Indirect orthodontic bonding systems and methods

Abstract

An indirect orthodontic bonding (IDB) tray preloaded with one or more orthodontic brackets with uncured pre-pasted adhesive. The loaded IDB tray can be produced by an IDB tray manufacturer and distributed to an orthodontist in a container that prevents the adhesive from curing. The loaded IDB tray can be removed from the container when the patient is ready for treatment. The loaded IDB tray can be placed over the dental arch of the patient such that the one or more orthodontic brackets can bond, via curing of the adhesive, to the teeth of the patient.

Description

BACKGROUND

Field of the Invention

This invention relates in some aspects to indirect orthodontic bonding systems and methods, including indirect orthodontic bonding trays.

SUMMARY

Indirect orthodontic bonding (IDB) trays can be used by orthodontists to place one or more brackets on a patient's teeth in predetermined locations. The IDB tray can be custom made for a patient's dental arch. The IDB tray can include one or more wells to receive an orthodontic bracket therein. The orthodontist can place an orthodontic bracket in a well with a bonding surface facing outward. An adhesive can be applied to a bonding surface of the orthodontic bracket. The IDB tray can be placed over a dental arch of the patient to apply the bonding surface of the orthodontic brackets to the patient's teeth. The adhesive can bond the bonding surfaces of the orthodontic brackets to the surfaces of the patient's teeth, securing the orthodontic brackets in predetermined locations on the patient's teeth. Loading one or more orthodontic brackets into the one or more wells of the IDB tray can be a time intensive process. Additionally, orthodontic brackets may be dropped on a contaminated surface during the loading process, requiring the orthodontic brackets to be cleaned—prolonging the administration of orthodontic care. Inadequate or excessive adhesive may be applied to the bonding surfaces, decreasing bonding reliability.

The IDB systems (e.g., kits) and methods described herein solve at least the foregoing problems. The IDB systems and methods described herein can advance the ease of use of IDB trays and minimize errors during bracket bonding. The IDB trays can be custom designed and formed for a particular patient's dental arch or segment of a dental arch segment based on images (e.g., scans) of a patient's mouth. The IDB tray can be formed by an IDB tray manufacturer. The IDB tray can include one or more wells shaped to receive an orthodontic bracket. The IDB tray manufacturer can load an orthodontic bracket into each of the one or more wells of the IDB tray with a bonding surface of the orthodontic bracket facing out of the well. The IDB tray manufacturer can apply an adhesive to the bonding surface of the orthodontic brackets in the one or more wells. The IDB tray manufacturer can select the quantity and type of adhesive used, which can improve bonding reliability. The loaded IDB tray (e.g., the IDB tray with the preloaded brackets and bonding surfaces with uncured pre-pasted adhesive) can be placed in a container to prevent curing of the adhesive. The loaded IDB tray, also referred to as an preloaded or preassembled IDB system or preloaded IDB tray, within the container can be shipped to an orthodontist's office for use. When ready for use, the orthodontist can remove the loaded IDB tray from the container and/or another controlled environment and place the loaded IDB tray over the dental arch of the patient to bond the one or more orthodontic brackets to the patient's teeth.

In some variants, a kit for bonding one or more orthodontic brackets to a dental arch of a patient is disclosed. The kit can include a preloaded indirect orthodontic bonding (IDB) tray. The preloaded IDB tray can include an IDB tray with one or more wells. The preloaded IDB tray can include one or more orthodontic brackets placed within the one or more wells. A bonding surface of the one or more orthodontic brackets can face out of the one or more wells. The preloaded IDB tray can include an adhesive applied onto the bonding surface of the one or more orthodontic brackets. The kit can include a container for housing the preloaded IDB tray during shipment. The container can prevent the adhesive from curing.

In some variants, the preloaded IDB tray can include a primer applied to the bonding surface of the one or more orthodontic brackets.

In some variants, the kit can include one or more archforms that can couple to the one or more orthodontic brackets when bonded to a patient's teeth. The one or more archforms can move the patient's teeth.

In some variants, the kit can include a tool that can facilitate coupling an archform of the one or more archforms to the one or more orthodontic brackets when bonded to a patient's teeth.

In some variants, the IBD tray can be in separate segments corresponding to portions of a patient's dental arch.

In some variants, a method of producing a loaded indirect orthodontic bonding (IDB) tray for distribution is disclosed herein. The method can include forming the IDB tray with one or more wells. The method can include placing an orthodontic bracket into the one or more wells such that a bonding surface of the orthodontic bracket can face out of the one or more wells. The method can include applying an adhesive to the bonding surface of the orthodontic bracket. The method can include placing the IDB tray preloaded with the orthodontic bracket and pre-pasted adhesive into a container for distribution. The container can prevent the adhesive from curing.

In some variants, the method can include applying a primer to the bonding surface of the orthodontic bracket.

In some variants, forming the IDB tray with the one or more wells can include 3D printing the IDB tray based on a digital model of at least a portion of a patient's dental arch.

In some variants, forming the IDB tray with the one or more wells can include molding over a 3D model of a patient's dental arch or portion thereof with one or more features positioned to form the one or more wells.

In some variants, a preloaded indirect orthodontic bonding (IDB) tray for distribution is disclosed herein. The preloaded IDB tray can include an IDB tray with one or more wells. The preloaded IDB tray can include one or more orthodontic brackets placed within the one or more wells. A bonding surface of the one or more orthodontic brackets can face out of the one or more wells. The preloaded IDB tray can include a primer applied to the bonding surface of the one or more orthodontic brackets. The preloaded IDB tray can include an adhesive pasted onto the bonding surface of the one or more orthodontic brackets.

