US20170049607A1

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Info

Publication number: US20170049607A1
Application number: US15/342,475
Authority: US
Inventors: W. Keith Thornton; Alastair E. McAuley
Original assignee: Airway Technologies LLC
Current assignee: Airway Technologies LLC
Priority date: 2011-04-05
Filing date: 2016-11-03
Publication date: 2017-02-23
Also published as: US8662084B2; US20120255563A1

Abstract

An apparatus for improved breathing is provided. The apparatus may include an improved oral appliance, an improved mask, an improved coupler to couple an oral appliance to a mask, and/or a combination of these improvements.

Description

This application is a continuation-in-part of U.S. Ser. No. 14/009,821, filed Nov. 1, 2013, which is a U.S. National Stage Filing under 35 U.S.C. §371 of International Patent Application Serial No. PCT/US2012/032407, filed Apr. 5, 2012 and entitled “Apparatus for Improved Breathing,” which is a continuation of U.S. application Ser. No. 13/080,167, filed Apr. 5, 2011 and entitled “Universal Oral Appliance with a Universal Coupler,” U.S. application Ser. No. 13/080,050, filed Apr. 5, 2011 and entitled “Custom Dental Appliance and Method of Creating a Custom Dental Appliance,” and U.S. application Ser. No. 13/080,103, filed Apr. 5, 2011 and entitled “Apparatus for Prevention of Snoring and Improved Breathing.” This application claims priority to each of PCT/US2012/032407 and U.S. application Ser. Nos. 14/009,821, 13/080,167, 13/080,050, and 13/080,103.

TECHNICAL FIELD OF THE INVENTION

This invention relates generally to medical and dental devices; and more particularly to an apparatus for improving a user's breathing.

BACKGROUND

Many people experience difficulty in sleeping because of breathing problems. These problems may result in snoring, or the more serious condition of sleep apnea. One treatment for sleep breathing disorders involves the use of dental devices for extending forward the lower jaw of the patient. These devices operate to more fully open the breathing passageway, thereby allowing for easier breathing, whether that breathing be through the nose or through the mouth. Furthermore, many people suffer from degraded teeth or jaw pain arising from bruxing or the grinding of teeth during sleep. One treatment for grinding involves the use of dental devices that put pressure on a patient's front teeth to relax and unclench the patient's jaw.

These dental devices may be created in labs after a dentist sends in a patient's dental impressions. This procedure can cost the patient substantial time and money because the dentist creates a dental impression and then the lab creates the dental device after the dentist sends in the dental impression. Also, these lab-created dental devices are often designed to target particular problems. For example, a device for treating snoring may not help a patient who grinds his teeth.

People who suffer from sleep problems may seek help from a sleep laboratory. Doctors at the laboratory may perform tests on patients as they sleep. Doctors may further test the effectiveness of various dental devices on the patients as treatment options. During tests, doctors may need quick access inside a patient's mouth, and dental devices that hook or attach inside the patient's mouth may hinder the doctors' ability to gain quick access inside the mouth. This scenario may also occur during surgery when a patient is unconscious, and a dental device is inserted into the mouth to maintain the patient's airway.

Another treatment for sleep breathing disorders involves the use of masks to deliver air to users. These masks may also be used to deliver oxygen or other gases to a user. One difficulty with these masks is that they often move while the user is sleeping or they are uncomfortable to the user when worn.

SUMMARY OF THE INVENTION

In accordance with the teachings of the present invention, a dental device is provided which may reduce or eliminate disadvantages and problems associated with prior art devices.

In one embodiment, a dental device is provided comprising an arched frame and a moldable tray. The arched frame may be configured to be positioned proximate to the occlusal surface of a user's dental arch such that the arched frame extends beyond the cuspids of the user's dental arch. The arched frame may define a plurality of apertures and may comprise an adjustment mechanism. The moldable tray may be coupled to the arched frame and may engage the plurality of apertures. The moldable tray may comprise a channel configured to engage at least some of the teeth of the user's dental arch.

In a particular embodiment, a dental device is provided comprising an arched frame, a moldable tray, a second arched frame, and a second moldable tray. The arched frame may be configured to be positioned proximate to the occlusal surface of a user's maxillary arch such that the arched frame extends beyond the cuspids of the user's maxillary arch. The arched frame may define a plurality of apertures and may comprise an adjustment mechanism. The adjustment mechanism may comprise a hook and a threaded adjustor. The moldable tray may be coupled to the arched frame and may engage the plurality of apertures. The moldable tray may comprise a channel configured to engage at least some of the teeth of the user's maxillary arch. The second arched frame may be configured to be positioned proximate to the occlusal surface of a user's mandibular arch such that the second arched frame extends beyond the cuspids of the user's mandibular arch. The second arched frame may define a second plurality of apertures and may comprise a receiving mechanism coupled to the lingual portion of the lower arched body. The second moldable tray may be coupled to the second arched frame and may engage the plurality of apertures. The second moldable tray may comprise a second channel configured to engage at least some of the teeth of the user's mandibular arch. The hook may engage the receiving mechanism, and the threaded adjustor may adjust the forward position of the arched frame relative to the second arched frame.

In another embodiment, a dental device may include an arched frame configured to be positioned proximate to the occlusal surface of a user's dental arch such that the arched frame extends beyond the cuspids of the user's dental arch. The arched frame may define a plurality of apertures. The dental device may further include an adjustment mechanism coupled to the arched frame. The dental device may further include a moldable tray coupled to the arched frame. The moldable tray may engage the plurality of apertures and may comprise a channel configured to engage at least some of the teeth of the user's dental arch.

