ORTHODONTIC BRACKETS, SYSTEMS, AND METHODS

Abstract

Orthodontic brackets are disclosed. An orthodontic bracket is formed such that the body and mesh portions are formed integrally in one piece, and the tooth-side mounting surface includes bonding elements that have an undercut angle to the mounting surface. The bonding elements can further include geometry to facilitate the spreading of bonding material. In some aspects, the bracket can also comprise elements for wire-mounting and aligner tray interaction. A system and methods of treatment are further disclosed. The bracket can be customized for an individual patient.

Claims

1. An orthodontic bracket, comprising: a mounting portion and a treatment portion formed integrally in one part; the mounting portion comprising a mounting surface for attachment to a tooth and at least one bonding element configured to receive a bonding material; and the treatment portion comprising at least one wire-mounting element, wherein the at least one bonding element is disposed at an undercut angle with respect to the mounting surface.

2. The orthodontic bracket according to claim 1, wherein the mounting surface comprises a plurality of bonding elements.

3. The orthodontic bracket according to claim 2, wherein the plurality of bonding elements are formed as protrusions above the mounting surface.

4. The orthodontic bracket according to claim 2, wherein the plurality of bonding elements are formed as recesses beneath the mounting surface.

5. The orthodontic bracket according to claim 3, wherein the bonding elements are a square shape with side lengths in a range of 200-400 μm and a depth in a range of 100-350 μm.

6. The orthodontic bracket according to claim 3, wherein the mounting surface further comprises a plurality of grooves to facilitate spreading of the bonding material.

7. The orthodontic bracket according to claim 1, wherein the at least one wire-mounting element comprises a slot with a curved base.

8. The orthodontic bracket according to claim 1, wherein the at least one wire-mounting element comprises a slot with a tapered cross-section.

9. The orthodontic bracket according to claim 1, wherein the treatment portion further comprises a second wire-mounting element in the form of a wire-receiving tube.

10. The orthodontic bracket according to claim 9, wherein the wire-receiving tube is disposed at an angle in a range of 10°-45° from the occlusal plane.

11. The orthodontic bracket according to claim 1, wherein the mounting portion is formed in a convex angle configured to mount on a lingual side of a tooth.

12. The orthodontic bracket according to claim 11, wherein the treatment portion further comprises a through-hole located between the mounting portion and the treatment portion, the through-hole being disposed transverse to an exterior surface of the mounting portion.

13. An orthodontic bracket configured for attachment to a tooth, comprising: a mounting portion and a treatment portion; the mounting portion comprising a mounting surface for attachment to a tooth and at least one bonding element configured to receive a bonding material, and the treatment portion comprising at least one wire-mounting element; and wherein the mounting portion is formed in a convex angle configured to mount on a lingual side of a tooth, and wherein the bracket a through-hole located between the mounting portion and the treatment portion, the through-hole being disposed transverse to an exterior surface of the mounting portion.

14. The orthodontic bracket according to claim 13, wherein the bracket is formed using an additive manufacturing process.

15. A system of orthodontic treatment comprising: a plurality of orthodontic brackets each configured for attachment to a tooth, wherein at least some of the orthodontic brackets comprise: a mounting portion and a treatment portion formed integrally in one part; the treatment portion comprising at least one wire-mounting element; and the mounting portion comprising a mounting surface for attachment to a tooth and at least one bonding element configured to receive a bonding material, wherein the at least one bonding element is disposed at an undercut angle with respect to the mounting surface.