In some variants, the preloaded IDB tray can be distributed to an orthodontist in a container that can prevent the adhesive from curing such that the preloaded IDB tray is ready for placement on a dental arch of a patient upon receipt by the orthodontist.

In some variants, the IDB tray can include a channel and the archform can be disposed in the channel.

In some variants, the preloaded IDB tray can include an archform disposed in the IDB tray.

In some variants, the archform can be coupled to the one or more orthodontic brackets.

In some variants, a preloaded indirect bonding (IDB) tray for distribution is disclosed herein. The preloaded IDB tray can include an indirect bonding (IDB) tray with a plurality of wells. Each of the plurality of wells can hold an adhesive therein. The preloaded IDB tray can include a retainer that can be adhered to the surfaces of a patient's teeth. The retainer can be disposed in the IDB tray and through the adhesive disposed in the plurality of wells.

In some variants, the retainer can be bonded to lingual surfaces of a patient's teeth.

In some variants, the retainer can be a braided stainless steel wire.

In some variants, the IDB tray can include a channel holding the retainer.

The channel can extend through the plurality of wells.

In some variants, the channel can span between adjacent wells of the plurality of wells.

In some variants, a kit for bonding a retainer to surfaces of a patient's teeth is disclosed herein. The kit can include a preloaded IDB tray, such as any disclosed herein. The kit can include a container for housing the preloaded IDB tray. The container can prevent the adhesive from curing.

In some variants, a method of bonding a retainer to surfaces of a patient's teeth is disclosed herein. The method can include placing a retainer into an indirect bonding (IDB) tray. The retainer can be flexible. The retainer can conform to contours of the IDB tray. The method can include flowing adhesive into wells of the IDB tray. The method can include positioning the IDB tray over the patient's teeth. The method can include curing the adhesive to bond the retainer to the surfaces of the patient's teeth and to form rounded mounds of cured adhesive on the surfaces of the patient's teeth. Portions of the retainer extending between rounded mounds of cured adhesive can be rigid. The method can include removing the IDB tray.

In some variants, curing the adhesive can include exposing the adhesive to UV light.

In some variants, the method can include forming the IDB tray.

In some variants, the forming the IDB tray can include 3D printing the IDB tray.

In some variants, the retainer can be a braided stainless steel wire.

In some variants, the placing the retainer into the IDB tray can include placing the retainer into a channel of the IDB tray. The channel can be disposed in a surface of the IDB tray that can face lingual surfaces of the patient's teeth when the IDB tray is positioned over the patient's teeth.

BRIEF DESCRIPTION OF THE DRAWINGS

These drawings are illustrative embodiments and do not present all possible embodiments of this invention. The illustrated embodiments are intended to illustrate, but not to limit, the scope of protection. Various features of the different disclosed embodiments can be combined to form further embodiments, which are part of this disclosure.

FIG. 1 illustrates an indirect orthodontic bonding (IDB) tray.

FIG. 2 illustrates an IDB tray with brackets positioned within wells of the IDB tray.

FIG. 3 illustrates a method of producing a preloaded IDB tray for distribution.

FIG. 4 illustrates an orthodontic bracket with a spring removed.

FIGS. 5A and 5B illustrate various views of the orthodontic bracket with the spring disposed in the orthodontic bracket.

FIG. 6 illustrates an archform.

FIG. 7 illustrate the archform coupled with the orthodontic bracket.

FIG. 8 illustrates an indirect orthodontic bonding (IDB) tray being positioned over a patient's teeth to bond a retainer to the patient's teeth.

FIG. 9 illustrates the IDB tray disposed over the patient's teeth.

FIG. 10 illustrates the retainer bonded to the patient's teeth with adhesive mounds.

FIG. 11 illustrates a method of installing a retainer in the patient's mouth with the IDB tray.

DETAILED DESCRIPTION

It can be difficult and/or time consuming to properly position one or more orthodontic brackets on a patient's teeth for bonding when administering a treatment plan to move the patient's teeth from maloccluded positions to predetermined positions. An indirect orthodontic bonding (IDB) tray can be used to assist an orthodontist or other individual attending to a patient to properly position the one or more orthodontic brackets on a patient's teeth in predetermined locations for bonding. The IDB tray can be used, in some variants, to position a plurality of orthodontic brackets simultaneously on a patient's teeth for bonding. Once the one or more orthodontic brackets are bonded to the patient's teeth, an archform can be coupled to the one or more orthodontic brackets to move the patient's teeth using sliding or non-sliding mechanics.

Disclosed herein are IDB systems (e.g., kits) and methods to advance the ease of use of IDB trays and minimize errors during bracket bonding. Preloaded IDB trays can include custom formed IDB trays with preloaded brackets with uncured pre-pasted adhesive applied thereto. The preloaded IDB trays can be produced by an IDB tray manufacturer and distributed to orthodontists in a container that prevents curing of the adhesive. In some variants, the container can be air tight, temperature controlled, and/or light blocking. The preloaded IDB trays can remain in the container or be removed from the container and placed in a controlled environment until the orthodontist or other individual is ready to bond the orthodontic brackets to the teeth of the patient.

