped member is cast to have a thickness between 0.20 millimeters and 0.30 millimeters.