SURGICAL TEMPLATE FOR DENTAL AND/OR ORTHODONTIC IMPLANTS AND METHOD FOR DESIGNING A SURGICAL TEMPLATE

Abstract

A computer-aided method for designing a surgical template for dental and/or orthodontic implants comprises acquiring a first 2D or 3D image of the oral cavity and of the overlying anatomical structures of a patient, processing the first image for defining one or more second 2D images showing corresponding views or sections of the oral cavity, realizing a digital model of the upper dental arch and of the palate of the patient to identify one or more suitable sites for inserting a corresponding implant, selecting one or more slices of the digital model at one or more sagittal or parasagittal planes passing through respective insertion sites, overlapping the slices with corresponding second 2D images for generating a third 2D image, providing a digital library of implants for the selection thereof and for their virtual positioning into the third image in order to allow the adjustment of the inclination and/or the deepness of insertion. A surgical template for dental and/or orthodontic implants suitable to be manufactured with the above method.

Claims

1. A computer-aided method for designing a surgical template for dental and/or orthodontic implants, characterized by comprising the following steps: a) acquiring a first 2D or 3D image of the oral cavity and of the overlying anatomical structures of a patient; b) processing said first image for defining one or more second 2D images showing corresponding views or sections of the oral cavity with respect to a sagittal plane; c) realizing a digital model of the upper dental arch and of the palate of the patient and identifying one or more suitable sites for inserting a corresponding implant; d) selecting one or more slices of said digital model at one or more sagittal or parasagittal planes passing through respective of said one or more insertion sites previously identified; e) overlapping said one or more slices with corresponding second 2D images for generating a third 2D image; f) providing a digital library of implants; g) selecting the implants from said library; h) virtual positioning of said implants into said third image; i) adjusting the inclination and/or the deepness of insertion of said virtual implants.

2. Method as claimed in claim 1, characterized in that said first image is a 3D image captured by a computerized tomography, preferably of the cone beam type.

3. Method as claimed in claim 2, characterized in that said processing step b) comprises a step b′) for identifying one or more areas, preferably a pair of areas, of the palate on said first image, which areas being suitable to receive a respective implants and a step b″) for selecting respective second 2D images at sagittal or parasagittal planes passing thorough said selected areas.

4. Method as claimed in claim 1, characterized in that said first image is a 2D image captured by a radiography, said processing step b) comprising a reduction with predetermined reduction to bring it to a 1:1 ratio with respect of the real anatomy of the patient.

5. Method as claimed in claim 1, characterized in that the implants are selected from said library in function of the size and amount of the available bone at said previously identified positioning areas.

6. Method as claimed in claim 1, characterized by comprising, downstream of said step i), a step j) for designing the guides for positioning the implants in function of said size, inclination and/or deepness of said implants, a final step l) being also provided for designing the definitive model.

7. A surgical template (1) for dental and/or orthodontic implants, in particular palatal implants, manufactured according to a method as claimed in one or more of the preceding claims, comprising: a palate portion (2) reproducing the shape of the palate of a patient; at least one substantially cylindrical guide (5) provided in said palate portion (2) and having an axial passage (6) with an inlet section (7) and an outlet section (8) for the insertion of a corresponding implant in the palate of the patient with predetermined inclination and deepness; characterized in that said at least one guide (5) has end-stroke means (11) adapted to define an axial abutment for the implant (9) at the insertion thereof into said passage (6) for adjusting the insertion deepness.

8. Template as claimed in claim 7, characterized in that said axial passage (6) comprises an inlet cylindrical length (12) for the insertion of the implant (9) and an outlet length (13) defining a restriction comprising said end-stroke means (11) and adapted to house in a snugly fit manner the conical or cylindrical head (14) of the implant (9) for blocking it at a predetermined height.

9. Template as claimed in claim 7, characterized in that at least said guide (5) is optically transparent or translucent and has an axial slot adapted to divide it at least partially into two semi-cylindrical portions (5′, 5″) and a perimeter window (15) adapted to allow, together with said axial slot, to look inside said passage (6) and to define a reference for inserting the implant at the right deepness.

10. Template as claimed in claim 7, characterized in that said at least one guide (5) is fastened to said palate portion (2) through connection areas with reduced strength (17) and/or pre-cut lines adapted to make easier the removal of the template (1) from the palate and in that said at least one guide (5) is made of a pair of semi-cylindrical portions (5′, 5″) radially off-set and fastened to said palate portion (2) by respective and different connection weakness areas (17).