FIG. 1 illustrates a gingival auxiliary view of an indirect orthodontic bonding (IDB) tray 100. The IDB tray 100 can be custom formed for a patient's dental arch. The IDB tray 100 can be custom formed based on digital data from images (e.g., scans) of a patient's teeth which can be captured using a variety of techniques, which can include a digital intra-oral scanner, a cone-beam computed tomography (CBCT) X-ray scanner, and/or others. The IDB tray 100 can be formed via a variety of techniques. In some variants, the IDB tray 100 can be 3-D printed—also known as additive manufacturing. The IDB tray 100 can be 3-D printed based on a digital model of at least a portion of the patient's dental arch. The IDB tray 100 can be 3-D printed with a variety of materials, which can include one or more resins. In some variants, the IDB tray 100 can be formed via molding over a 3D model of a patient's dental arch with features (e.g., functional or non-functional brackets, bite turbos, auxiliaries, temporary anchoring devices, archform, buttons, etc.) positioned to create wells to receive the brackets, bite turbos, auxiliaries, temporary anchoring devices, archform, buttons, etc. that will be transferred to the patient's teeth. The moldable material can be a polyvinyl siloxane (PVS) material. The indirect bonding tray 100 can be formed of a single piece. The IDB tray 100 can be formed of multiple pieces.

In some variants, the IDB tray 100 can be formed of a soluble material, such as melted/dried (caramelized) sugar and/or cellulose. The soluble material can be structurally stiff when dry but dissolve when wet. Accordingly, the IDB tray 100, when formed of soluble material, can be used to place one or more orthodontic brackets on a patient's teeth and, after placement (e.g., bonding), the patient's mouth can be rinsed with water or another liquid—dissolving the IDB tray 100 made of soluble material.

The indirect bonding tray 100 can correspond to a patient's upper or lower dental arch. The IDB tray 100 can correspond to a section of a patient's upper or lower dental arch (e.g., 1, 2, 3, 4, or more teeth). The IDB tray 100 can include cavities to receive the patient's teeth. The indirect bonding tray 100 can include one or more wells for receiving orthodontic brackets, bite turbos, auxiliaries, temporary anchoring devices, archform, buttons, etc. to be transferred to the teeth of a patient. The one or more wells can be disposed in the portion (e.g., walls) of the IDB tray 100 defining a cavity to receive a tooth of the patient. The indirect bonding tray 100 can include one or more lingual orthodontic bracket wells 102. The indirect bonding tray 100 can include one or more buccal orthodontic button wells 104. The indirect bonding tray 100 can include one or more occlusal orthodontic bracket wells 106. The illustrated indirect bonding tray 100 includes lingual orthodontic bracket wells 102 for each tooth, occlusal bite turbo wells 106 on the first molars, and buccal orthodontic button wells 104 on the second molars. Other locations for the wells are contemplated. In some variants, a well is positioned to place an orthodontic bracket on one or more teeth of the patient's upper or lower dental arch. In some variants, a well is positioned to place an orthodontic bracket on each tooth of a patient's upper or lower dental arch. In some variants, the IDB tray 100 can include wells to receive orthodontic brackets and channel(s), slot(s), hook(s), and/or other feature(s) to receive an archform (e.g., archwire). The IDB tray 100 can receive the archform in the channel(s), slot(s), hook(s), and/or other feature(s). In some variants, the IDB tray 100 can include pins, rods, brackets, hooks, or the like that can be coupled with the IDB tray 100 to retain the archform within the channel or the like of the IDB tray 100. The orthodontic brackets can be loaded into the wells and couple with the archform. In some variants, the brackets can include a spring that facilitates the archform to be secured to the brackets. Adhesive can be applied to the bonding surfaces of the orthodontic brackets and the loaded IDB tray placed over the dental arch of the patient. The adhesive can be cured (e.g., exposure to UV light, air, and/or chemical(s)) to bond the orthodontic brackets to the patient's teeth (lingual, buccal, and/or occlusal surfaces). The IDB tray 100 can be removed, leaving the orthodontic brackets and archform installed in the patient's mouth to move the patient's teeth.

As described herein, the IDB tray 100 can be pre-loaded with one or more pre-pasted brackets before distribution to an orthodontist. Brackets can be loaded into wells of an IDB tray with a bonding surface facing out of the well, a primer can be applied to the bonding surface, and/or an adhesive can be applied to the primer before distribution to an orthodontist for use. In some variants, adhesive can be applied directly to the bonding surface without a primer.

The IDB trays and/or other components referenced herein may, in some variants, be made with and/or used with the methods and/or include features described in U.S. patent application Ser. No. 16/804,734, filed Feb. 28, 2020, entitled Indirect Bonding Trays With Bite Turbo and Orthodontic Auxiliary Integration, and published as U.S. Pub. No. 2020/0275996, which is incorporated by reference herein in its entirety. The IDB trays and/or other components referenced herein may, in some variants, be made with and/or used with the methods and/or include features described in U.S. patent application Ser. No. 17/084,383, filed Oct. 29, 2020, entitled Indirect Orthodontic Bonding Systems and Methods, and published as U.S. Pub. No. 2021/0128275, which is incorporated by reference herein in its entirety. The IDB trays and/or other components referenced herein may, in some variants, be made with and/or used with the methods and/or features (e.g., brackets, archforms, etc.) described in U.S. patent application Ser. No. 17/303,860, filed Jun. 9, 2021, entitled Orthodontic Appliance with Non-Sliding Archform, and published as U.S. Pub. No. 2021/0401548, which is incorporated by reference herein in its entirety. The IDB trays and/or other components referenced herein may, in some variants, be made with and/or used with the methods and/or features (e.g., brackets, archforms, etc.) described in U.S. patent application Ser. No. 14/067,690, filed Oct. 30, 2013, entitled Orthodontic Appliance with Snap Fitted, Non-Sliding Archwire, and published as U.S. Pub. No. 2014/0120491, which is incorporated by reference herein in its entirety.