In another embodiment, a dental device may include an arched frame configured to be positioned proximate to the occlusal surface of a user's maxillary arch such that the arched frame extends beyond the cuspids of the user's maxillary arch. The arched frame may define a plurality of apertures. The dental device may further include an adjustment mechanism coupled to the arched frame. The adjustment mechanism may comprise a hook and a threaded adjustor. The dental device may further include a moldable tray coupled to the arched frame. The moldable tray may engage the plurality of apertures and may comprise a channel configured to engage at least some of the teeth of the user's maxillary arch. The dental device may further include a second arched frame configured to be positioned proximate to the occlusal surface of a user's mandibular arch such that the arched frame extends beyond the cuspids of the user's mandibular arch. The second arched frame may define a second plurality of apertures. The dental device may further include a receiving mechanism coupled to the lingual portion of the second arched frame and a second moldable tray coupled to the second arched frame. The second moldable tray may engage the second plurality of apertures and may comprise a second channel configured to engage at least some of the teeth of the user's mandibular arch. The hook may engage the receiving mechanism and the threaded adjustor may adjust the forward position of the arched frame relative to the second arched frame.

In another embodiment, a universal oral appliance is provided comprising an arched frame. The arched frame may be configured to be positioned proximate to the occlusal surface of a user's dental arch such that the arched frame extends beyond the cuspids of the user's dental arch when the universal oral appliance is inserted in the user's mouth. The arched frame may have a midline that aligns substantially with the anterior midline of the user's mouth when the universal oral appliance is inserted in the user's mouth. The arched frame may define a plurality of apertures and may comprise a universal coupler configured to removably engage a dental attachment. The universal coupler may comprise a substantially planar surface proximate to and extending across the midline of the arched frame. The universal coupler may be configured to be positioned proximate to the occlusal surface of a user's incisors when the universal oral appliance is inserted in the user's mouth. The universal coupler may further comprise a first rail coupled to a first end of the substantially planar surface and a second rail coupled to a second end of the substantially planar surface. The first rail, second rail, and substantially planar surface may define a slot.

In another embodiment, a kit for use in constructing a universal oral appliance is provided. The kit may comprise an arched frame and a plurality of dental attachments. The arched frame may be configured to be positioned proximate to the occlusal surface of a user's dental arch such that the arched frame extends beyond the cuspids of the user's dental arch when the universal oral appliance is inserted in the user's mouth. The arched frame may have a midline that aligns substantially with the anterior midline of the user's mouth when the universal oral appliance is inserted in the user's mouth. The arched frame may define a plurality of apertures and may comprise a universal coupler. The universal coupler may comprise a substantially planar surface proximate to and extending across the midline of the arched frame. The substantially planar surface may be configured to be positioned proximate to the occlusal surface of a user's incisors when the universal oral appliance is inserted in the user's mouth. The universal coupler may further comprise a first rail coupled to a first end of the substantially planar surface and a second rail coupled to a second end of the substantially planar surface. The first rail, second rail, and substantially planar surface may define a slot. The kit may further comprise a plurality of dental attachments comprising a rounded projection configured to be the point of contact between the user's upper and lower dental arches to prevent the user from clenching his jaw. The plurality of dental attachments may further comprise a hook configured to engage a receiving mechanism such that the forward position of a second arched frame may be adjusted relative to the position of the arched frame.

In another embodiment, a universal oral appliance is provided comprising an arched frame, a moldable tray, and a plurality of dental attachments. The arched frame may be configured to be positioned proximate to the occlusal surface of a user's dental arch such that the arched frame extends beyond the cuspids of the user's dental arch when the universal oral appliance is inserted in the user's mouth. The arched frame may have a midline that aligns substantially with the anterior midline of the user's mouth when the universal oral appliance is inserted in the user's mouth. The arched frame may define a plurality of apertures and may comprise a universal coupler. The universal coupler may comprise a substantially planar surface proximate to and extending across the midline of the arched frame. The substantially planar surface may be configured to be positioned proximate to the occlusal surface of a user's incisors when the universal oral appliance is inserted in the user's mouth. The universal coupler may further comprise a first rail coupled to a first end of the substantially planar surface and a second rail coupled to a second end of the substantially planar surface. The first rail, second rail, and substantially planar surface may define a slot. The moldable tray may be coupled to the arched frame and may comprise a channel configured to engage at least some of the teeth of the user's dental arch. The dental attachment may include a substantially rounded projection configured to be the point of contact between the user's upper and lower dental arches to prevent the user from clenching his jaw. The dental attachment may be an adjustable hook configured to engage the receiving mechanism such that the forward position of the arched frame is adjustable relative to the position of a second arched frame. The dental attachment may be a handle.

In another embodiment, a dental device is provided comprising an arch, a dental attachment with an anchoring element, a second arch with a second anchoring element, and a tension element. The arch may be configured to engage at least some of the teeth of a user's dental arch and may have a midline that aligns substantially with the anterior midline of the user's mouth when the arch is inserted in the user's mouth. The dental attachment may be configured to engage the arch along the midline of the arch. The dental attachment may comprise an anchoring element configured to be outside the user's mouth when the arch is inserted in the user's mouth. The second arch may be configured to engage at least some of the teeth of a user's second dental arch. The second arch may have a midline that aligns substantially with the anterior midline of the user's mouth when the second arch is inserted in the user's mouth. The second anchoring element may be coupled to the second arch along the midline of the second arch. The tension element may be configured to engage the second anchoring element. The tension element may be further configured to couple to the anchoring element outside the user's mouth when the arch is inserted in the user's mouth.

In another embodiment, a kit for constructing a dental device is provided. The kit may comprise an arch, a dental attachment with an anchoring element, a second arch with a second anchoring element, and a tension element. The arch may be configured to engage at least some of the teeth of a user's dental arch and may have a midline that aligns substantially with the anterior midline of the user's mouth when the arch is inserted in the user's mouth. The dental attachment may be configured to engage the arch along the midline of the arch. The dental attachment may comprise an anchoring element configured to be outside the user's mouth when the arch is inserted in the user's mouth. The second arch may be configured to engage at least some of the teeth of a user's second dental arch. The second arch may have a midline that aligns substantially with the anterior midline of the user's mouth when the second arch is inserted in the user's mouth. The second anchoring element may be coupled to the second arch along the midline of the second arch. The tension element may be configured to engage the second anchoring element. The tension element may be further configured to couple to the anchoring element outside the user's mouth when the second arch is inserted in the user's mouth.

