PROTECTIVE ORAL APPLIANCE

Abstract

A protective oral appliance for protecting the teeth and jaws of a user from injuries during physical activity or sports. The oral appliance includes an upper mouthpiece coupled to a lower mouthpiece, and holes passing through the upper mouthpiece and/or through the lower mouthpiece to allow air to pass through the upper and/or lower mouthpieces and into the user's mouth. The oral appliance also may include an open airway positioned between the upper and lower mouthpieces.

Claims

1. A protective oral appliance comprising: a first U-shaped channel adapted to engage a user's upper teeth when worn and having a first inner facing wall, a first outer facing wall, and a first bottom connecting the first inner facing wall and the first outer facing wall, and a second U-shaped channel adapted to simultaneously engage the user's lower teeth when worn and having a second inner facing wall, a second outer facing wall, and a second bottom connecting the second inner facing wall and the second outer facing wall; and at least one hole passing through the first inner facing wall, the first outer facing wall, the first bottom, the second inner facing wall, the second outer facing wall, and/or the second bottom; wherein the at least one hole is adapted to allow air to pass through the at least one hole and into the user's mouth.

2. The protective oral appliance of claim 1 wherein the first U-shaped channel is coupled to the second U-shaped channel.

3. The protective oral appliance of claim 2 further comprising an open airway between the first U-shaped channel and the second U-shaped channel.

4. The protective oral appliance of claim 3 wherein the open airway includes at least one support column extending from an upper side of the open airway to a lower side of the open airway.

5. The protective oral appliance of claim 1 wherein the at least one hole is about 1 mm-2 mm wide.

6. The protective oral appliance of claim 1 further comprising a bite tab configured to engage at least one tooth of the user's upper teeth and at least one tooth of the user's lower teeth when worn.

7. The protective oral appliance of claim 1 wherein the first U-shaped channel and the second U-shaped channel are formed using at least one of polyethylene-polyvinyl acetate copolymer (EVA), silicone, carbon fiber, and nanofiber.

8. An oral device for protecting a user from injuries, comprising: a U-shaped base composed of resin callout having a U-shaped cross-section comprising a lower, a horizontal floor with upwardly extending inner lingual and outer labial walls, and a posterior section proximate to the user's molar, wherein the oral device includes a plurality of irrigation channels in the form of holes for increased uptake of oxygen while wearing the oral device, a continuous ridge composed of the resin callout having the U-shaped base and integral with the base, wherein the ridge comprises an outer horizontal portion disposed on the exterior surface of the outer labial wall of the anterior section and terminating in opposite inner horizontal portions disposed on the interior surface of the horizontal floor of the posterior section.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0026] The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific methods and structures disclosed herein. The description of a method step or a structure referenced by a numeral in a drawing is applicable to the description of that method step or structure shown by that same numeral in any subsequent drawing herein.

[0027] FIGS. 1-5 show conventional sports guards.

[0028] FIG. 6 shows an oral appliance according to some embodiments of the present invention.

[0029] FIGS. 7-8 show an oral appliance with irrigation channels according to some embodiments of the present invention.

[0030] FIGS. 9-10 show an oral appliance with irrigation channels according to some embodiments of the present invention.

[0031] FIG. 11 shows an oral appliance with extrusions according to some embodiments of the present invention.

[0032] FIG. 12 shows an oral appliance with an open airway according to some embodiments of the present invention.

[0033] FIG. 13 shows an oral appliance with one support column according to some embodiments of the present invention.

[0034] FIG. 14 shows an oral appliance with three support columns according to some embodiments of the present invention.

[0035] FIG. 15 shows an oral appliance with a bite tab according to some embodiments of the present invention.

[0036] FIG. 16 shows a flowchart illustrating a method for designing an oral appliance according to some embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0037] The present invention is best understood by reference to the detailed figures and description set forth herein.

[0038] It is expected that the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

[0039] FIGS. 6-8 show perspective views of a protective oral appliance or dental device (hereinafter referred as device) 600 for protecting the teeth and jaws of a user during physical activities or sports settings, according to some embodiments of the present invention. In some embodiments, the device 600 includes an oral splint appliance designed for the upper jaws (as shown in FIG. 6). In some embodiments, the device 600 includes a sports guard. The device 600 also may be used in treating medical conditions such as bruxism, as well as sleep conditions such as sleep apnea. In some embodiments, the device 600 includes a thick splint designed in dental CAD software, and additively manufactured using flexible 3D printer resin. In some embodiments, the device 600 includes a plurality of irrigation holes to facilitate breathing through the device.