FIG. 2 illustrates an IDB tray 100 with an orthodontic bracket 108, orthodontic bracket 109, and orthodontic bracket 110 loaded, respectively, into wells of the IDB tray 100. In some variants, the brackets are the same. In some variants, the brackets are configured for the type of tooth upon which the bracket will be bonded (e.g., molar, lower anterior, etc.). The bracket 108 is positioned within a well with a bonding surface 116 facing out of the well. The bonding surface 116 can be bonded to a surface of a patient's tooth. The bonding surface 116 can include one or more features to improve bonding. For example, the bonding surface 116 can include features that increase the surface area of the bonding surface 116. In some variants, the bonding surface 116 can include grooves, slots, cuts, recesses, contours, and/or other features to improve bonding to the patient's tooth.

The bracket 109 is positioned within a well of the IDB tray 100. The bracket 109 is illustrated with a primer 112 disposed over the bonding surface 116. The primer 112 can be applied in preparation for the application of an adhesive. In some variants, no primer 112 is applied.

The bracket 110 is positioned within a well of the IDB tray 100. The bracket 110 is illustrated with an uncured adhesive 114 applied to the cured primer 112 disposed on the bonding surface 116 of bracket 110. In some variants, adhesive 114 is applied to the bonding surface 116 without primer 112. With an adhesive applied, the IDB tray 100 can be positioned over the patient's dental arch such that the bonding surface 116 is bonded to the surface of a patient's tooth via the adhesive 114. In some variants, the adhesive 114 cures from exposure to air, UV light, high temperatures, chemical(s), low temperatures, and/or other curing methods. As described herein, the pre-loaded IDB tray 200 (e.g., IDB tray with preloaded brackets that are pre-pasted with uncured adhesive), also referred to as the preassembled IDB system 200, can be placed within a container that prevents or delays curing of the adhesive 114 for distribution. The orthodontists can remove the pre-loaded IDB tray 200 from the container or another controlled environment for application of the preloaded IDB tray 200 on the dental arch of the patient. The adhesive 114 can cure, bonding the one or more orthodontic brackets to the patient's teeth. The IDB tray 200 can be removed from the patient's dental arch. An archform can be coupled to the one or more orthodontic brackets to move the patient's teeth according to a treatment plan. In some variants, the pre-loaded IDB tray 200 can hold an archform coupled to the one or more orthodontic brackets such that an orthodontist can omit the step of coupling an archform to the one or more brackets and install the one or more orthodontic brackets and archform in the same step.

FIG. 3 illustrates a method 300 of producing a preloaded IDB tray. The flow diagram is provided for the purpose of facilitating description of aspects of some embodiments. The diagram does not attempt to illustrate all aspects of the disclosures and should not be considered limiting. In some variants, some of the steps described in reference to method 300 may be omitted.

At block 302, an IDB tray manufacturer can form an IDB tray 100. As described herein, the IDB tray 100 can be formed for a patient's dental arch (e.g., section of or entire dental arch). The IDB tray 100 can be custom formed based on digital data from images (e.g., scans) of a patient's teeth which can be captured via using a variety of techniques, which can include a digital intra-oral scanner, a cone-beam computed tomography (CBCT) X-ray scanner, and/or others. In some variants, the patient may capture images of the patient's own teeth with a portable device (e.g., smartphone, tablet, laptop, desktop, and/or a device connected to one or more of the foregoing).

The IDB tray 100 can be formed via a variety of techniques. In some variants, the IDB tray 100 can be 3-D printed. The IDB tray 100 can be 3-D printed with a variety of materials, which can include one or more resins. In some variants, the IDB tray 100 can be formed via molding over a 3D model of a patient's dental arch with features (e.g., functional or non-functional brackets) positioned to create wells to receive the brackets that will be transferred to the patient's teeth. In some variants, the IDB tray 100 can be formed using a soluble material, as described herein. The IDB tray 100 can be formed with one or wells to receive one or more orthodontic brackets to transfer the one or more orthodontic brackets to a patient's teeth. As described herein, the IDB tray 100 can be formed with wells and/or a channel or slot to receive bite turbos, auxiliaries, temporary anchoring devices, an archform, buttons, etc. to be transferred to the teeth of a patient.

At block 304, the IDB tray manufacturer can place an orthodontic bracket in the one or more wells of the IDB tray 100. The orthodontic brackets can be placed into the wells with a bonding surface facing out of the well. The bonding surface, as described herein, can include one or more features to improve bonding to a tooth using an adhesive. In some variants, the IDB tray 100 can include one or more features to help retain the orthodontic brackets in the wells until placement on a patient's teeth. In some variants, an archform (e.g., archwire) can be loaded into a channel or slot in the IDB tray 100 before the orthodontic brackets are placed in the wells. When the orthodontic brackets are placed in the wells, the orthodontic brackets can couple with the archform. In some variants, the orthodontic brackets may include springs to secure the orthodontic brackets to the archform.

At block 306, the IDB tray manufacturer can optionally apply a primer to the bonding surfaces of the orthodontic brackets placed in the one or more wells of the IDB tray 100. The primer can improve adhesion of the adhesive to the bonding surface of the orthodontic brackets. The IDB tray manufacturer can elect the type and quantity of primer and ensure proper application.

At block 308, the IDB tray manufacturer can apply an adhesive to the bonding surfaces of the orthodontic brackets. When primer is applied to the bonding surfaces, the IDB tray manufacturer can apply the adhesive to the primer. In some variants, the primer can be cured before application of an adhesive. The IDB tray manufacturer can elect the type and quantity of adhesive and ensure proper application.