In another embodiment, a dental device is provided comprising an arched frame, a moldable tray, a dental attachment with an anchoring element, a second arched frame with a second anchoring element, a second moldable tray, and a tension element. The arched frame may be configured to be positioned proximate to the occlusal surface of a user's maxillary arch such that the arched frame extends beyond the cuspids of the user's maxillary arch. The arched frame may define a plurality of apertures. The moldable tray may be coupled to the arched frame and may engage the plurality of apertures. The moldable tray may comprise a channel configured to engage at least some of the teeth of the user's maxillary arch. The dental attachment may be configured to removably engage the arch along the midline of the arch. The dental attachment may comprise an anchoring element configured to be outside the user's mouth when the arch is inserted in the user's mouth. The second arched frame may be configured to be positioned proximate to the occlusal surface of a user's mandibular arch such that the second arched frame extends beyond the cuspids of the user's mandibular arch. The second arched frame may define a second plurality of apertures. The second moldable tray may be coupled to the second arched frame and may engage the second plurality of apertures. The second moldable tray may comprise a channel configured to engage at least some of the teeth of the user's mandibular arch. The second anchoring element may be coupled to the second arch along the midline of the second arch. The tension element may be configured to removably engage the second anchoring element. The tension element may be configured to couple to the anchoring element outside the user's mouth when the second arch is inserted in the user's mouth. The dental attachment may comprise a post and a buckle coupled to a first end of the post. A second end of the post may engage the arch. The tension element may comprise a coupler and a strap coupled to the coupler. The coupler may engage the second anchoring element. A length of the strap may be configured to engage the buckle. The buckle may be configured to substantially secure the length of the strap engaging it. By increasing the length of the strap engaging the buckle, the forward position of the arched frame relative to the second arched frame may be adjusted.

In another embodiment, a coupler includes a support structure, at least one flange, and an elongated fastener. The support structure includes a first channel and a slot passing through the first channel and being substantially orthogonal to the first channel. The flange is partially within the first channel and the flange has a slot disposed through the flange. The elongated fastener is disposed within the slot of the support structure and passes through the slot of the flange to engage the flange, such that the flange is adjustably positioned within the first channel. The coupler is attached to an oral appliance having an occlusal surface and to a mask configured to deliver gas to a user, such that the orientation of the mask to the oral appliance is adjustable by rotating the flange about the fastener and adjustable in a direction substantially orthogonal to the occlusal surface of the oral appliance.

In another embodiment, an apparatus for use in forming a dental device includes a substantially rigid arched frame configured to be positioned proximate to the occlusal surface of a user's dental arch, such that the arched frame extends beyond the cuspids of the user's dental arch. The arched frame includes a first occlusal surface, a second occlusal surface, and a flange. The first occlusal surface is configured to be positioned proximate to the occlusal surface of the user's left molars. The second occlusal surface is configured to be positioned proximate to the occlusal surface of the user's right molars. The second occlusal surface is separated from the first occlusal surface. The flange connects the first and second occlusal surfaces, the flange extends in a direction substantially orthogonal to the first and second occlusal surfaces, and the flange is configured to be positioned labial to the user's dental arch. In another embodiment, a dental device includes a substantially rigid arched frame and a thermoplastic material. The substantially rigid arched frame is configured to be positioned proximate to the occlusal surface of a user's dental arch, such that the arched frame extends beyond the cuspids of the user's dental arch. The arched frame includes an occlusal surface configured to be positioned proximate to the occlusal surface of the user's dentition. The thermoplastic material encloses at least a portion of the arched frame, such that occlusal surface of the arched frame is substantially enclosed by the thermoplastic material.

In another embodiment, an improved breathing device includes a mask, an oral appliance, and a tension element. The mask includes an opening configured to be positioned in front of the user's mouth when the mask is positioned on the user's face. The mask further includes a coupling element proximate to the opening. The oral appliance includes a maxillary arch with an anchor point proximate to the midline of the maxillary arch. The tension element is configured to couple to the a dental device at the anchor point and to couple to the mask at the coupling element. In certain embodiments, the tension element may be adjusted to pull the mask towards the oral appliance. In a particular embodiment, the coupling element is a strap that extends across a portion of the opening and includes one or more apertures through which the tension element may extend, the tension element includes a hook and a threaded knob, and the anchor point includes a loop, such that the mask is pulled toward the oral appliance as the threaded knob is turned while hook is coupled to the loop and extends through an aperture in the strap.

In another embodiment, a dental device includes a first arch, a first coupler, a second arch, a second coupler, and a flexible tension element. The first arch engages at least some of the teeth of a user's dental arch. The first arch has a midline that aligns substantially with the anterior midline of the user's mouth when the first arch is inserted in the user's mouth. The first coupler couples to the first arch along the midline of the arch. The first coupler is inside the user's mouth when the first arch is inserted in the user's mouth. The second arch engages at least some of the teeth of the user's second dental arch. The second arch has a midline that aligns substantially with the anterior midline of the user's mouth when the second arch is inserted in the user's mouth. The second coupler couples to the second arch along the midline of the second arch. The second coupler extends anterior to the user's second dental arch when the second arch is inserted in the user's mouth. The flexible tension element removably engages the second coupler and the first coupler. The tension element maintains a forward position of the first arch relative to the second arch. In another embodiment, a dental device includes a first arch, a first coupler, a second arch, a second coupler, and a first tension element. The first arch engages at least some of the teeth of a user's dental arch and has a midline that aligns substantially with the anterior midline of the user's mouth when the first arch is inserted in the user's mouth. The first coupler couples to the first arch along the midline of the arch. The second arch engages at least some of the teeth of the user's second dental arch and has a midline that aligns substantially with the anterior midline of the user's mouth when the second arch is inserted in the user's mouth. The second coupler couples to the second arch. The first tension element removably engages the second coupler and the first coupler. The first tension element maintains a forward position of the first arch relative to the second arch.