16. A method of orthodontic treatment, comprising: scanning a patient's teeth with a 3D scanning machine to create a computer model of a patient's current dentition; using a computer processor to model an ideal occlusion from the current dentition; determining an initial alignment stage of the current dentition; performing a computer simulation to virtually move the patient's teeth from the initial alignment stage to the ideal occlusion in incremental steps; designing, using a computer processor, a plurality of custom lingual brackets which are configured to arrange the patient's teeth in the ideal occlusion, wherein at least one or more or all of the custom lingual brackets comprise: a through-hole located between the mounting portion and the treatment portion, the through-hole being disposed transverse to an exterior surface of the mounting portion; fabricating the custom lingual brackets; bonding the custom lingual brackets to the patient's teeth; inserting at least one archwire into the custom lingual brackets to align and level teeth; re-scanning the patient's teeth to create an aligned-crude model; performing a computer simulation to create incremental alignment steps for moving the patient's teeth from the aligned-crude model to the ideal occlusion model; designing, using a computer processor, one or more clear alignment tray for each incremental alignment step; and fabricating the one or more clear alignment tray, wherein the clear alignment trays are configured for orthodontic treatment.

17. The method according to claim 16, wherein the at least one archwire is removed after delivery of the clear alignment trays and a first alignment tray is inserted in the patient's mouth.

18. The method according to claim 16, wherein the at least one archwire is a round, superelastic archwire.

19. The method according to claim 16, wherein the at least one archwire is formed from shape-memory alloy material.

20. The method according to claim 16, wherein the at least one archwire is formed using an additive manufacturing process.

21. The method according to claim 16, wherein the custom lingual brackets are formed in one piece using an additive manufacturing process.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1A is a front view of an orthodontic bracket according to the disclosure herein;

[0013] FIG. 1B is a cross-sectional side view drawn along line A-A of FIG. 1A;

[0014] FIG. 1C is a top view of an orthodontic bracket according to the disclosure herein;

[0015] FIG. 2 is a rear isometric view of an orthodontic bracket according to the disclosure herein;

[0016] FIG. 3 is a rear oblique view of an orthodontic bracket according to the disclosure herein;

[0017] FIG. 4 is another isometric view of an orthodontic bracket according to the disclosure herein;

[0018] FIGS. 5A-5B are isometric views of another embodiment of an orthodontic bracket according to the disclosure herein;

[0019] FIG. 6 is an installed view of an orthodontic bracket according to the disclosure herein;

[0020] FIGS. 7A-7E are various views of another embodiment of an orthodontic bracket according to the disclosure herein;

[0021] FIGS. 8 and 9 are installed views of orthodontic brackets according to the disclosure herein;

[0022] FIGS. 10-12 are top isometric views of an orthodontic system used for teeth according to the disclosure herein;

[0023] FIG. 13 is a schematic diagram of a method of orthodontic treatment according to the disclosure herein; and

[0024] FIG. 14 is a flow chart of a method of orthodontic treatment according to the disclosure herein.

DETAILED DESCRIPTION

[0025] The subject matter disclosed herein addresses problems encountered in a traditional method of orthodontic treatment using conventional brackets. By providing an integrally made orthodontic bracket with features disclosed herein, orthodontic treatment can be customized for each individual patient. Custom orthodontic brackets and attachments improve orthodontic outcomes and reduce treatment time by optimizing the interactions between the bracket, the wire, and the tooth.

[0026] Referring to FIGS. 1A-1C, an example embodiment of an orthodontic bracket, generally designated 100, is depicted wherein bracket 100 is configured for attachment, such as lingual or facial attachment, to a portion of a tooth with or without completely encircling the tooth. Orthodontic bracket 100 has two general regions: a treatment portion 110 and a mounting portion 120. Treatment portion 110 is also conventionally referred to as a body. Mounting portion 120 generally corresponds to a conventional “mesh” portion of an orthodontic bracket, which is typically manufactured as a separate part from the body and later joined to the body. According to the disclosure herein, orthodontic bracket 100 is formed as a single part, with treatment portion 110 and mounting portion 120 integrally joined. Treatment portion 110 has features for attaching treatment devices, such as bosses, hooks, and slots. Mounting portion 120 has a tooth-side mounting surface 122, which features for facilitating attachment to a tooth with a bonding material (e.g., curable composite). Mounting portion 120 further includes at least one bonding element, which can be in the form of a protrusion or a recession (e.g., 124, 126). This protrusion or recession is disposed at least in part at an undercut angle relative to the mounting surface to form an undercut such as undercut 130. In other words, the bonding element joins the mounting surface at an angle less than perpendicular. These features are discussed in further detail below.