11. Template as claimed in claim 8, characterized in that at least said guide (5) is optically transparent or translucent and has an axial slot adapted to divide it at least partially into two semi-cylindrical portions (5′, 5″) and a perimeter window (15) adapted to allow, together with said axial slot, to look inside said passage (6) and to define a reference for inserting the implant at the right deepness.

12. Template as claimed in claim 8, characterized in that said at least one guide (5) is fastened to said palate portion (2) through connection areas with reduced strength (17) and/or pre-cut lines adapted to make easier the removal of the template (1) from the palate and in that said at least one guide (5) is made of a pair of semi-cylindrical portions (5′, 5″) radially off-set and fastened to said palate portion (2) by respective and different connection weakness areas (17).

13. Template as claimed in claim 9, characterized in that said at least one guide (5) is fastened to said palate portion (2) through connection areas with reduced strength (17) and/or pre-cut lines adapted to make easier the removal of the template (1) from the palate and in that said at least one guide (5) is made of a pair of semi-cylindrical portions (5′, 5″) radially off-set and fastened to said palate portion (2) by respective and different connection weakness areas (17).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Further features and advantages of the invention will become more apparent in light of the detailed description of some preferred but not exclusive embodiments of a surgical template of the invention and of two embodiments of a method for designing a template, illustrated by way of non-limiting example with the aid of the accompanying drawing, wherein:

[0058] FIG. 1 is a perspective view of a template of the invention in a first embodiment;

[0059] FIG. 2 is a front view of the template of FIG. 1;

[0060] FIG. 3 is a front view of a first correction device anchored by implants adapted to be applied by means of the template of FIG. 1;

[0061] FIGS. 4a, b, c shows three imagines relative to corresponding designing steps of the template of the invention in a second embodiment;

[0062] FIG. 5 is a front view of a second corrective device anchored by means of implants adapted to be applied with the template of FIG. 4;

[0063] FIG. 6 is a first partial perspective view of the template of FIG. 1 applied to the palate and during the positioning step of a implant;

[0064] FIG. 7 is a second partial perspective view of the template of FIG. 1 applied to the palate and during the positioning step of a implant;

[0065] FIG. 8 is a further front view of the template of FIG. 1 during the positioning of a pair of implants;

[0066] FIG. 9 is an exploded perspective view of an implant adapted to be used with a template of the invention;

[0067] FIGS. 10 to 12 show three different embodiments of a device for inserting the implant;

[0068] FIGS. 13 to 21 show the steps for carrying out a method of the invention in a first preferred embodiment;

[0069] FIGS. 22 to 28 show the steps for carrying out a method of the invention in a second preferred embodiment.

BEST MODES OF CARRYING OUT THE INVENTION

[0070] With reference to the accompanying figures, there is illustrated a surgical template for positioning orthodontic implants in the oral cavity of a patient.

[0071] Although in the figures there is shown a template in association with orthodontic implants, in particular for applications in the palate, the same template may also be used for positioning prosthetic implants or other removable or non-removable types of implants.

[0072] In its most general embodiment, a surgical template for orthodontic implants, generally indicated by 1, comprises a palatal central portion 2 with an upper surface 3 which reproduces in negative the shape of the palate of a patient to be positioned in contact therewith in a precise manner.

[0073] In addition, the template 1 has a support peripheral portion 4 which preferably reproduce at least partially the shape of the dental arch of the patient to be lean thereon, and in particular on the surface of occlusion of the posterior teeth, so as to ensure the stability of the template 1 during use.

[0074] As visible from FIG. 1, two substantially cylindrical guides 5 are made in the palatal portion 2 each having a respective axial passage 6 with an inlet section 7 and an outlet section 8 for the insertion of a corresponding dental implant 9 designed to be set in the palate of the patient with predetermined angle and deepness.

[0075] The two guides 5 have substantially identical dimensions with respective passages 6 having central extension axes X as much as possible parallel to each other to ensure uniformity in the positioning of the implants 9, necessary for the correct performance of the therapy.

[0076] From FIG. 2 it could be observed that the two guides 5 are laterally and mutually staggered in side-by-side position with a predetermined distance d between the respective central extension axes X.

[0077] FIG. 3 shows a particular embodiment of a corrective device D1 fixed to the palate P by a pair of implants 9 positioned by means of the template 1 described above.

[0078] FIG. 4 shows a second embodiment of the template 1 which differs from that described above in particular for the fact that it further comprises, in addition to said pair of guides 5, a third guide 10 disposed in the forward position with respect to one of the side guides 5.

