WO2010126716A1

WO2010126716A1 - Elastomeric orthodontic bracket packaging system

Info

Publication number: WO2010126716A1
Application number: PCT/US2010/031137
Authority: WO
Inventors: Paul E. Lewis
Original assignee: Ultradent Products, Inc.
Priority date: 2009-04-30
Filing date: 2010-04-15
Publication date: 2010-11-04

Abstract

A packaging and organizing system (100) for orthodontic brackets (106) includes a frame (102) and at least one bracket receiving elastomeric pod (104) attached to the frame (102). Each elastomeric pod (104) includes a bottom surface (108) and a top cover (1 10) including a central opening (112) formed in the top cover (110) through which an enlarged bonding pad (107) of the bracket (106) is inserted. The central opening (112) is sized smaller than the enlarged bonding pad (107) so that the bonding pad (107) is trapped between the bottom surface of the pod and the top cover once the bonding pad (107) is inserted through the central opening (112). A first slit (114) is formed from the central opening (112) to a perimeter edge of the pod (104). A second slit (116) extends along a portion of the perimeter edge of the pod (104) so that the first slit (114) interconnects with the second slit (116).

Description

ELASTOMERIC ORTHODONTIC BRACKET PACKAGING SYSTEM

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention relates to orthodontic bracket packaging systems.

2. The Relevant Technology Orthodontics is a specialized field of dentistry that involves the application of mechanical forces to urge poorly positioned or crooked teeth into correct alignment and orientation. Orthodontic procedures can be used for cosmetic enhancement of teeth, as well as medically necessary movement of teeth to correct underbites or overbites. For example, orthodontic treatment can improve the patient's occlusion and/or enhanced spatial matching of corresponding teeth.

The most common form of orthodontic treatment involves the use of orthodontic brackets and wires, which together are commonly referred to as "braces." Orthodontic brackets are small slotted bodies configured for direct attachment to the patient's teeth or, alternatively, for attachment to bands which are, in turn, cemented or otherwise secured around the teeth. Once the brackets are affixed to the patient's teeth, such as by means of glue or cement, a curved arch wire is inserted into the bracket slots. The arch wire acts as a template or track to guide movement of the teeth into proper alignment. End sections of the arch wire are typically captured within tiny appliances known as tube brackets or terminal brackets, which are affixed to the patient's bicuspids and/or molars. The remaining brackets typically include open arch wire slots and apply orthodontic forces by means of ligatures attached to the brackets and arch wire (e.g., by means of tie wings on the brackets).

The brackets are very small (e.g., often measuring only 1-4 mm in each dimension). In addition, brackets intended for placement on different teeth often differ in minor ways, and because of their small size, it can be difficult to recognize the identity of any individual bracket, particularly where multiple brackets become commingled.

BRIEF SUMMARY OF THE INVENTION The present invention provides a packaging and organizing system for orthodontic brackets. The packaging system includes a frame and at least one bracket receiving elastomeric pod attached to the frame. Each elastomeric pod includes a bottom surface and a top cover including a central opening formed in the top cover through which an enlarged bonding pad of the bracket is inserted and through which the upper portion of the bracket extends. The central opening is sized smaller than the enlarged bonding pad, so that the bonding pad is trapped between the bottom surface of the pod and the top cover once the bonding pad is inserted through the central opening.

In order to assist in insertion and removal of the bonding pad from the cavity defined between the top cover and the bottom surface of the pod, a first slit is formed from the central opening to a perimeter edge of the pod. A second slit (e.g., bisected by the first slit) extends along a portion of the perimeter edge of the pod so that the first slit connects with the second slit. The top cover is formed of an elastomeric material (e.g., a thermoset silicone and/or a thermoplastic elastomer). The slits allow the top cover adjacent the central opening to easily be spread open so as to effectively increase the size of the central opening during insertion and removal of the oversized bonding pad from the cavity of the pod. When the enlarged bonding pad of a bracket is received within the pod, the upper portion of the bracket (e.g., the tie wings and adjacent portions of the bracket body) extend outwardly through the central opening, while the oversized bonding pad of the bracket is trapped between the top cover and the bottom surface of the pod. Because the top cover (and preferably the entirety of the pods and frame) is formed of an elastomeric material which easily stretches, it permits the portions of the top cover adjacent the central opening and slit to be spread open during insertion or removal of the bracket. When the adjacent portion of the top cover is spread open (e.g., by being folded over), the size of the central opening is effectively increased so as to accommodate the size of the bonding pad. Once insertion or removal is complete, the folded portion of the top cover simply falls or springs back into place, thereby trapping the bonding pad.