Previous dental devices may be constructed in labs independent of a dentist's office. Labs could not construct custom dental devices for particular patients without first having the patients' dental impressions. Labs may also charge patients an extra fee for constructing the dental devices. In particular embodiments, the dental device may be constructed at the dentist's office without sending dental impressions to a lab, thus saving patients time and money. Furthermore, previous dental devices may be created to treat only one disorder (such as, for example, snoring or jaw-clenching). In particular embodiments, the dental device may be customized to treat multiple dental problems. As an example, and not by way of limitation, the dental device may comprise a universal coupler configured to engage various dental attachments. Each dental attachment may be designed to treat a different disorder. Additionally, previous dental devices may limit the lower jaw's range of motion when the dental devices were inserted in the user's mouth. Previous dental devices may also limit a third party's access to the user's mouth when the dental device is in the user's mouth. In particular embodiments, the dental device may comprise a tension element engaging an anchoring element outside the user's mouth. The tension element and anchoring element may pull the user's lower jaw forward without locking the user's lower jaw in place. Furthermore, a third party may pull on the tension element to open the user's airway, or a third party may release the tension element from the anchoring element to quickly gain access to a user's mouth. Certain embodiments may provide all, some, or none of these advantages. Certain embodiments may provide one or more other advantages, one or more of which may be apparent to those skilled in the art from the figures, descriptions, and claims included herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example arched frame.

FIG. 2A illustrates an example arched frame comprising an adjustment mechanism.

FIG. 2B illustrates an example arched frame comprising a receiving mechanism.

FIG. 2C illustrates an example arched frame comprising a receiving mechanism.

FIG. 3A illustrates an example arched frame comprising an adjustment mechanism, and an example moldable tray.

FIG. 3B illustrates an example arched frame comprising a receiving mechanism, and an example moldable tray.

FIG. 3C illustrates an example arched frame comprising an adjustment mechanism, and an example moldable tray.

FIG. 3D illustrates an example arched frame comprising a receiving mechanism, and an example moldable tray.

FIG. 4 illustrates an example dental device in a user's mouth.

FIG. 5A illustrates an example universal oral appliance comprising a universal coupler.

FIG. 5B illustrates an example universal oral appliance comprising a universal coupler.

FIG. 5C illustrates an example universal oral appliance comprising a universal coupler.

FIG. 5D illustrates an example universal oral appliance comprising a universal coupler comprising a guided channel.

FIG. 5E illustrates an example universal oral appliance comprising a universal coupler comprising a raised surface.

FIG. 6 illustrates an example universal oral appliance comprising a universal coupler, and an example plurality of dental attachments.

FIG. 7 illustrates an example dental device in a user's mouth.

FIGS. 8A through 8E illustrate an example arched frame.

FIGS. 9A through 9D illustrate an example moldable tray.

FIGS. 10A through 10C illustrate an example arched frame disposed within an example moldable tray.

FIGS. 10D through 10H illustrate an example dental device.

FIGS. 11A and 11B illustrate an example moldable tray and an example post.

FIG. 12 illustrates example moldable trays, an example post, and an example mask.

FIG. 13 illustrates example moldable trays, an example post, and an example mask.

FIG. 14A illustrates an example post.

FIG. 14B illustrates an example arched frame and tension element.

FIGS. 15A and 15B illustrate example flanges.

FIGS. 16A and 16B illustrate an example post.

FIGS. 17A through 17F illustrate example flanges engaged with an example post.

FIG. 18 illustrates an example post.

FIGS. 19A and 19B illustrate an example mask.

FIG. 20 illustrates an example mask, post, and oral appliance.

FIG. 21A illustrates an example mask and post.

FIG. 21B illustrates an example mask, post, and oral appliance.

FIG. 22A illustrates an example mask including a strap.

FIG. 22B illustrates an example tension element, oral appliance, and mask.

FIGS. 23A and 23B illustrate an example mask comprising a strap.

FIG. 24 illustrates an example tension element, oral appliance, and mask.

FIGS. 25A and 25B illustrate an example mask and adapter.

FIGS. 26A and 26B illustrate an example adapter.

FIG. 27 illustrates an example dental device comprising a universal coupler and an example dental attachment.

FIG. 28 illustrates an example dental device comprising a universal coupler and an example dental attachment.

FIG. 29 illustrates an example arch comprising a dental attachment.

FIG. 30 illustrates an example arch comprising a tension element.

FIG. 31 illustrates an example dental device comprising a dental attachment and a tension element.

FIG. 32 illustrates an example dental attachment and tension element.

FIG. 33 illustrates an example dental device in a user's mouth.

FIG. 34 illustrates an example process for creating a dental device.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an examplearched frame100.Arched frame100 may comprise anarched body105 that defines a plurality ofapertures110 througharched frame100. In particular embodiments,arched frame100 may be configured to be positioned proximate to the occlusal surface of a user's dental arch. In some embodiments,arched frame100 may extend beyond the cuspids of the user's dental arch whenarched frame100 is inserted in the user's mouth. In some embodiments,arched frame100 may have a consistent thickness between 1.5 and 2 millimeters.FIG. 2A illustrates an example arched frame comprising an adjustment mechanism. As shown inFIG. 2A, anarched frame100 is provided comprising anarched body105 defining a plurality ofapertures110 and anadjustment mechanism115. In particular embodiments,arched body105 may define a plurality of grooves, or a slot.Adjustment mechanism115 may be coupled toarched body105 along the midline ofarched frame100. In certain embodiments,Adjustment mechanism115 may comprise ahook120 and a threadedadjustor125.FIGS. 2B and 2C illustrate arched frames each comprising a receiving mechanism. As shown inFIGS. 2B and 2C, anarched frame100 is provided comprising anarched body105 defining a plurality ofapertures110 and areceiving mechanism130. In particular embodiments, receivingmechanism130 may be a bar spanning a portion of the arch ofarched body105. In other embodiments, receivingmechanism130 may be a surface coupled to the lingual portion ofarched frame100. In some embodiments, the surface may be rounded.