At block 310, the IDB tray manufacturer can place the loaded IDB tray with the preloaded brackets with pre-pasted uncured adhesive into a container. The container can help to prevent the adhesive from curing during shipping. In some variants, the container can be airtight to prevent the adhesive from curing or slow the curing of the adhesive. In some variants, the container can be opaque to reduce and/or prevent the transmission of light through the container to prevent the adhesive from curing or slow the curing of the adhesive. In some variants, the container can be thermally insulated to prevent the adhesive from curing or slow the curing of the adhesive.

At block 312, the IDB tray manufacturer can distribute the container with the loaded IDB tray to the orthodontist, which can include providing the container to a distributor.

The orthodontist can receive the container with the loaded IDB tray. In some variants, the orthodontist can leave the loaded IDB tray in the container until a patient is ready for treatment to prevent the adhesive from curing or slow curing. In some variants, the orthodontists can remove the loaded IDB tray from the container and place the loaded IDB tray into a controlled environment that will prevent the adhesive from curing or slow curing. When a patient is ready for treatment, the orthodontists can remove the IDB tray from the container and/or controlled environment and place the loaded IDB tray over the dental arch of the patient. The adhesive can bond the bonding surfaces of the orthodontic brackets to the patient's teeth. The IDB tray can be removed from the patient's dental arch. An archform can be coupled to the orthodontic brackets to move the patient's teeth using sliding or non-sliding mechanics. As described herein, in some variants, the archform can be transferred with the orthodontic brackets by way of the IDB tray to the teeth of the patient. As described herein, in some variants, bite turbos, auxiliaries, temporary anchoring devices, buttons, etc. can be transferred with the IDB tray, which can include being transferred with one or more orthodontic brackets and/or archform.

The IDB tray manufacturer, in some variants, can supply a kit and/or system to orthodontists. For example, in some variants, a kit and/or system can include a preloaded IDB tray (e.g., an IDB tray with preloaded brackets with uncured pre-pasted adhesive), one or more archforms (e.g., two, three, four, or more), a tool for handling and/or installing archforms, primer, and/or an adhesive (e.g., bonding agent) for attaching the plurality of brackets to the teeth of the patient in the event that more is needed. In some variants, the kit and/or system can include the components to install an orthodontic appliance (e.g., brackets and archform) in the mouth of the patient. In some variants, one archform can be loaded in the IDB tray and coupled to the preloaded brackets.

FIG. 4 illustrates an example orthodontic bracket 500. The orthodontic bracket 500 can be transferred to a tooth of a patient with the IDB trays described herein. For example, the orthodontic bracket 500 can be placed in a well of an IDB tray. Primer and/or adhesive can be applied to a contact or bonding surface facing out of the well.

As shown, the bracket 500 can include lateral extensions or wings 508, 509 that extend in the medial-distal direction when the bracket 500 is bonded to a tooth. In some variants, the bracket 500 may not include lateral extensions or wings 508, 509. The lateral extensions or wings 508, 509 can improve rotational control of a tooth.

The bracket 500 can include a contact or bonding surface 514 that is configured to be bonded to the surface of a tooth of the patient. Accordingly, primer and/or adhesive can be applied to the contact or bonding surface 514 to facilitate bonding to a surface (e.g., lingual or buccal) of a tooth of the patient. The contact or bonding surface 514 can include grooves, slots, etc. that can receive primer and/or adhesive. As illustrated, the lateral extensions 508, 509 increase the size of the contact surface 514, which can further increase the strength of the bond between the bracket 500 and the surface of the tooth. The bonding surface 514 can be exposed when the orthodontic brackets are disposed in the wells of the IDB tray, which can facilitate the bonding surfaces 514 being bonded, respectively, to the surfaces of the teeth of the patient during curing.

The bracket 500 can include a variety of features that facilitate coupling to an archform. The bracket 500 can include a slot 502, which can extend in the medial-distal direction, disposed between a retainer 504 and stops 506, 507. The slot 502 can receive a bracket connector of an archform therein such that the archform does not slide with respect to the bracket 500. The retainer 504 and the stops 506, 507 can at least prevent movement of the bracket connector relative to the bracket 500 in the gingival-occlusal direction. The bracket 500 can include a spring 510 (e.g., C-spring) that can lock the bracket connector within the slot 502. The spring 510 can be disposed in the retainer 504 and push the connector against the stops 506, 507 to lock the connector within the slot 502. The spring 510 can be disposed in a hole or cavity 516 of the bracket 500. In some variants, the bracket 500 does not include a spring 510. A gap 512 can space apart the stops 506, 507 and receive a portion of the bracket connector therein such that the stops 506, 507 impede medial-distal movement of the bracket connector relative to the bracket 500.

FIGS. 5A and 5B illustrate the bracket 500 with the spring 510 disposed in the hole or cavity 516.

FIG. 6 illustrates an example archform 700, which can also be referred to as an archwire. In some variants, the archform 700 can be transferred, via an IDB tray, to couple with orthodontic brackets bonded to the patients teeth. In some variants, the archform 700 can be disposed in an IDB tray and coupled with orthodontic brackets disposed in the IDB tray to transfer orthodontic brackets and the archform 700 together to the teeth of a patient.

The archform 700 can have a polygonal (e.g., square, rectangular), circular, and/or other shaped cross-section. The archform 700 can be cut from a sheet of material, such as shape memory material (e.g., nickel titanium). The archform 700 can include a plurality of bracket connectors or connector portions 704 that can be coupled to orthodontic brackets to install the archform 700 in the mouth of a patient. The connectors 704 can include one or more features (e.g., tongue, arms, etc.) to facilitate locking the connectors 704 within an orthodontic bracket.