These and other advantages and features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

Figure 1 is a perspective view of an exemplary elastomeric packaging system for storing and organizing a plurality of orthodontic brackets; Figure 2 A is a close up perspective view of a single pod of the system of

Figure 1, including a bracket retained therein;

Figure 2B is a cross-sectional view of the single pod and bracket of Figure 2 A; Figure 3 is a perspective view of the pod in Figures 2A and 2B with the orthodontic bracket removed from the pod; Figure 4 is a perspective view of the pod and bracket of Figures 2 A and 2B, in which a practitioner is gripping the bracket with a pair of tweezers in preparation for removing the bracket from the pod;

Figure 5 is a perspective view of the pod and bracket of Figure 4, in which the bracket is being removed from the pod; and Figure 6 is a perspective view of the pod and bracket of Figure 5 once the bracket has been removed from the pod.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS I. Introduction

The present invention provides a packaging, retaining, and organizing system for orthodontic brackets. The system includes a frame and at least one bracket receiving elastomeric pod attached to the frame. In one embodiment, the system includes a plurality of pods (e.g., one pod per bracket within the bracket set). Each elastomeric pod includes a bottom surface and a top cover including a central opening formed through the top cover through which the bonding pad of the bracket is received. The central opening is sized smaller than the bonding pad, so that the bonding pad is trapped between the bottom surface of the pod and the top cover once the bonding pad is inserted through the central opening. In order to assist in inserting and removing the bonding pad from the cavity, the top cover is formed of an elastomeric material, and a first slit is formed from the central opening to a perimeter edge of the pod. A second slit (e.g., whose length is bisected by the first slit) extends along a portion of the perimeter edge of the pod so that the first slit connects with the second slit. The flexible, elastomeric nature of the top cover as well as the presence of the slits allow the top cover adjacent the central opening and slits to easily spread open or fold out of the way (effectively increasing the size of the central opening) during insertion and removal of an oversized bonding pad from the cavity of the pod. IL Exemplary Elastomeric Orthodontic Bracket Packaging Systems Figure 1 shows a perspective view of an exemplary elastomeric packaging system 100. System 100 includes a frame 102 and at least one elastomeric pod 104 attached to frame 102. Frame 102 may have any suitable configuration of interconnecting elastomeric pods 104. The illustrated example includes a backbone 102a to which a plurality of arms 102b are attached. One end of each arm 102b is attached to backbone 102a, while the other end of each arm is attached to an elastomeric pod 104. Each pod 104 holds an orthodontic bracket 106. In an exemplary system including only a single pod the frame may simply include the corresponding arm (i.e., no backbone member).

Figures 2A and 2B show a close up and cross-sectional view, respectively, of one of the elastomeric pods 104, better illustrating how orthodontic bracket 106 is trapped therein. Figure 3 is a perspective view similar to Figure 2A, but with the orthodontic bracket 106 removed from the pod 104. Each elastomeric pod 104 includes a bottom surface 108 and a top cover 110. Top cover 110 includes a centrally disposed opening 112 through which the upper bracket body and tie wings of the bracket 106 can extend. The enlarged bonding pad 107 is formed by the lower bracket body portion of bracket 106 located below the central opening 112 and top cover 110. As perhaps best seen in Figures 2B and 3, the central opening 112 is sized smaller than the enlarged bonding pad 107 of bracket 106 so as to trap the bonding pad 107 (and thus the bracket 106) within the cavity of pod 104 defined between top cover 110 and bottom surface 108. For example, central opening 112 may have a width and length that is less than the corresponding width and length of the bonding pad of bracket 106.