In particular embodiments,arched frame100 may be formed from any material suitable for dental uses, for example, a hard plastic.Arched frame100 may be formed from methyl methacrylate or a polycarbonate resin thermoplastic such as that sold under the Registered Trademark Lexan. Such materials are known to those familiar with dental devices, and other suitable materials may be used to formarched frame100 without departing from the intended scope of the present invention.

FIGS. 3A and 3C illustrate example arched frames each comprising an adjustment mechanism and example moldable trays. As shown inFIGS. 3A and 3C, anarched frame100 and amoldable tray135 are provided.Arched frame100 may comprise anarched body105 defining a plurality ofapertures110 and anadjustment mechanism115.Moldable tray135 may be coupled toarched frame100 and may engage the plurality ofapertures110. In particular embodiments,moldable tray135 may form through plurality ofapertures110 to couple to two sides ofarched body105. In some embodiments,moldable tray135 may form into a plurality of grooves defined byarched body105. In some embodiments,moldable tray135 may be secured toarched frame100 by forming through a slot defined byarched body105.Moldable tray135 may further comprise achannel140 that is configured to engage at least some of a user's dental arch. In particular embodiments,channel140 may engage the incisors and cuspids of the user's dental arch. In some embodiments,channel140 may engage the incisors, cuspids, and some of the molars of the user's dental arch. In some embodiments,channel140 may engage the incisors, cuspids, and all the molars of the user's dental arch. In particular embodiments,channel140 may be shaped to conform to a generic user's teeth. In other embodiments,channel140 may be a smooth channel that covers a user's teeth. In particular embodiments,channel140 may be further shaped to conform to a particular user's teeth.

In particular embodiments, moldable tray135 may comprise a polycaprolactone polymer or other aliphatic polyester. One or more of the polycaprolactone polymers may have the formula:

where R is an aliphatic hydrocarbon and n may range from approximately 300 to approximately 650. Certain embodiments may utilize polycaprolactone polymers using other suitable formulas. One particular embodiment may utilize Nylon.
Moldable tray135 may include any suitable polycaprolactone polymer or other aliphatic polyester, for example, and not by way of limitation, theTONE P 700, TONE P 767, or TONE P 787 polycaprolactone polymers manufactured by Union Carbide Corporation, taken singly or in any combination. A suitable light cured material, another polymer, or any other suitable material, such as a filler, coloring agent, stabilizer, antioxidant, or antimicrobial agent, may be used to replace or combine with one or more of the polycaprolactone polymers in forming a deformable material20 having any number of characteristics, properties, or uses.
The TONE polycaprolactone polymers are described in U.S. Pat. Nos. 5,112,225 and 4,784,123, and in literature distributed by Union Carbide Corporation, as homopolymers, block copolymers, graft copolymers, or other polymers that contain epsilon caprolactone. Polymerization may be initiated using one or more diols, for example, and not by way of limitation, ethylene glycol; diethylene glycol; neopentyl glycol; butane diol; hexane diol; or any other suitable diol.
In particular embodiments,moldable tray135 may be custom molded to a user's teeth. For example,moldable tray135 may comprise a material that is moldable when heated. Once heated, the material may be pressed around a user's dental arch to form amoldable tray135 that conforms to the user's teeth. In particular embodiments,moldable tray135 may be used witharched frame100 to form a custom dental device. For example,arched frame100 may comprise a hard plastic material. Whenmoldable tray135 is forming around a user's teeth,arched frame100 may be pressed againstmoldable tray135, so thatmold tray135 forms through plurality ofapertures110 defined byarched body105. Asmoldable tray135 cools and hardens,moldable tray135 may couple toarched frame100 through plurality ofapertures110. In some embodiments,moldable tray135 may couple toarched frame100 through a slot or by forming into a plurality of grooves. In particular embodiments,arched frame100 may provide structural support formoldable tray135 asmoldable tray135 engages the user's teeth. For example, asmoldable tray135 engages the user's teeth,arched frame100 may preventmoldable tray135 from deforming or shifting under the stresses caused by movement of the user's mouth.
In particular embodiments, a custom dental device may comprisearched frame100 andmoldable tray135. A dentist may be able to construct the custom dental device for a patient without having to send the patient's dental impressions to a lab. The dentist may heatmoldable tray135 and pressmoldable tray135 around the user's teeth. The dentist may then pressarched frame100 againstmoldable tray135 to construct the custom dental device. As a result, the patient may not have to wait for the lab to create the dental device, nor does the patient have to pay an extra fee charged by the lab.
FIGS. 3B and 3D illustrate example arched frames each comprising a receiving mechanism, and example moldable trays. As shown inFIGS. 3B and 3D, anarched frame100 and amoldable tray135 are provided.Arched frame100 may comprise anarched body105 defining a plurality ofapertures110 and areceiving mechanism130.Receiving mechanism130 may be coupled toarched body105. In particular embodiments, receivingmechanism130 may be a bar that spans a portion of the arch ofarched body105.Moldable tray135 may comprise achannel140 that is configured to engage at least some of the teeth of a user's dental arch.
FIG. 4 illustrates an example dental device in a user's mouth. As shown inFIG. 4, a dental device is provided that comprises anarched frame100, amoldable tray135, a secondarched frame200, and a secondmoldable tray235.Arched frame100 may comprise anadjustment mechanism115 that comprises ahook120 and a threadedadjustor125.Moldable tray135 may be coupled toarched frame100.Moldable tray100 may comprise achannel140. In some embodiments,channel140 may be shaped to conform to a generic user'smaxillary arch305. In other embodiments,channel140 may be a smooth channel that covers some of teeth of a user'smaxillary arch305. In particular embodiments,channel140 may be further shaped to conform to a particular user'smaxillary arch305. Secondarched frame200 may comprise a secondarched body205 defining a second plurality ofapertures210. Secondarched frame200 may further comprise areceiving mechanism130 coupled to the lingual portion of secondarched body205. In some embodiments, receivingmechanism130 may be a bar that spans a portion of the arch of secondarched body205. Secondmoldable tray235 may be coupled to secondarched frame200 and may engage second plurality ofapertures210. Secondmoldable tray235 may be configured to engage some of the teeth of the user'smandibular arch300. In particular embodiments,hook120 may engage receivingmechanism130. Threadedadjustor125 may be used to adjust the forward position ofarched frame100 relative to secondarched frame200. The relative positions of the twoarched frames100 and200 may adjust the position of the user'smaxillary arch305 relative to the user'smandibular arch300. In some embodiments, the relative position of the user's maxillary and mandibular arches may help to improve a user's breathing and/or prevent the user from snoring while sleeping.
FIGS. 5A and 5B each illustrate an example universal oral appliance comprising a universal coupler. As shown inFIGS. 5A and 5B, a universal oral appliance is provided comprising anarched frame100 and amoldable tray135 coupled toarched frame100.Arched frame100 may comprise anarched body105 defining a plurality ofapertures110. In particular embodiments,arched frame100 may be configured to be positioned proximate to the occlusal surface of a user's dental arch such thatarched frame100 extends beyond the cuspids of the user's dental arch whenarched frame100 is inserted in the user's mouth.Arched frame100 may have a midline that aligns substantially with the anterior midline of the user's mouth whenarched frame100 is inserted in the user's mouth.Arched frame100 may further comprise a universal coupler. In particular embodiments, the universal coupler may comprise a substantiallyplanar surface145, afirst rail146, and asecond rail147. Substantiallyplanar surface145 may be proximate to and extend across the midline ofarched frame100. In particular embodiments, substantiallyplanar surface145 may be configured to be positioned proximate to the occlusal surface of a user's incisors when the universal oral appliance is inserted in the user's mouth.First rail146 may be coupled to a first end of substantiallyplanar surface145. In particular embodiments,first rail146 may be distal to the midline ofarched frame100. In other embodiments,first rail146 may be anterior toarched frame100.Second rail147 may be coupled to a second end of substantiallyplanar surface145. In particular embodiments,second rail147 may be distal to the midline ofarched frame100. In other embodiments,second rail147 may be posterior toarched frame100.First rail146 andsecond rail147 may form an acute angle with substantiallyplanar surface145. In particular embodiments,first rail146,second rail147, and substantiallyplanar surface145 may define a slot. In particular embodiments, a dental attachment may slide into the slot and engagearched frame100. In some embodiments, the universal coupler may comprise a locking mechanism (such as, for example, a screw, a tab, or a groove). The screw may secure a dental attachment to the universal coupler by screwing through the dental attachment and into the universal coupler. The tab may secure the dental attachment by engaging the exterior of the dental attachment or by engaging a slot in the dental attachment. The groove may secure the dental attachment by frictionally engaging the dental attachment. In particular embodiments, the universal coupler may further comprise astop148 coupled to substantiallyplanar surface145. Stop148 may be coupled to the labial or lingual ends of substantiallyplanar surface145. Alternatively, stop148 may be coupled to a distal end of substantiallyplanar surface145. Although this disclosure describes a universal oral appliance comprisingarched frame100,moldable tray135, and a universal coupler coupled toarched frame100, this disclosure contemplates a one-piece universal oral appliance and a universal coupler coupled to the universal oral appliance.