[0040] In some embodiments, as shown in FIG. 7, the device 600 includes one or more mouthpieces each configured to form a U-shaped channel 602 having an inner facing wall 604, an outer facing wall 606, and a bottom 608 connecting the inner and outer facing walls 604, 606. In some embodiments, the device 600 includes a plurality of mouthpieces, e.g., an upper mouthpiece for the upper teeth and a lower mouthpiece for the lower teeth. The upper and lower mouthpieces may be used in conjunction or independently.

[0041] In some embodiments, as shown in FIGS. 7 and 8, the mouthpiece device 600 includes one or more irrigation holes or air channels 610 passing through the inner facing wall 604, through the outer facing wall 606, and/or through the bottom 608 to facilitate the flow of air through the device 600 for increased oxygen uptake by the user. In some embodiments, the irrigation channels 610 may include width and/or height dimensions of about 0.5 mm to 5 mm, and preferably of about 1 mm to 2 mm.

[0042] In some embodiments, the device 600 is made of a material including but not limited to polyethylene-polyvinyl acetate copolymer (EVA), silicone, carbon fiber, nanofiber, other suitable materials, and/or any combinations thereof.

[0043] In some embodiments, the device 600 changes color upon undergoing heat damage, age, and/or deterioration. For example, the resin chosen to form the device 600, once cured, may change color under at least one of the following conditions: (i) when exposed to a high temperature above a predetermined threshold, (ii) when a specific amount of time has passed, and (iii) when the cured material has deteriorated to a particular level.

[0044] In some embodiments, the device 600 includes an antimicrobial surface to prevent the growth and accumulation of pathogens on the surface of the oral device 600. The antimicrobial surface may include a coating that is applied to the device 600 after the device 600 has been formed (e.g., by spraying, dipping, etc.), and/or may be a result of using an antimicrobial material to form the outer layer of the device 600 during the fabrication process.

[0045] In some embodiments, as shown in FIG. 9, the device 600 includes a double guard 700. The double guard 700 includes a first sports guard 700-1 designed to engage the user's upper teeth when worn and a second sports guard 700-2 designed engage the user's lower teeth when worn. The first and second sports guards 700-1, 700-2 may be coupled together to form the double guard 700 as shown in FIG. 10. That is, the side of the first sports guard 700-1 opposite its U-shaped channel 702-1 may be coupled (e.g., bonded or integrally formed) with the side of the second sports guard 700-2 opposite its U-shaped channel 702-2. The first and second sports guards 700-1, 700-2 may be fabricated separately and then coupled together (e.g., bonded) or fabricated as a single unit and integrally connected as such. In this arrangement, it is preferable that the first and second sports guards 700-1, 700-2 are aligned with one another such that each respective U-shaped channel 702-1, 702-2 may properly receive and engage the user's upper and lower teeth, respectively, simultaneously. As such, by engaging the user's upper teeth and lower teeth simultaneously when worn, the double guard 700 may reduce the chance of concussions or other physical damage due to impact to the user's jaw.

[0046] FIG. 9 shows two instances of the double guard 700, with a first instance on the left showing the double guard 700 with its first guard 700-1 facing upward coupled to the second guard 700-2 facing downward, and a second instance on the right showing the double guard 700 with its second guard 700-2 facing upward and coupled to the first guard 700-1 facing downward. As shown, the first guard 700-1 includes a U-shaped channel 702-1 having an inner facing wall 704-1, an outer facing wall 706-1, and a bottom 708-1 connecting the inner and outer facing walls 704-1, 706-1. Similarly, the second guard 700-2 includes a U-shaped channel 702-2 having an inner facing wall 704-2, an outer facing wall 706-2, and a bottom 708-2 connecting the inner and outer facing walls 704-2, 706-2.

[0047] In some embodiments, as shown in FIG. 9, the double guard 700 includes irrigation channels 710 in one or both of the first and second sports guards 700-1, 700-2. For example, the double guard 700 may include first irrigation channels 710-1 in its first sports guard 700-1 passing through the inner facing wall 704-1, outer facing wall 706-1, and/or bottom 708-1, and/or second irrigation channels 710-2 in its second sports guard 700-2 passing through the inner facing wall 704-2, outer facing wall 706-2, and/or bottom 708-2.