Although central opening is illustrated as having a rectangular configuration, alternative shapes (e.g., circular, oval, or square) may be possible. A rectangular configuration is particularly preferred as the bracket bonding pad also has a substantially rectangular configuration. This allows the top cover 104 to overhang the bonding pad to a substantially constant degree around the perimeter of the bonding pad. In addition, the rectangular configuration of the central hole 112 snuggly fits against the outwardly extending bracket body, which has a rectangular cross-sectional configuration (see Figure 2A), and which is advantageously sized approximately the same as the opening 112. Such a snug fit minimizes the tendency for debris to enter through opening 112 and accumulate within the cavity of pod 104.

Each pod 104 further includes a plurality of slits that advantageously aid in insertion and removal of the bracket from the retained configuration shown in Figures 2 A and 2B, in which the bracket is trapped securely by top cover 110. A first slit 114 extends from central opening 112 outwardly to the perimeter edge of pod 104. Second slit 116 extends along a portion of the perimeter edge of pod 104 between bottom surface 108 and top cover 110. Slits 114 and 116 are placed so that first slit 114 connects with second slit 116. As illustrated, placement of slits may be such that the length of the second slit 116 is substantially bisected by the intersection with first slit 114. In other words, second slit may extend a substantially equal length away from the connection point with first slit 114 in both directions.

Second slit 116 preferably extends along about 10 percent to about 50 percent of the perimeter edge (i.e., circumference) of pod 104. More preferably second slit 116 extends along about 15 percent to about 35 percent of the perimeter edge, and most preferably second slit 116 extends along about 20 percent to about 30 percent of the perimeter edge (e.g., about 25 percent). Such a length has been found to be sufficient to allow top cover 110 to easily bend and fold out of the way during removal of bracket 106, while not being so long as to allow inadvertent opening of cover 104 so as to allow bracket 106 to fall out of pod 104 before when it is desired to manually remove it. These undesireable characteristics might occur if slit 116 were to extend around significantly more than about 50 percent of the perimeter edge (or circumference) of pod 104.

Pod 104 is illustrated as having a substantially circular configuration, which is preferred. As such, first slit 114 extends radially outward to intersect with second slit 116 running along the circumferential edge of pod 104. Of course, other pod shapes may alternatively be used (e.g., oval, square, or rectangular).

The presence of slits 114 and 116, as well as the fact that the top cover 110 is elastomeric, advantageously allow the practitioner to easily spread open or fold a portion of top cover 110 (i.e., that portion between slits 114 and 116) out of the way, effectively increasing the size of central opening 112 temporarily. In this folded configuration, the bracket 116 may be removed from the flexible, elastomeric pod 104. Because of the presence of slits 114 and 116, any required stretching of the top cover 110 is advantageously reduced during bracket insertion and removal. This is a distinct advantage over a configuration without the slits, in which the central opening must be widened solely by stretching the adjacent material. The inclusion of the slits reduces required stretching, and allows the central opening to be sized smaller than might otherwise be possible if stretching of the cover adjacent central opening 112 were relied on solely for bracket removal.

As shown in Figure 2B, bottom surface 108 may be convexly curved to match the curvature of the bonding pad of bracket 106. In the illustrated example, bottom surface 108 further includes a well 109 for receiving the tooth attachment surface of the bonding pad of orthodontic bracket 106. An orthodontic bonding adhesive 111 may be pre-applied to the tooth attachment surface of the bracket bonding pad and/or within well 109. As shown, the uncured adhesive 111 may be applied over only a portion of the underside tooth attachment surface of the bonding pad of bracket 106. Because of the corresponding curvature of the bonding pad and bottom surface 108 (i.e., the bottom surface of well 109), adhesive 111 will be spread over time as a result of the bracket's own weight, forming the adhesive 111 to provide a continuous, even layer of adhesive covering substantially the entirety of the tooth attachment surface of bracket 106. Such spreading may occur during shipment and storage of the system, prior to use. Where well 109 is sized to have dimensions equal to the dimensions of the bonding pad, adhesive will further be prevented from spreading out onto the other surfaces of the bonding pad. A snug fit between well 109 and the bonding pad of bracket 106 is advantageously provided. In other words, the dimensions and curvature of well 109 force adhesive 111 to cover substantially all of the tooth attachment surface of the bonding pad, but prevents the adhesive from migrating to the lateral side edges of the bonding pad and the top surface of the bonding pad. This advantageously provides an even layer of pre-applied adhesive to the bracket for ease in bonding by the practitioner, and prevents adhesive from migrating to unwanted locations of the bracket. A method of removal according to another aspect of the invention is illustrated in Figures 4-6. As seen in Figure 4, the practitioner may grip the bracket 106 to be removed with a pair of tweezers 118, fingers (not shown), or any other suitable tool. Optionally, with the other hand, the practitioner may fold open one side of top cover 110 adjacent slit 114 (Figure 5). Alternatively, the required bending or folding of top cover 110 may be accomplished by simple pulling on bracket 106. By pulling on bracket 106, the practitioner is able to remove the bracket 106 from the pod, as seen in Figure 6. As pulling force is applied to bracket 106, the portion of top cover 110 adjacent to slit 114 will automatically fold or bend out of the way, effectively widening central opening 112 temporarily so as to allow removal of bracket 106. The presence of second slit 116 reduces strain or stretching at the radial end of first slit 114 that might otherwise be present if second slit 116 were not present. Both slits aid in facilitating removal of bracket 106.