[0079] This embodiment would be particularly useful for positioning a corrective device D2 as shown in FIG. 5.

[0080] Regardless of the number of guides provided for the specific template, advantageously each of these guides 5, 10 comprises respective end-stroke means 11 adapted to define an axial abutment for the implant 9 at the time of its insertion in the respective passage 6, so as to allow the adjustment of the insertion deepness within the bone.

[0081] In a preferred but not exclusive manner, the axial passage 6 of each guide 5 may have a substantially cylindrical inlet length 12 wherein the implant 9 could be inserted and an outlet length 13 which defines a constriction.

[0082] According to the preferred embodiment shown in FIGS. 6 and 7, referred to the template 1 according to the first embodiment, the axial passage 6 of each guide 5 comprises a substantially cylindrical inlet length 12 in which the implant 9 could be inserted and an outlet length 13 with a substantially frusto-conical shape whose lateral wall define the end-stroke means 11.

[0083] In particular, the frusto-conical outlet length 13 will be suitably dimensioned during the design step to snugly fit a conical head of the specific selected implant, e.g. the transmucosal collar 14 of a miniscrew for orthodontic anchorage 9, to lock it at a predetermined height also selected during design step as function of the amount of available bone, as will become more clear in the following description of the method.

[0084] If the used implant has a portion of transmucosal collar with cylindrical shape, the outlet length 13 may be also cylindrical with an axial abutment for the collar.

[0085] Regardless of the specific configuration of the end-stroke means, the guides 5 will have respective perimeter windows 15 adapted to allow viewing inside the corresponding passages 6 and to define a reference for the insertion of the implant 9 at the correct deepness.

[0086] More precisely, through the window 15, the operator will have the opportunity to verify that the implant 9 has actually reached the end-stroke 11 and has not been blocked by any obstacles, such as areas of bone with greater resistance.

[0087] To this end, as shown more clearly from FIG. 8, the implant 9 or the tool for its screwing may be provided with a reference element 16 suitably sized to be placed at the window 15 when the implant 9 is in the correct position.

[0088] In particular, it is possible to use implants or mini-implants and tools of the type commonly available on the market and the axial position of the window 15 may be determined in the design step of the template 1 as a function of detected measures.

[0089] In order to further increase the visibility inside the guides 5, even in the absence of the windows 15, the palatal portion 2, or only the guides 5 may be made of an optically transparent or translucent material, such as transparent resins for 3D printing.

[0090] Advantageously, the whole template 1 may be in an optically transparent or translucent material.

[0091] To make the removal of the template 1 easier when the implants 9 have been applied, the guides 5 will be connected to the palatal portion 2 by means of areas with structural weakening 17 adapted to define connection lines with reduced strength.

[0092] For example, according to a first configuration, not shown, the weakening areas will be pre-cut lines, or, as in the embodiments of the figures, each of the guides 5 will be formed by a pair of semi-cylindrical portions 5′, 5″ opposite to each other to define the corresponding passage 6 and radially offset from each other so as to be partially or completely separated along the whole axial extension.

[0093] In this way between the two semi-cylindrical portions 5′, 5″ a further axial slot will be defined to facilitate even more the control of the moving forward of the implants inside of the passages 6.

[0094] The two semi-cylindrical portions 5′, 5″ are connected to the palatal portion 2 by respective and distinct weakness areas 17 defined by a plurality of bridges or beams made of resin or other polymeric material that will ensure sufficient stability to the connection between the guides and the palatal portion but which at the same time may easily be cut to allow removal of the template 1 and of the guides 5.

[0095] In particular, the staggered half-cylinders shape for the guides 5 will allow the simple removal from the implant 9 upon the breaking of the bridges 17.

[0096] FIG. 9 shows a particular embodiment, exemplifying and not limiting of the invention, of a implant 9 adapted to be inserted in the palate by means of a template 1 of the invention.

[0097] The illustrated implant 9 is a miniscrew for orthodontic anchorage of the Spider screw regular Plus type, whose orthodontic head 14 may be associated with an abutment element 18 fixable to the orthodontic head 14 by means of a fixing screw 19 to allow the stable connection of the correction devices to the implants.

[0098] FIGS. 10 to 12 show alternative embodiments of the guides 5 and of the end stroke means 11 which may be either associated with a template 1 according to the present invention, or advantageously implemented also in further templates, in particular in templates not designed according to the method of the present invention or templates not provided of the above weakening areas and/or the above windows.