[0048] In some embodiments, the upper guard 700-1 and the lower guard 700-2 may be formed and/or merged together prior to cutting a plurality of irrigation channels 710-1, 710-2 through the upper and/or lower guards 700-1, 700-2, respectively. In some embodiments, the irrigation channels 710 are through holes (as shown in FIGS. 9 and 10). In some embodiments, the plurality of irrigation channels 710 may be in the shape of circle, oval, rectangle, square, hexagonal, polygonal, and/or any other suitable shape. In addition, the irrigation channels 710 may be formed in any suitable pattern(s) on the first and second guards 700-1, 700-2. In some embodiments, the plurality of irrigation channels 710 may be formed and added manually while in other embodiments, the plurality of irrigation channels 710 may be formed automatically during the fabrication of the double guard 700 (e.g., in predefined shapes and/or patterns) using an application software, for example, CAD software). The double guard 700 preferably comprises a plurality of irrigation channels 710 in its anterior region to facilitate breathing of users, for example, athletes, while wearing the double guard 700.

[0049] In some embodiments, the double guard 700 includes a pair of splints merged together by a designer during an additive manufacturing process for increased control of occlusion while biting. To develop the upper double guard 700-1 and/or the lower double guard 700-2 of the double guard 700, the upper and/or lower arches of the user may preferably be aligned in an appropriate position such that a scan or impression may be taken. Based on specific patient needs and expert analysis by a clinician or AI/software, a preferred relative position of the user's upper and lower arches may be determined. This position may be the rest position of the user, or an alternative position. Once the position is determined, the pair of splints can be arranged accordingly with one another (aligned per the determined position of the user's upper and lower arches) and merged together accordingly.

[0050] In some embodiments, as shown in FIG. 11, the double guard 700 is designed to prevent specific regions of the cutting jig from intersecting the boundary of the splint. In some embodiments, the double guard 700 further includes raised surfaces with extrusions 712. In some embodiments, the sports guard surfaces are raised to the antagonist's occlusion if needed. This variable thickness helps to ensure an even bite while designing the double guard 700 to prevent stress to the patient when impacted. The designer chooses the position of the first and second sports guards 700-1, 700-2 to preferably match a position of the patient's jaw during the time of a potential impact.

[0051] In another embodiment, an oral device for protecting a user from injuries, comprising a U-shaped base composed of resin callout having a U-shaped cross-section comprising a lower, horizontal floor with upwardly extending inner lingual and outer labial walls, and a posterior section proximate to the user's molar; wherein the oral device includes a plurality of irrigation channels in the form of holes for increased uptake of oxygen while wearing the oral device; and a continuous ridge composed of the resin callout having the U-shaped base and integral with the base, wherein the ridge comprises an outer horizontal portion disposed on the exterior surface of the outer labial wall of the anterior section and terminating in opposite inner horizontal portions disposed on the interior surface of the horizontal floor of the posterior section.

[0052] FIGS. 12-15 illustrate perspective views of a double guard 800 with irrigation, according to different embodiments of the present invention. The double guard 800 comprises an upper guard 802 and a lower guard 804. The upper guard 802 and the lower guard 804 may be coupled together to form the double guard 800. In some embodiments, the double guard 800 comprises an open airway 806 (as shown in FIG. 12) between the upper guard 802 and the lower guard 804 at their front ends. The open airway 806 passes entirely through the double guard 800 to facilitate breathing through the double guard 800 (through the open airway 806) when the double guard 800 is worn. In this way, air may pass through the open airway 806 into the user's mouth to facilitate easier breathing.

[0053] In another embodiment, the double guard 800 comprises one or more support columns and/or other types of support structures at (e.g., within) the open airway 806. In some embodiments, the support columns are provided to dampen sharp impacts to the anterior region of the user's jaw. In some embodiments, the support columns are designed specific to the user's/patient's jaw motion data. The patient's jaw motion data may be obtained using analog or digital methods, e.g., impressions, scans, etc.

[0054] In some embodiments, the double guard 800 includes at least one support column 808 within the open airway 806. For example, as shown in FIG. 13, the open airway 806 may include a single support column 808 generally positioned vertically at the lateral midpoint of the open airway 806. It is appreciated that the single support column 808 also may be positioned off-center.

[0055] In other embodiments, the double guard 800 may include multiple support columns. For example, in some embodiments, as shown in FIG. 14, the double guard 800 may include three support columns 808, 810, and 812 within the open airway 806, e.g., towards the left side of the open airway 806, at the midpoint of the open airway 806, and towards the right side of the open airway 806. It is appreciated that the open airway 806 may include other numbers of support columns 808 positioned at other locations within the open airway 806. For example, in some embodiments, the frequency and size of the support columns (808, 810, and 812) may be designed specific to the patient's use case. Typically, higher impact sports may require more support columns than lower impact sports.