FIG. 5C illustrates an example universal oral appliance comprising a universal coupler. As shown inFIG. 5C, a universal oral appliance is provided comprising anarched frame100 and amoldable tray135 coupled toarched frame100.Arched frame100 may comprise a universal coupler comprising a substantiallyplanar surface145, afirst rail146, asecond rail147, and astop148. In particular embodiments, eachrail146 and147 may comprise afirst segment149 and asecond segment150.First segment149 may be coupled at a first end to substantiallyplanar surface145, andsecond segment150 may be coupled to a second end offirst segment149. In particular embodiments,first segment149 andsecond segment150 may be substantially perpendicular to each other.
FIG. 5D illustrates an example universal oral appliance comprising a universal coupler comprising a guided channel. As shown inFIG. 5D, a universal oral appliance is provided comprising anarched frame100 and amoldable tray135.Arched frame100 may comprise a universal coupler comprising a substantiallyplanar surface145, afirst rail146, asecond rail147, and astop148.First rail146,second rail147, and substantiallyplanar surface145 may define a slot. In particular embodiments, the universal coupler may further comprise a guidedchannel151. Guidedchannel151 may be configured to guide a dental attachment through the slot.
FIG. 5E illustrates an example universal oral appliance comprising a universal coupler comprising a raisedsurface152. As shown inFIG. 5E, a universal oral appliance is provided comprising anarched frame100 and amoldable tray135.Arched frame100 may comprise a universal coupler comprising a substantiallyplanar surface145, afirst rail146, asecond rail147, and astop148.First rail146,second rail147, and substantiallyplanar surface145 may define a slot. In particular embodiments, the universal coupler may further comprise a raisedsurface152. Raisedsurface152 may be configured to guide a dental attachment through the slot. In particular embodiments, raisedsurface152 may be further configured to secure or lock the dental attachment.
FIG. 6 illustrates an example universal oral appliance comprising a universal coupler, and an example plurality ofdental attachments400. As shown inFIG. 6, an example universal oral appliance is provided that comprises anarched frame100 and amoldable tray135.Arched frame100 comprises anarched body105 that defines a plurality ofapertures110.Arched frame100 further comprises a universal coupler. The universal coupler may comprise a substantiallyplanar surface145, afirst rail146, asecond rail147, and astop148. In particular embodiments,first rail146,second rail147, and substantiallyplanar surface145 may define a slot.FIG. 6 also illustrates a plurality ofdental attachments400. In particular embodiments, the plurality ofdental attachments400 may comprise dental attachments configured to treat different disorders. For example, the plurality ofdental attachments400 may include ahook405, a substantially roundedprojection415, and anadjustable hook420. Other attachments may include a handle or any other appropriate attachment configured for use with an oral appliance. A user or a medical professional may choose which dental attachment to use without having to hire a lab to construct a new oral appliance. In some embodiments,dental attachments400 may be configured to engage the slot.
FIG. 7 illustrates an example dental device in a user's mouth. As shown inFIG. 7, a dental device is provided that comprises anarched frame100, amoldable tray135 coupled toarched frame100, a secondarched frame200, and a secondmoldable tray235 coupled toarched frame200.Arched frame100 may comprise a universal coupler. The universal coupler may comprise astop148.Moldable tray135 may comprise achannel140 that is configured to engage at least some of the teeth of the user'smaxillary arch305. Secondarched frame200 may comprise a secondarched body205 that defines a second plurality ofapertures210. Secondarched frame200 may further comprise areceiving mechanism130 that spans the lingual portion of secondarched frame200. In particular embodiments, receivingmechanism130 may be a bar. Secondmoldable tray235 may engage second plurality ofapertures210. The dental device further comprises a dental attachment that is configured to engage the universal coupler. In some embodiments, the dental attachment may be anadjustable hook420 that comprises ahook120 and a threadedadjustor125.Hook120 may engage receivingmechanism130. Threadedadjustor125 may be used to adjust the forward position of secondarched frame200 relative toarched frame100. This adjustment may adjust the forward position of the user'smandibular arch300 relative to the position of the user'smaxillary arch305. In some embodiments, this adjustment may help to prevent the user from snoring while sleeping.
FIG. 8A illustrates an examplearched frame700.Arched frame700 may include anocclusal surface702 and aflange706. In particular embodiments archedframe700 may be configured to be positioned proximate to a user's dental arch, withocclusal surface702 positioned proximate to the occlusal surface of the user's dental arch. In certain embodiments,occlusal surface702 may be contiguous throughout the length ofarched frame700. In alternative embodiments, as shown inFIG. 8A,occlusal surface702 may not be contiguous throughout the length ofarched frame700. For example,occlusal surface702 may have a first portion configured to be positioned proximate to the user's left bicuspid and first molar; and have a second portion configured to be positioned proximate to the user's right bicuspid and first molar. As shown inFIG. 8A, in certain embodiments,occlusal surface702 may not extend to the area proximate to the user's incisors. Certain embodiments in which theocclusal surface702 is not contiguous throughout the length ofarched frame700 may allow for improved flexibility ofarched frame700. In certain embodiments,arched frame700 may be capable of flexing inward and/or outward, allowingarched frame700 to conform to a wider variety of dental arch shapes and sizes. Such embodiments may also improve the ability ofarched frame700 to accommodate the overlap of the user's maxillary and mandibular incisors, allowing the user's jaw to close more fully. In certain embodiments,occlusal surface702 may have a thickness of approximately 1.5 millimeters, although other thicknesses may be used.
Flange706 may run along the labial edge ofarched frame700. In certain embodiments,flange706 may be contiguous throughout the length ofarched frame700. In alternative embodiments, as shown inFIG. 8A,flange706 may not be contiguous throughout the length of the arched frame. For example,flange706 may include adistal flange portion708 and amesial flange portion710, separated by aflange recess712. In certain embodiments, becauseflange706 is positioned proximate to the labial surface of the user's dental arch, it may be pushed outward by the labial surface of the user's dental arch whenarched frame700 is inserted into the user's mouth during the molding process, allowingarched frame700 to automatically flex and align with the user's dental arch, which may improve the ability ofarched frame700 to accommodate different dental arch sizes and shapes. In certain embodiments, flange recesses712 may allow for improved flexibility ofarched frame700. In addition, whenarched frame700 is used with deformable material, flange recesses712 may allow the deformable material to form an improved mold of the user's teeth. In some embodiments,flange recess712 may improve the user's ability to press moldable material against their teeth during the molding process, which allow for improved dental molds. In certain embodiments,mesial flange portion710 may allow for an improved mold whenarched frame700 is pressed toward the user's teeth during fitting. As shown inFIG. 8A, in certain embodimentsmesial flange portion710 may have a thickness greater than that ofdistal flange portion708. For example,mesial flange portion710 may have a thickness of approximately 3 millimeters anddistal flange portion708 may have a thickness of approximately 1.5 millimeters, although other thicknesses may be used. In such embodiments, the greater thickness ofmesial flange portion710 may improve the stability ofarched frame700 during flexion and may provide a more secure anchor point for other attached structures, such asanterior structure716 shown inFIG. 8B.