The archform 700 can include a plurality of interproximal segments 702. The interproximal segments 702 can be disposed between adjacent connectors 204. The interproximal segment 702 can include loops. The loops can extend in a gingival direction when the archform 200 is installed in the mouth, which can improve aesthetics and/or facilitate flossing. The loops can open to move adjacent teeth apart from each other. The loops can close to move adjacent teeth closer together.

As shown, the archform 700 is a two-dimensional shape. The archform 700 can be set in a custom nonplanar shape using a fixture based on a digital model of a patient's teeth in second positions, which may be an expected final alignment of the teeth. The archform 700 can be held in the custom nonplanar shape by the fixture and set by exposure to heat such that the custom nonplanar shape is the default or memorized position of the archform 700. The archform 700 can follow the entire upper or lower dental arch of a patient or a segment thereof. The archform 700 can be deflected from the memorized custom nonplanar shape and coupled to orthodontic brackets (e.g., coupling the connectors 704 to orthodontic brackets). The archform 700 can exert forces on the brackets and/or directly on the patient's teeth, causing the teeth to move toward second positions (e.g., an expected planned alignment) planned in the digital model.

FIG. 7 illustrates the bracket 500 with a connector 704 of the archform 700 coupled thereto such that the connector 704 may not slide with respect to the bracket 500. The bracket connector 704 can be disposed within the slot 502 of the bracket 500. The stops 506, 507 and retainer 504 can cooperate to retain the bracket connector 704 within the slot and prevent movement of the bracket connector 704 in the occlusal-gingival direction. A portion of the bracket connector 704, e.g., the tongue or tab, can be disposed in the gap 512 between the stops 506, 507 which can help impede the connector 704 from sliding relative to the bracket 500 in the medial-distal direction. As described herein, the spring 510, when incorporated, can push the connector 704 against the stops 506, 507, locking the connector 704 within the bracket 500. In some variants, the connector 704 may be tied to the bracket 500. The bracket 500 can include tie wings.

FIG. 8 illustrates an indirect orthodontic bonding (IDB) tray 400 being used to transfer a retainer 408 (e.g., permanent retainer) to the teeth 800 of a patient. The IDB tray 400 can be formed using the techniques described herein (e.g., 3D printing, overmolding on a physical model of a patient's teeth, etc.). The IDB tray 400 can correspond to an entire lower or upper dental arch of the patient. The IDB tray 400 can correspond to a section of the lower or upper dental arch of the patient. As illustrated in FIG. 8, the IDB tray 400 corresponds to the anterior section of the lower dental arch of a patient. The IDB tray 400 can include one or more cavities 402 that can receive the teeth of the patient.

The retainer 408 (e.g., permanent retainer) can be bonded to the lingual or buccal surfaces of the patient's teeth to maintain the alignment of the patient's teeth. The retainer 408 can be cut to a length to span the dental arch of the patient or a section of the dental arch. The retainer 408 can be made of a variety of materials, which can include stainless steel wire, lightweight braided stainless steel wire, and/or others. The retainer 408 can be disposed in a channel 410, which can also be referred to as a slot or groove, in the IDB tray 400 when transferring the retainer 408 to the teeth of the patient. The channel 410 can be formed in the walls of the IDB tray 400 that face the buccal or lingual surfaces of the patient's teeth when disposed on the dental arch of the patient. The retainer 408 can be flexible, allowing the retainer 408 to confirm to the contours of the IDB tray 400. In some variants, the retainer 408 can be made of nickel titanium (e.g., Nitinol) and custom-shaped to correspond to the alignment of the patient's teeth. In some variants, the IDB tray 400 does not have a channel 410. The retainer 408 can be disposed against the inner surface of the IDB tray 400 that is positioned proximate the lingual surfaces of the patient's teeth when the IDB tray 400 is positioned on the patient's teeth.

The IDB tray 400 can include one or more wells 404, which can be disposed in the portion (e.g., walls) of the IDB tray 400 forming the cavities 402. The one or more wells 404 can be positioned to be open to the lingual surfaces of the patient's teeth. In some variants, the one or more wells 404 can be positioned to be open to the buccal surfaces of the patient's teeth. The channel 410 can span several of the wells 404 such that the retainer 408, when placed in the channel 410, extends through the wells 404. The one or more wells 404 can receive adhesive 406 or the like therein. The one or more wells 404 can include a contoured profile, which can include rounded, smooth, and/or curved surfaces. The one or more wells 404 can be shaped to form rounded mounds, bumps, beads, or the like with cured adhesive 406 on the surfaces (buccal or lingual) of the patient's teeth. The surfaces of the IDB tray 400 forming the one or more wells 404 can be smooth such that the surfaces of the adhesive 406, once cured, can be smooth to reduce adhesive cleanup for a clinician and/or avoid irritating the soft tissue and/or tongue of the patient. The adhesive 406, once cured, can bond the retainer 408 to the surfaces of the patient's teeth. The adhesive 406 can cure from exposure to light (e.g., UV light), air, temperature (high or low), chemicals, and/or other influences. The adhesive 406 can be clear or colored. In some variants, the IDB tray 400 does not have a channel 410 and the retainer 408 is disposed against the inner surface of the IDB tray 400 that is positioned proximate the lingual surfaces of the patient's teeth when the IDB tray 400 is positioned on the patient's teeth and the retainer 408 is disposed through the adhesive 406 in the wells 404.