[0056] It is appreciated that other types of reinforcement structures also may be used to reinforce the double guard 800, e.g., in the area of the open airway 806. For example, the open airway 806 may include a reinforced perimeter (e.g., of thickened material). In addition, other shaped reinforcement structures also may be used, such as, without limitation X shaped reinforcement structures within the open airway 806.

[0057] In some embodiments, as shown in FIG. 15, the double guard 800 includes a bite tab 814. The bite tab 814 may comprise a cushion material that may dampen the forces caused by impacts to the user's jaws, and of any clinching of the user's upper and lower teeth. In some embodiments, the bite tab 814 may comprise a porous material such that air may pass through the bit tab 814 into the user's mouth to facilitate easier breathing.

[0058] FIG. 16 illustrates a flowchart 900 depicting an example design method for designing an oral device 600 for protecting a user from injuries, according to some embodiments of the present invention. The method comprises the following steps. At step 902, an impressions and/or scans of the user's jaw are acquired along with bite position as an input during the time of seating. The impressions or scans are acquired from mandibular, maxillary, and/or gum-like areas. The acquired data is inputted to a dental CAD software. At step 904, a sports guard is designed by a designer based on the acquired impressions or input scan. At step 906, an upper guard mouthpiece is designed based on the acquired impression or input scan. At step 908, a lower guard mouthpiece is designed based on the acquired impression or input scan. At step 910, the designed upper guard and lower guard are merged together (e.g., at their respective arches). In some embodiments, the double guard is a pair of splints. At step 912, the splint is added or cut with irrigation holes using a custom pattern in the CAD software to obtain a file. In some embodiments, the double guard is provided with a fully open airway (as shown in FIG. 12) with one or more bite support columns (as shown in FIGS. 13-14). This pattern is adapted for function, such as dynamic scaling or dimensions. In some embodiments, logos, text, and/or other markings may be added for technical and/or aesthetic purposes. In some embodiments, the irrigation holes may not be placed in the area of the device 600 that engage the user's molars to ensure a stable bite during impact in this area.

[0059] At step 914, the obtained file is transferred to a 3D printer's slicing software or cloud interface to print the device 600. The file is oriented, supported and responsively added to a layout and queued with similar models using the cloud software. In some embodiments, the user sets up the file on desktop software. After printing, the print is washed and cured. At step 916, the print is post-processed with automated wash solutions, ultrasonic cleaning, or warm soapy water after curing.

[0060] In some embodiments, the print is optionally polished with a lathe, wheel, and a series of pumice, steam and polishing compound. This process obfuscates the layer lines from 3D printing and makes the appliance nearly indistinguishable from a thermoformed equivalent. Polishing also helps the patient with aftercare, as it will be easier to clean. In some embodiments, optional heat seat delivery method involves placing the appliance in warm (95-115? F.) water for 10-20 seconds and then adapting the malleable appliance to the patient's teeth by hand while still pliable from the heated bath. In some embodiments, the patient may handle optional adjustments by soaking the splint in hot water before seating. Further, the dentist may handle optional adjustments by using a handpiece or other tool to grind and/or polish the splint or redesign, potentially based on new scans.

[0061] Advantageously, the device of the present invention provides safety to a user from injuries caused during physical activities and sports settings. The device of the present invention provides a unitary, customizable oral device protecting the teeth and jaws and having a continuous integral ridge with an outer portion for further protection of the anterior teeth and an inner portion for further protection of the posterior teeth. The device is a durable, impact-resistant barrier while maintaining form-fitting comfort. The device of the present invention is designed with increased thickness and material which helps lessen sports or other impacts. For example, the variable thickness specific to the patient's anatomy creates an even bite plane and further reduces damage when impacted. The method of designing also is adapted to be used for the manufacture of various other dental appliances.

[0062] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. It should be understood that the illustrated embodiments are exemplary only and should not be taken as limiting the scope of the invention.

[0063] The foregoing description comprise illustrative embodiments of the present invention. Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings in the foregoing descriptions. Although specific terms may be employed herein, they are used only in generic and descriptive sense and not for purposes of limitation. Accordingly, the present invention is not limited to the specific embodiments illustrated herein.