[0027] Treatment portion 110 can further comprise archwire slot 112 and tiewings 118, on which can be mounted elastic ligatures to retain an archwire. The geometry of archwire slot 112 can be customized to accommodate various archwires. In the example embodiment of orthodontic bracket 100, slot 112 has tapered walls 114. However, other profiles can be envisioned, for example, walls 114 can have a rectangular or arc-shaped profile to match the geometry of a particular archwire. Additionally, the base of slot 112 is preferably formed a longitudinal arc shape in the wire direction to follow the curvature of a patient's dentition. Orthodontic bracket 100 can further optionally comprise additional features 116 in the form of bosses, slots, etc., which can be used for functions such as bracket orientation and additional treatment device interfaces.

[0028] FIG. 2 is an isometric view of orthodontic bracket 100 as seen from the tooth-facing side, wherein bracket 100 is configured for attachment to a portion of a tooth with or without completely encircling the tooth. As depicted here, orthodontic bracket 100 has a plurality of bonding pedestals 124, which are disposed at a level above mounting surface 122. In this example embodiment, bonding pedestals 124 are disposed in a grid array; however, other configurations are also possible, such as circular or random patterns, or even a single element. Each bonding pedestal 124 is preferably attached to mounting surface 122 at an angle less than 90° with respect to mounting surface 122 to form undercut 130. In the embodiment shown in FIGS. 1B-1C, bonding pedestal 124 has undercut 130 on all four sides of the pedestal. However, it is also possible to have undercut 130 on one, two, or three sides of the pedestal. This geometry provides an improved interface between the bonding material and the bracket by providing an increased volume for the composite to flow into as compared to conventional brackets. This can also be helpful in resisting separation from the tooth after the composite hardens by creating a mechanical interlock.

[0029] FIG. 3 depicts an alternate embodiment of orthodontic bracket 100, generally designated 100′, wherein bracket 100′ is configured for attachment to a portion of a tooth with or without completely encircling the tooth. In this embodiment, the bonding elements of mounting surface 122 are in the form of bonding recesses 126. Bonding recesses 126 are disposed at an angle relative to mounting surface 122 to form undercut 130. I.e., in embodiments using bonding recesses 126, the lower or inner surface of the recess has a greater area than the outer surface of the recess. As with bonding pedestal 124, bonding recess can have undercut 130 on one, two, three, or all four sides. For both bonding pedestals 124 and bonding recesses 126, the bonding elements can be a square shape with outer side lengths of approximately 200-400 μm and a depth of approximately 100-350 μm. It is to be understood that other shapes are also possible.

[0030] To achieve undercut 130 in bonding pedestal 124 or bonding recess 126, orthodontic bracket 100 can be produced by various, suitable processes known to those skilled in the art. Current methods include additive manufacturing processes such as powder bed fusion such as selective laser sintering (SLS) and direct metal laser sintering (DMLS), and powder fed such as directed energy deposition (DED). This construction allows the inclusion of features in the bracket that are difficult to obtain using conventional techniques. This also allows an orthodontic bracket to be designed and built at the point of service (i.e., “chairside”) and customized for an individual patient. An additional benefit of a single part construction is that designing and fabricating the bracket chairside reduces the high tooling and fabrication costs often associated with changes to bracket design. Yet further advantages of the bracket disclosed herein are improved dimensional tolerances, faster production, and more desirable aesthetics.