FIG. 9 illustrates the IDB tray 400 disposed over the anterior teeth of the lower dental arch of the patient. The adhesive 406 can contact the lingual surfaces of the patient's teeth and cure, bonding the retainer 408 to the lingual surfaces of the patient's teeth. As described herein, the adhesive can be cured from exposure to light (e.g., UV light), air, temperature (high or low), chemicals, and/or other influences. In some variants, the adhesive 406 can be cured while covered by the IDB tray 400. In some variants, the adhesive 406 can be cured while covered and/or with the IDB tray 400 removed.

FIG. 10 illustrates the retainer 408 bonded to the lingual surfaces of the patient's teeth by way of the beads of cured adhesive 406. As described herein, the retainer 408 can be flexible when placed into the IDB tray 400, enabling the retainer 408 to conform to the contours of the IDB tray 400. When the adhesive 406 cures and bonds the retainer 408 onto the surfaces of the patient's teeth, the length of the portions of the retainer 408 between adjacent cured adhesive beads 406 can be sufficiently short such that the portions of the retainer 408 are stiff (e.g., rigid) and prevent movement of the patient's teeth. Accordingly, the portions of the retainer 408 between adjacent beads of adhesive 406 can be stiff (e.g., rigid), as well as the portions of the retainer 408 disposed in the adhesive.

FIG. 11 illustrates a method 600 of installing a retainer on a patient's teeth. The flow diagram is provided for the purpose of facilitating description of aspects of some embodiments. The diagram does not attempt to illustrate all aspects of the disclosures and should not be considered limiting. In some variants, some of the steps described in reference to method 600 may be omitted.

At block 602, an IDB tray manufacturer can form an IDB tray 400. As described herein, the IDB tray 400 can be formed for a patient's dental arch (e.g., section of or entire upper or lower dental arch). The IDB tray 400 can be custom formed based on digital data from images (e.g., scans) of a patient's teeth, which can be captured via using a variety of techniques, which can include a digital intra-oral scanner, a cone-beam computed tomography (CBCT) X-ray scanner, and/or others. In some variants, the patient may capture images of the patient's own teeth with a portable device (e.g., smartphone, tablet, laptop, desktop, and/or a device connected to one or more of the foregoing). The IDB tray 400 can include one or more wells 404 to receive adhesive as described herein. The IDB tray 400 can include a channel 410 to receive a retainer 408 as described herein.

The IDB tray 400 can be formed via a variety of techniques. In some variants, the IDB tray 400 can be 3-D printed. The IDB tray 400 can be 3-D printed with a variety of materials, which can include one or more resins. In some variants, the IDB tray 400 can be formed via molding over a 3D model of a patient's dental arch with features (e.g., mounds, bumps, ridges, protrusions, etc.) thereon to form the wells 404 and channel 410. In some variants, the IDB tray 400 can be formed without a channel 410. In some variants, the IDB tray 400 can be formed using a soluble material, as described herein.

At block 604, the retainer 408 can be disposed in the IDB tray 400. In some variants, the retainer 408 can be disposed in the channel 410 of the IDB tray 400. In some variants, the IDB manufacturer or clinician can cut the retainer 408 to a length corresponding to the portion of the dental arch to be retained. The IDB manufacturer or clinician can place the retainer 408 in the channel 410. In some variants, the IDB tray manufacturer can ship the IDB tray 400 with the retainer 408 loaded therein to the clinician. As described herein, the retainer can be flexible and conform to the surfaces of the IDB tray 400.

At block 606, adhesive 406 can be flowed (e.g., disposed) into the wells 404. In some variants, adhesive 406 can be flowed into the wells 404 by a clinician immediately before placing the IDB tray 400 on the patient's dental arch. In some variants, adhesive 406 can be flowed into the wells 404 by the IDB tray manufacturer and the loaded IDB tray 400 can be shipped to the clinician in a container that prevents or slows the curing of the adhesive 406, as described herein. The adhesive 406 can flow around the portions of the retainer 408 extending through the wells 404.

At block 608, the IDB tray 400 with the adhesive 406 and retainer 408 can be placed over the lower or upper dental arch or a portion thereof of the patient. The adhesive 406 can contact the surfaces (buccal or lingual) of the patient's teeth.

At block 610, the adhesive 406 can be cured to bond the retainer 408 to the surfaces (lingual or buccal) of the patient's teeth. The adhesive 406 can be cured via a variety of techniques, which can at least include exposure to light (e.g., UV light), air, temperature (high or low), chemicals, and/or other influences. Due to the shape of the wells 404, the cured adhesive 406 can form beads, mounds, or the like on the surfaces of the patient's teeth. The cured adhesive 406 can have contours that are smooth and/or curved to reduce irritation to the tongue and/or tissue of the patient. In some variants, the walls of the IDB tray 400 forming the wells 404 can be smooth such that the cured adhesive 406 has smooth surfaces.

At block 612, the IDB tray 400 can be removed from the dental arch of the patient. In some variants, the adhesive 406 can be cured, in addition to the curing performed at block 610, after removal of the IDB tray 400. In some variants, the IDB tray 400 is removed before curing at block 610.

In some variants, the IDB tray 400 loaded with a retainer 408 or a retainer 408 and adhesive 406 can be incorporated into a kit, which can be distributed to a clinician.

It is intended that the scope of this present invention herein disclosed should not be limited by the particular disclosed embodiments described above. This invention is susceptible to various modifications and alternative forms, and specific examples have been shown in the drawings and are herein described in detail. This invention is not limited to the detailed forms or methods disclosed, but rather covers all equivalents, modifications, and alternatives falling within the scope and spirit of the various embodiments described and the appended claims.