[0099] In general in these further embodiments the end stroke means may be associated with both the outlet length 13 of the guides 5 and the tool 20 for inserting the implant 9.

[0100] In particular, the end stroke means 11 will be of the male and female type with a male element associated to one between the outlet length 13 of the guide 5 and the head of the tool 20 and a female element associated with the other between the outlet length 13 of the guide 5 and the head of the tool 20 so as to be engaged by the male element only when the implant 9 is in the right designed position.

[0101] In the embodiment of FIG. 10 the guides 5 have a passage 6 totally cylindrical and the end stroke means 11 comprise a male element 21 defined by an abutment tooth placed in correspondence of the outlet section 8. The outlet length 13 may be either cylindrical or tapered as in the figure.

[0102] The male element 21 is adapted to interact with a corresponding female abutment element 22 associated with the head of the tool 20 so that the tooth 21 engages the abutment element 22 upon a movement of roto-translation of the tool 20 and to the achievement of the design predetermined deepness.

[0103] In this way, when the implant will be inserted with the correct deepness, the above abutment element 22 will impact on the abutment tooth 21 preventing further rotation.

[0104] FIG. 11 shows a further embodiment in which the outlet length 13 of the guide 5 has a conical narrowing 21 with a radial abutment surface for the conical head 22 of the tool 20.

[0105] In FIG. 12 the head of the tool 20 will be provided with shaped radial projections 21 realized on the peripheral wall of its head to be inserted into corresponding recesses defining the female elements 22, countershaped with respect of the radial projections.

[0106] Also in this case the outlet length 13 may indifferently be either cylindrical or tapered as in figures.

[0107] However, such embodiments are solely exemplifying and not restrictive and in particular further configurations may be provided in which the male and female elements may be differently shaped and arranged.

[0108] For example, an additional configuration, not shown, may have a cylindrical passage 6 of the guide 5 provided with a perimetric protrusion which narrows the lumen of the passage at a predetermined height so as to create an abutment for the head of the tool screwing the implant.

[0109] As matter of fact, since the tool is wider than the implant itself, it will be only the latter to pass, while the abutment will prevent the head of the tool to further penetrate, so that the same will be locked.

[0110] Moreover, the abutment screw may also be performed by inserting in the cylindrical guides 5 one or more metal rings reducing the lumen of the guide 5 and always acting in abutment against the screwing tool.

[0111] The rings may be different in thickness, or height and operate as thickness gauges to lock the descent of the screwing tool.

[0112] In a further configuration the passage 6 is cylindrical and the head of the tool 20 is provided with a flat abutment which counter-act in correspondence of the inlet front section 7 of the guide.

[0113] The template described above in the different embodiments may be designed and manufactured according to any of the known techniques, without particular limitations.

[0114] FIGS. 13 to 21 show a particular preferred, but not exclusive, embodiment of a method for computer-aided designing of surgical template for dental implants.

[0115] This method may advantageously be used both for designing and manufacturing the template according to the present invention that for templates of known type, or other types of templates.

[0116] The method will be particularly suitable for the realization of templates for palatal anchorages as the palate does not present uniform thickness but has a conformation highly variable from person to person.

[0117] Therefore in this type of applications it needs to get the most accurate measurements, taking into account the real bone conformation of the palate.

[0118] The method provides a step a) of acquiring a first 2D or 3D image in the oral cavity of the patient (FIG. 13).

[0119] The object of this step is to obtain an image as more reliable as possible of the structure of the jawbone and will preferably be carried out by means of a CAT or even more preferably by a technique of computed tomography cone beam (CBCT—Cone Beam Computed Tomography). This will make it possible to elaborate the first image to generate one or more second 2D digital images, preferably according to the DICOM standard, in order to identify the anatomical structure of the palate and identify the most suitable areas of the palate for implant placement (step b).

[0120] In particular, the processing step b) includes a step b′) of identifying one or more areas of the palate on the first image, preferably a pair of areas, suitable to receive a respective implant, and a step b″) of selecting respective second 2D images at parasagittal planes passing through the selected areas.

[0121] The second images will reproduce corresponding views or sections of the oral cavity with respect of a parasagittal plane.

[0122] At the same time a digital model of the dental arch and of the palate of the patient may be realized (step c), according to any known technique, which may be obtained either directly by a intraoral scanner or making first an imprinting of the arch and then scan it to get the digital model.

[0123] One or more suitable sites for insertion of a respective implant may be identified on the digital model thus obtained to subsequently select (step d) one or more slices of the digital model in correspondence with one or more parasagittal planes passing through respective insertion sites previously identified.