[0031] FIG. 4 depicts another alternative embodiment of orthodontic bracket 100, generally designated 100″, wherein bracket 100″ is configured for attachment to a portion of a tooth with or without completely encircling the tooth. In addition to bonding recesses 126, orthodontic bracket 100″ also has optional grooves 128. Grooves 128 can be disposed longitudinally and/or laterally with respect to the horizontal plane of the bracket. Grooves 128 provide an additional path for even distribution of bonding material in bonding recesses 126.

[0032] FIGS. 5A-5B illustrate another embodiment of an orthodontic bracket generally designated 150, wherein bracket 150 is configured for attachment to a portion of a tooth with or without completely encircling the tooth. Orthodontic bracket 150 includes a treatment portion 110, mounting portion 120, and bonding recesses 126 disposed at a negative or undercut angle to form undercut 130. Instead of tiewings, the treatment portion 110 of orthodontic bracket 150 is a tube-shaped element 152 for inserting an archwire. Brackets of this type are used, for example, at a terminal end of an archwire. Orthodontic bracket 150 also includes an optional second wire tube 154. Second wire tube 154 is preferably disposed at an angle α in the range of 10-45° from the occlusal plane.

[0033] FIG. 6 illustrates a usage case for orthodontic bracket 150. Second wire tube 154 can be used as an alternative path for archwire 160, for the purpose of producing a distal crown moment in a molar. This distal crown moment counteracts the mesial crown moment produced when aligning teeth T and protracting molars forward during space closure. The balanced moments can aid in keeping in the molar in place while retracting anterior teeth, which is a very desirable biomechanical movement in treating patients with spacing or extractions. Although the embodiment described herein uses a one-piece construction, it is envisioned that second wire tube 154 can also be used with a conventional banded mounting type that completely encircles the tooth.

[0034] Routing an archwire through second wire tube 154 provides advantages over the traditional technique of bonding a bracket at an angle on the tooth. Second wire tube 154 can allow the dental provider to make significant adjustments to the archwire tension without having to remove and re-bond the bracket.

[0035] FIGS. 7A-7E show yet another example embodiment of an orthodontic bracket, generally designated 200, wherein bracket 200 is configured for attachment to a portion of a tooth with or without completely encircling the tooth. Orthodontic bracket 200 has treatment portion 210 and mounting portion 220. Whereas orthodontic bracket 100 is configured such that mounting surface 122 is generally concave (i.e., suitable for mounting on a facial surface), orthodontic bracket 200 is configured such that mounting surface 222 is convex in some cases and is configured for mounting on a lingual surface of a tooth. Various embodiments of orthodontic bracket 200 can be used as a system in a lingual orthodontic treatment, such as with archwires, aligner trays, or a combination thereof.

[0036] As with orthodontic bracket 100, orthodontic bracket 200 is formed integrally as one part. This advantageously allows orthodontic bracket 200 to be produced with small features and overall size that provides improved comfort to a patient and ease of archwire insertion by the clinician. Additionally, if orthodontic bracket 200 is produced by an additive manufacturing process at the point of service, mounting surface 222 customized to individual tooth anatomy.

[0037] Similarly to orthodontic bracket 100′, orthodontic bracket 200 includes bonding elements to facilitate the adhesion of bonding material to the bracket. For example, mounting surface 222 includes a number of bonding recesses 226, which can be provided with dimensions as described for bonding recesses 126. Bonding recesses 226 can be arranged in a regular, semi-regular, or random pattern as necessary to maximize bonding.

[0038] In the example embodiment shown in FIGS. 7A-7E, treatment portion 210 differs from the treatment portions in orthodontic brackets 100 and 150. In the case of orthodontic bracket 200, a through-hole 212 is provided. Through-hole 212 is located between the mounting portion and the treatment portion and is configured to receive an archwire. The diameter of the through-hole corresponds to the size of a round archwire for connecting lingual brackets. Treatment portion 210 can also be used as part of a clear alignment therapy, which is described in more detail below.