Top cover 110 is formed of an elastomeric material. Silicone and thermoplastic elastomers are examples of materials that can be injection molded to form the disclosed device. Preferably, the entirety of the frame 102 and pods 104 are injection molded from a single material and as a single integral piece. Exemplary suitable two-part silicone materials are available from Shin-Etsu Silicones of America, located in Akron, OH. One preferred material is KEG2000-50A/B, the physical properties of which are described in Table 1 below. Various other Shin-Etsu silicone products and silicone materials from other suppliers can alternatively be used. Table 1

Property Value

Hardness - Shore-A 52

Tensile Strength - MPa 1 1.1

Elongation - % 580

100% Modulus - MPa 1.72

Tear Strength - kN/m 40

Comp Set 22h/302°F - lh/302°F 31

Comp Set 22h/302°F - 4h/392°F 8

Linear Shrinkage 2.6

Specific Gravity 1.13

Viscosity - Part A-Pa.s 1700

Viscosity - Part B-Pa. s 1600

Preferred examples of thermoplastic elastomers include styrene-ethylene- butylene-styrene (SEBS) and VERSAflex, a proprietary thermoplastic elastomer alloy that exhibits elastic elongation and other properties similar to silicone. VERSAflex is sold by GLS Corporation, based in McHenry, IL. SEBS and VERSAflex are especially useful examples of thermoplastic elastomers exhibiting properties similar to silicone. An exemplary SEBS material, SEBS TPE 45A, is available from various providers. Physical properties for SEBS TPE 45A are summarized in Table 2 below. Various other SEBS products may also be used. Table 2

Property Value

Density (g/cm³) 0.94

Surface Hardness- Shore A 45

Tensile Strength (MPa) 6

Flexural Modulus (GPa) 0.02

Notched Izod (kJ/m) 1.06+

Linear Expansion (/⁰C x 10^"5) 16

Elongation at Break (%) 800

Water Absorption (%) 0.3

Oxygen Index (%) 19

Melting Temp. Range (⁰C) 200 - 240 Mold Shrinkage (%) 1.5 Mold Temp. Range (⁰C) 50 - 70

Several suitable VERSAFLEX TPE materials are available from GLS Corporation, located in McHenry, IL. Preferred VERSAFLEX materials include VERSAFLEX CL30 and VERSAFLEX CL40, properties of each of which are summarized in Table 3 below. Various other VERSAFLEX products from GLS Corporation can also be used.

Table 3

Examples of additional elastomeric silicone and silicone-like thermoplastic elastomers that may be used are listed in Table 4 below. It is noted that each of the elastomeric materials listed below have an elasticity (i.e., elastic elongation) of at least about 300 percent, more typically between about 450 percent and about 800 percent.

Table 4

Of course, the foregoing product listings are not meant to be exhaustive, and other silicone and thermoplastic elastomer materials can alternatively be used. Such thermoplastic elastomers will have elastic elongation values of at least about 50%, more preferably at least about 75%, more preferably at least about 100%, and most preferably at least about 300%. Such thermoplastic elastomers preferably will have a Shore A durometer hardness value between about 20 and about 90. Such elastic elongation values and durometer hardness values have been found to correlate to the desired flexibility, elasticity, and softness of the inventive device.