[0124] In this way further digital 2D images will be obtained, which may be converted into a STL file, on which one or more ideal points for the positioning of the implants may be identified.

[0125] The points will be preferably detected in areas meeting the biomechanical needs, for example in an area between the distal surface of the canines and the mesial surface of the premolars, also considering that usually the distance between the two points is close to 10 mm (FIG. 14) and also considering the design configuration of the device to be associated to the implant.

[0126] In a subsequent step e) the slices are overlapped with the corresponding second digital image, i.e. to the DICOM file (FIG. 15 and FIG. 16) for defining a third complex 2D digital image.

[0127] In this way it will be possible to identify the most suitable spatial position for the micro-screws on the basis of the deepness and thickness of the palate.

[0128] In particular, it could identify both the transverse plane that parasagittal planes corresponding to the sites of insertion of implants.

[0129] In this way the virtual position of the implant or miniscrews inside the third digital complex image at respective slice CBCT images (FIG. 16-20) will be possible.

[0130] The implant or the implant having the greater length compatible with the amount of available bone at previously identified positioning sites may be selected by adjusting the position of the virtual plants within a digital library appropriately prepared (step f and step g).

[0131] At this point the three-dimensional check of the application of mini-screws on 3D model occurs in order to assess the adequacy of the length of the screws and or mini-implants and that they are parallel (FIG. 21), also ensuring the availability of bone at the points of intersection of the transverse plane with the parasagittal planes.

[0132] Subsequently, you can proceed to the design of the template, for example of the type illustrated in FIG. 1, taking into account that the same must rest on the surface of occlusion of the posterior teeth and starting from the design of the positioning guides of the implants.

[0133] The use of STL images of the miniscrews allows to faithfully reproduce the measures that have to be reported with the utmost precision in the design of the guides, in particular at the length 13 designed to house the transmucosal collar of the implant and the portion designed for the tool insertion.

[0134] These measures will be transferred to the inner part of the cylindrical guides 5 which replicate the previously predetermined angle of insertion and which will be configured to prevent that the implant can be introduced with excessive or lower deepness than the needs.

[0135] Finally, any resin bridges or equivalent weakness areas may be virtually determined.

[0136] According to an alternative configuration, not illustrated, the cylindrical guides 5 may be provided with connection means to the template 1 of the bayonet, screw/nut or the like type to allow the coupling by screwing or movement of roto-translation. In this way the cylinder of the guide 5, which can also be in metal and can be prefabricated in standard size, is screwed into the individual template and will thread up to the deepness designed in the previous processing of the 2D and 3D images.

[0137] Then, the metal cylinder acts as a guide and as a stop for the insertion of the implant and/or of the miniscrew.

[0138] The virtual model of the template so designed may be used for the realization of the real template with 3D printing techniques, stereolithography techniques or according to any technique suitable for the purpose.

[0139] The insertion of the implants and application of the fixed or removable prostheses or devices of correction may be performed according to any methods of known type and are not described in this text because it does not fall within the scope of the present invention.

[0140] FIGS. 22 to 28 show a variant of the method described above, which differs from that described above first of all for the fact that the step a) of acquisition of the first image is a two-dimensional x-ray of the oral cavity, such as a latero-lateral and/or anterior-posterior teleradiography.

[0141] The first 2D image so acquired will be subsequently processed (step b) to be reduced with a predetermined reduction coefficient and brought to a 1:1 ratio with respect to the real anatomy of the patient.

[0142] After making the digital model of the patient's mouth the median sagittal plane of the model will be selected for generating a single slice to be overlapped on the first 2D image processed and get the third image on which the implants will be designed and in particular to define the deepness and/or angle thereof in the manner described above to then proceed to the design of the guides, in a manner substantially identical to that described above.

[0143] However, in this case if it is decided to apply two implants, they will be arranged in positions substantially symmetrical with respect to the median sagittal plane at a distance selected according to anatomical features of the palate.

[0144] From above it appears evident that the template and its design method according to the invention reach the intended objects.

[0145] The template and its design method according to the invention are susceptible of numerous modifications and variations, all falling within the inventive concept expressed in the accompanying claims. All the details may be replaced with other technically equivalent elements, and the materials may be different according to requirements, without departing from the scope of the present invention.

[0146] Although the template and the method have been described with particular reference to the attached figures, reference numbers used in the description and in the claims are used to improve the intelligence of the invention and do not constitute any limitation the claimed scope.