[0039] The overall shape of mounting portion 220 can be produced in virtually any shape as required to match the contours of a tooth. FIGS. 8 and 9 illustrate possible embodiments for lingual brackets. For example, FIG. 8 depicts lingual brackets 230, 232, 234 mounted on incisor and canine teeth T. In this case, the mounting portions are generally convex and configured to fit the lingual surface of the teeth. In FIG. 9, on the other hand, lingual brackets 236 and 238 are shown mounted on molar teeth T, and the mounting portion in this case has a generally concave shape. It can also be seen in FIGS. 8 and 9 that the axes of adjacent through-holes are not aligned; the insertion of a lingual archwire (e.g., an archwire made of a shape-memory alloy) produces aligning forces to cause movement in the teeth.

[0040] Referring now to FIG. 10, a system of lingual brackets 300, including individual brackets 240, 242, 244, 246, 248, 250, 252, 254, 256, 258 and an archwire 260 is shown in the mouth of a patient P. Here it can be seen that each bracket is customized for each individual tooth T and that the brackets have a low profile. Additionally, the lingual brackets can be quickly mounted in the mouth of patient P with the use of an indirect bonding tray. Accordingly, the system of lingual brackets 300 can provide a comfortable and minimally-intrusive treatment. It can additionally be seen in FIG. 10 that some of the brackets have mounting portions with convex curvatures (e.g., 246, 248, 250), while others have a more concave form (e.g., 256, 258).

[0041] FIGS. 11 and 12 depict an alternate embodiment of system 300, generally designated 300′. System 300′ (including brackets 340, 342, 344, 346, 348, 350, 352, 354, 356, 358 that are each configured for attachment to a portion of a tooth with or without completely encircling the tooth) presents a hybrid approach to lingual orthodontic treatment. For example, system 300′ can be applied to the teeth T as shown in FIG. 11. Each bracket comprises a mounting portion with bonding elements and a treatment portion with a through-hole. In an initial treatment stage, brackets 340 to 358 can, for example, be connected using an archwire (not shown). After a certain degree of alignment has been achieved, the archwire is then removed and clear alignment therapy begins. The archwire is replaced with clear aligner tray 370, as seen in FIG. 12. Conventionally, clear aligner trays interact with ridges that are adhered to the patient's teeth. The treatment portion of the lingual brackets in system 300′ replace these ridges and provide the interaction with clear aligner tray 370 to move the teeth the final desired position.

[0042] This general hybrid approach is adapted to a unique method of treatment in accordance with the disclosure herein and described in the schematic diagram of FIG. 13 and the flow chart of FIG. 14. This treatment can achieve a desired dental alignment in two procedural stages. The first stage (Stage 1) moves a patient's teeth into partial alignment by using a system of orthodontic brackets, which is configured for lingual attachment and use with lingual archwires (e.g., 300). In the second stage (Stage 2), the alignment progress is measured and adjusted, and the brackets are used in conjunction with clear alignment therapy. Treatment may occur on either an upper or lower portion of the jaw, or both at the same time.

[0043] The treatment begins with an imaging scan of the inside of the patient's mouth (1001). This can be accomplished, for example, by using a laser scanner 10. The scanned image is sent to a 3D CAD program on a computer 20, where it is processed as required to separate the single image of the scanned teeth into separate, isolated elements (1002). The processed 3D model can be referred to as an initial stage model (ISM). The dental provider then uses skill and judgement to place the modeled tooth elements in a final desired state for that particular patient (e.g., improved bite, straight appearance, decreased crowding, etc.) (1003). This final state can be referred to as an ideal occlusion, and it can be based, for example, on biomechanical principles that match individual malocclusion. Next, a computer algorithm can be used to define a specific path for each tooth, in order to move the teeth from the initial location to the ideal occlusion. An intermediate state along the path is chosen as the end of Stage 1, which can be referred to as the initial alignment stage, or IAS (1004). A second simulation is then performed to move the teeth from the IAS to the ideal occlusion (1005). These paths are segmented into several discrete models that represent incremental states (1006). At this point, the dental provider can refer to the computer model to aid in the design of custom lingual brackets (e.g., similar to orthodontic bracket 200), which preferably have recessed bonding elements and through-holes in the treatment portion. The custom lingual brackets, also known as attachments, are configured to move the teeth from the initial alignment stage to the ideal occlusion (1007) with the aid of clear aligners.