Various other modifications, adaptations, and alternative designs are of course possible in light of the above teachings. Therefore, it should be understood at this time that within the scope of the appended claims the invention may be practiced otherwise than as specifically described herein. It is contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments disclosed above may be made and still fall within one or more of the inventions. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with an embodiment can be used in all other embodiments set forth herein. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above. Moreover, while the invention is susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but to the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the various embodiments described and the appended claims. Any methods disclosed herein need not be performed in the order recited. The methods disclosed herein include certain actions taken by a practitioner; however, they can also include any third-party instruction of those actions, either expressly or by implication. For example, actions such as “tying a tie onto an orthodontic bracket” includes “instructing the tying of a tie onto an orthodontic bracket.” The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited. Numbers preceded by a term such as “approximately”, “about”, and “substantially” as used herein include the recited numbers (e.g., about 10%=10%), and also represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount.

Claims

1. A kit comprising: a preloaded indirect orthodontic bonding (IDB) tray comprising: an IDB tray with a plurality of wells and a channel;a plurality of orthodontic brackets placed within the plurality of wells, each of the plurality of orthodontic brackets comprising a slot, a spring disposed in the slot, one or more stops, and a bonding surface, wherein the bonding surfaces are facing out of the plurality of wells;an archform disposed in the channel, the archform comprising a plurality of bracket connectors and a plurality of interproximal loops disposed between adjacent bracket connectors of the plurality of bracket connectors, the plurality of bracket connectors disposed in the slots of the plurality of orthodontic brackets such that the springs are deflected to push the plurality of bracket connectors in an occlusal-gingival direction against the one or more stops of the plurality of orthodontic brackets to lock the plurality of bracket connectors to the plurality of orthodontic brackets; andan adhesive applied onto the bonding surfaces of the plurality of orthodontic brackets;a container for housing the preloaded IDB tray, the container configured to prevent the adhesive from curing.

2. The kit of claim 1, wherein the preloaded IDB tray further comprises a primer applied to the bonding surfaces of the plurality of orthodontic brackets.

3. The kit of claim 1, wherein the IDB tray is in separate segments corresponding to portions of a patient's dental arch.

4. A method of producing a loaded indirect orthodontic bonding (IDB) tray for distribution, the method comprising: forming an indirect orthodontic bonding (IDB) tray with a plurality of wells and a channel;placing an archform in the channel of the IDB tray, the archform comprising a plurality of bracket connectors and a plurality of interproximal loops disposed between adjacent bracket connectors of the plurality of bracket connectors;placing a plurality of orthodontic brackets into the plurality of wells such that bonding surfaces of the plurality of orthodontic brackets are facing out of the plurality of wells and the plurality of bracket connectors are disposed in slots of the plurality of orthodontic brackets such that springs disposed in the slots of the plurality of orthodontic brackets are deflected to push the plurality of bracket connectors in an occlusal-gingival direction against one or more stops of the plurality of orthodontic brackets to lock the plurality of bracket connectors to the plurality of orthodontic brackets;applying an adhesive to the bonding surfaces of the plurality of orthodontic brackets; andplacing the IDB tray loaded with the archform, the plurality of orthodontic brackets, and pre-pasted adhesive into a container for distribution, the container configured to prevent the adhesive from curing.

5. The method of claim 4, further comprising applying a primer to the bonding surfaces of the plurality of orthodontic brackets.

6. The method of claim 4, wherein forming the IDB tray with the plurality of wells comprises 3D printing the IDB tray based on a digital model of at least a portion of a patient's dental arch.

7. The method of claim 4, wherein forming the IDB tray with the plurality of wells comprises molding over a 3D model of a patient's dental arch with a plurality of features positioned to form the plurality of wells.

8. A preloaded indirect orthodontic bonding (IDB) tray for distribution, the preloaded IDB tray comprising: an indirect bonding tray (IDB) tray with a plurality of wells and a channel;a plurality of orthodontic brackets placed within the plurality of wells, each of the plurality of orthodontic brackets comprising a slot, a spring disposed in the slot, one or more stops, and a bonding surface, wherein the bonding surfaces are facing out of the plurality of wells;an archform disposed in the channel, the archform comprising a plurality of bracket connectors and a plurality of interproximal loops disposed between adjacent bracket connectors of the plurality of bracket connectors, the plurality of bracket connectors disposed in the slots of the plurality of orthodontic brackets such that the springs are deflected to push the plurality of bracket connectors in an occlusal-gingival direction against the one or more stops of the plurality of orthodontic brackets to lock the plurality of bracket connectors to the plurality of orthodontic brackets;a primer applied to the bonding surfaces of the plurality of orthodontic brackets; andan adhesive pasted onto the bonding surfaces of the plurality of orthodontic brackets.

9. The preloaded IDB tray of claim 8, wherein the preloaded IDB tray is configured to be distributed to an orthodontist in a container that is configured to prevent the adhesive from curing such that the preloaded IDB tray is ready for placement on a dental arch of a patient upon receipt by the orthodontist.

10. The method of claim 4, wherein the IDB tray comprises a soluble material configured to dissolve in a patient's mouth, and wherein the soluble material is cellulose.

11. The kit of claim 1, wherein the IDB tray comprises a soluble material configured to dissolve in a patient's mouth.

12. The preloaded IDB tray of claim 8, wherein the IDB tray comprises a soluble material configured to dissolve in a patient's mouth.