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 which come within the meaning and range of equivalency of the claims are to be embraced within their scope. What is claimed is:

Claims

L A system for packaging at least one orthodontic bracket in which each bracket has an upper bracket body extending bucally away from an enlarged bonding pad, the system comprising: a frame; and at least one bracket receiving elastomeric pod, each elastomeric pod being attached to the frame, wherein each elastomeric pod comprises: a bottom surface; a top cover including a central opening formed in the top cover for insertion of an enlarged bonding pad of an orthodontic bracket, the central opening being sized smaller than an enlarged bonding pad of an orthodontic bracket to be inserted so that the bonding pad of the bracket is trapped between the bottom surface and the top cover once the bonding pad is inserted through the central opening; a first slit extending from the central opening to a perimeter edge of the pod; and a second slit extending along a portion of the perimeter edge of the pod such that the first slit connects with the second slit, the first and second slits facilitating insertion and removal of an enlarged bonding pad of an orthodontic bracket from the central opening.

2. A system as recited in claim 1, wherein the second slit is substantially bisected by the first slit.

3. A system as recited in claim 1, wherein at least the top cover of each elastomeric pod comprises silicone.

4. A system as recited in claim 1, wherein at least the top cover of each elastomeric pod comprises a thermoplastic elastomer.

5. A system as recited in claim 4, wherein the thermoplastic elastomer has an elastic elongation of at least about 50%.

6. A system as recited in claim 4, wherein the thermoplastic elastomer has an elastic elongation of at least about 75%.

7. A system as recited in claim 4, wherein the thermoplastic elastomer has an elastic elongation of at least about 100%.

8. A system as recited in claim 4, wherein the thermoplastic elastomer has an elastic elongation of at least about 300%.

9. A system as recited in claim 4, wherein the thermoplastic elastomer has a shore A durometer hardness value in a range of about 20 to about 90.

10. A system as recited in claim 1, wherein each pod is substantially circular in shape.

11. A system as recited in claim 10, wherein the central opening of each top cover is substantially rectangular in shape.

12. A system as recited in claim 1, wherein the frame and the elastomeric pods are injection molded from silicone as a single integral piece.

13. A system as recited in claim 1, wherein the frame and the elastomeric pods are injection molded from a thermoplastic elastomer as a single integral piece.

14. A system as recited in claim 1, wherein the bottom surface of each pod is convexly curved, further comprising a well formed within the bottom surface for receiving an enlarged bonding pad of an orthodontic bracket, a bottom surface of the well being convexly curved to correspond to a curvature of the bonding pad.

15. A system as recited in claim 14, further comprising an uncured orthodontic adhesive disposed within the well such that the adhesive is pre-applied to a tooth attachment surface of the bonding pad.

16. A system as recited in claim 15, wherein the well is sized to receive the bonding pad and to prevent adhesive from migrating to surfaces of the bonding pad other than the tooth attachment surface.

17. A system for packaging at least one orthodontic bracket in which each bracket has an upper bracket body extending bucally away from an enlarged bonding pad, the system comprising: a frame; and at least one bracket receiving elastomeric pod, each elastomeric pod being attached to the frame, wherein each elastomeric pod comprises: a bottom surface; a top cover including a central opening formed in the top cover for insertion of an enlarged bonding pad of an orthodontic bracket, the central opening being sized smaller than an enlarged bonding pad of an orthodontic bracket to be inserted so that the bonding pad of the bracket is trapped between the bottom surface and the top cover once the bonding pad is inserted through the central opening; a first slit extending from the central opening to a perimeter edge of the pod; and a second slit extending along about 10 percent to about 50 percent of the perimeter edge of the pod such that the first slit connects with the second slit, the first and second slits facilitating insertion and removal of an enlarged bonding pad of an orthodontic bracket from the central opening.

18. A system as recited in claim 17, wherein the second slit is substantially bisected by the first slit.

19. A system as recited in claim 17, wherein the second slit extends along about 15 percent to about 35 percent of the perimeter edge of the pod.

20. A system as recited in claim 17, wherein the second slit extends along about 20 percent to about 30 percent of the perimeter edge of the pod.

21. A system as recited in claim 17, wherein each pod is substantially circular in shape.

22. A system as recited in claim 17, wherein the central opening of each top cover is substantially rectangular in shape.