[0044] The one-piece custom lingual brackets are then fabricated and delivered to the dental provider if necessary (1008). The custom lingual brackets can be produced by any appropriate method, for example, by using an additive manufacturing process on a 3D printer 30. The brackets are then loaded with adhesive (e.g., Transbond LV) on the mounting feature of the attachment. The attachments bonded to the patient's teeth in a manner to facilitate the movement of the teeth from the initial alignment stage to the ideal occlusion (1009). Lingual archwires, which are preferably shape memory alloy, are then inserted and used to align and level the patient's teeth for a time period, for example 3-6 months. The lingual archwires can be produced by any suitable method, include an additive manufacturing process. The end of this time frame is the end of Stage 1 (1010).

[0045] At the end of time period (for example 3-6 months), the patient's teeth will have moved partially toward the ideal occlusion. The patient's mouth is then scanned again, for example, by using a laser scanner 10 (2001), and the image is imported to a 3D CAD model on a computer 20 and processed to separate the teeth into individual elements (2002). The position of the teeth at this point can be referred to as the aligned crude model (ACM), which is targeted to be comparable to the ISM. The dental provider can then follow a process similar to Stage 1 by refining the ideal occlusion (2003) and using a computer algorithm to update and adjust the path from the ACM to the ideal occlusion. The path can be saved in incremental steps, also known as incremental step models, or ICM (2004). Each ICM defines a position for designing a series of clear alignment trays (2005). The clear alignment trays can then be constructed using any appropriate method (2006), including an additive manufacturing process using a 3D printer 30, and delivered to the dental provider for continued treatment (2007). The lingual attachments are left in place to serve as retentive points and to produce forces on the teeth in conjunction with the aligner trays in place of the conventional composite attachments. Using the treatment portions of the custom lingual brackets as the reaction points with the clear trays can advantageously provide a strong and accurate movement in the teeth.

[0046] Finally, the lingual archwires can be removed, and clear alignment therapy begins (2008). The series of trays are used in succession until the ideal occlusion is achieved. The patient's progress is monitored by the dental provider on a regular basis, and, if necessary, refinement trays can produced to correct alignment.

[0047] While several exemplary embodiments of the subject matter are disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). For example, although the figures depict embodiments with mounting portions that do not encircle a tooth, it is also possible to provide orthodontic brackets according to the disclosure that completely encircle a tooth.

[0048] The subject matter disclosed herein can be implemented in or in association with software in combination with hardware and/or firmware. For example, the subject matter described herein can be implemented in software executed by a processor or processing unit, for example that is or are in or associated with computer 20. In one exemplary implementation, the subject matter described herein can be implemented using a computer readable medium having stored thereon computer executable instructions that when executed by a processor of a computer control the computer to perform steps. Exemplary computer readable mediums suitable for implementing the subject matter described herein include non-transitory devices, such as disk memory devices, chip memory devices, programmable logic devices, and application specific integrated circuits. In addition, a computer readable medium that implements the subject matter described herein can be located on a single device or computing platform or can be distributed across multiple devices or computing platforms.

[0049] Various combinations and sub-combinations of the structures and features described herein are contemplated and will be apparent to a skilled person having knowledge of this disclosure. Any of the various features and elements as disclosed herein can be combined with one or more other disclosed features and elements unless indicated to the contrary herein. Correspondingly, the subject matter as hereinafter claimed is intended to be broadly construed and interpreted, as including all such variations, modifications and alternative embodiments, within its scope and including equivalents of the claims.