FIG. 8B illustrates another examplearched frame700 havingocclusal surface702,flange706, and ananterior structure716. As shown inFIG. 8B, in certain embodimentsocclusal surface702 may include anocclusal surface recess704. Whenarched frame700 is used with deformable material,occlusal surface recess704 may allow the deformable material to form a closer mold of the user's teeth. As shown inFIG. 8B, certain embodiments may includeanterior structure716 which extends forward frommesial flange portion710 in an anterior direction. In certain embodiments,anterior structure716 may be fixed toarched frame700, while in other embodimentsanterior structure716 may removeably coupled toarched frame700.FIGS. 8C and 8D illustrate side views of examplearched frames700 havingocclusal surface702 andflange706 withdistal flange portion708,flange recess712, andanterior structure710.
FIG. 8E illustrates an isometric view of an examplearched frame700. As shown inFIG. 8E,arched frame700 may includeanterior structure710,occlusal surface702 that is not contiguous throughout the length ofarched frame700, andflange706 that includes adistal flange portion708, aflange recess712, amesial flange portion710, and amesial flange recess714. As shown inFIG. 8E,flange706 may includemesial flange recess714 located approximately at the midline of the arched frame. In such embodiments,mesial flange recess714 may allow for improved conformity with the shape of the user's mouth. In certain embodiments, the distal ends ofarched frame700 may extend approximately to the user's first molar when the frame is inserted into the user's mouth. In alternative embodiments,arched frame700 may extend to the user's second molar or to the user's third molar.
FIGS. 9A through 9D illustrate examplemoldable trays730. As shown inFIG. 9A,moldable tray730 may include anocclusal surface732, anouter rim734, aninner rim736, and recesses738.Occlusal surface732 may be configured to be placed proximate to the occlusal surface of a user's dental arch.Outer rim734 may be configured to be positioned proximate to the labial surface of a user's dental arch. In certain embodiments,inner rim736 may be configured to be positioned proximate to the lingual surface of a user's dental arch. In certain embodiments,inner rim736 may lie mostly flat relative to the plane ofocclusal surface732 or may angle upward slightly. Such embodiments may makemoldable tray730 easier to slide into the user's mouth. In certain embodiments,inner rim736 may be capable of being pushed upward or downward to engage with the lingual surface of the user's dental arch during the molding process.
As shown inFIG. 9A, in certain embodimentsouter rim734 may have a thickness greater than that ofinner rim736. For example, in certain embodiments,outer rim734 may have a thickness of approximately 3 millimeters, whileinner rim736 may have a thickness of approximately 2 millimeters, although these dimensions are not required. Reduced thickness ofinner rim736 may allowmoldable tray730 to take up less space in the inner mouth area behind the teeth, which may allow the user to breath, swallow, and speak more easily and experience greater comfort. Reduced thickness ofinner rim736 may also help obviate any need to offer multiple sizes ofmoldable tray730 andarched frame700. In certain embodiments, reduced thickness ofinner rim736 may allow other medical and/or dental devices to be more easily inserted into the user's mouth. In certain embodiments, as shown inFIG. 9D,inner rim736 may be shorter thanouter rim734. A shorterinner rim736 may allow for easier insertion ofmoldable tray730 into the user's mouth. A shorterinner rim736 may also reduce the amount of moldable material in the inner mouth area, which may provide additional advantages as described above. In certain embodiments, distal portions ofmoldable tray730 may have a reduced height, which may improve the fit ofmoldable tray730 in the user's mouth.
As shown inFIG. 9A, in certain embodimentsocclusal surface732 may have one ormore recesses738, which may result from clamping or otherwise holding in placearched frame700 during an overmolding process. In certain embodiments,arched frame700 illustrated inFIGS. 8A through 8E may have a corresponding recess, which may allow for improved clamping and alignment during the manufacturing process.
FIG. 9B shows another examplemoldable tray730 havingocclusal surface732,outer rim734, andinner rim736. As shown inFIG. 9B, in certain embodimentsmoldable tray730 may further include ananterior structure740. It should be appreciated that in certain embodiments the optionalanterior structure740 may be fixed tomoldable tray730 or it may be removeably coupled tomoldable tray730.
In certain embodiments,moldable tray730 may be composed of a material that can be heated to a temperature at which the material softens and becomes capable of being molded to a different shape. In certain embodiments, the material can be heated in hot water. In some embodiments, the temperature range at which the material softens may be approximately 40-80 degrees Celsius, although materials with other softening ranges may be used. In a particular embodiment, the target softening temperature may be approximately 60 degrees Celsius. In certain embodiments, this material may be a thermoplastic. Such thermoplastic materials may be heated to a temperature at which the thermoplastic becomes soft and moldable, at which point it may be molded to the shape of at least a portion of a user's dental arch and become at least temporarily fixed in that shape. As one example,moldable tray730 may comprise a polycaprolactone polymer or other aliphatic polyester, as discussed above in reference tomoldable tray135. In particular embodiments, the thermoplastic material may comprise a cross-linked polycaprolactone reinforced with an aramid fiber such as the short length aramid fiber sold by Dupont under the brand name Kevlar®. In certain embodiments, using polycaprolacton combined with Kevlar® may allowmoldable tray730 to soften at low temperatures and set hard at temperatures of approximately 60 degrees Celsius. In certain embodiments, using polycaprolacton combined with Kevlar® may improve the hardness ofmoldable tray730 following the molding process, which may improve the ability ofmoldable tray730 to hold its shape when being used to adjust the user's jaw position and/or hold a mask or other breathing device in place. In certain embodiments, this increased hardness may also improve the ability ofmoldable tray730 to hold its shape for longer periods of time. For example, in certain embodiments, this may allowmoldable tray730 to substantially hold its shape for periods longer than approximately 1 month, though such period is not required. Using polycaprolacton combined with Kevlar® may also allow for thinner embodiments ofmoldable tray730, which may allowmoldable tray730 to take up less space in the user's mouth. Examples of polycaprolactone combined with an aramid fiber, including Kevlar® and a variety of other fibers, are described in U.S. application Ser. No. 11/368,991, publication number U.S. 2007/0004993 A1, which is incorporated herein by reference. Such embodiments may provide an improved moldable material that better maintains its form when heated, providing increased viscosity which may prevent the material from flowing excessively around the user's teeth and/or getting stuck on the user's teeth during the molding process. Such embodiments may also possess increased strength after molding. In certain embodiments, the thermoplastic material may be cross-linked by radiation, which may create cross-linking of certain molecules to improve the material's shape retention characteristics and/or make the material better able to return to its original shape after reheating. In certain embodiments, radiation may be applied aftermoldable tray730 has been overmolded witharched frame700, but before being molded to the user, though this is not required. Cross-linking by radiation is further described in U.S. Pat. No. 5,415,623, which is incorporated herein by reference. In certain embodiments, the material may exhibit slight shrinkage after being molded to the user's dental arch. In particular embodiments, such shrinkage may be less than 1%. Slight shrinkage of the material following the molding process may allow for improved fit with the user's dental arch. In some embodiments, slight shrinkage of the material following the molding process may allowmoldable tray730 to have a “snap” fit with the user's dental arch.
In some embodiments,arched frame700 may be primarily composed of a substantially rigid material, such as Nylon or any other material providing substantial rigidity while allowing moderate flexion. In certain embodiments,arched frame700 may be composed of a material whose form does not substantially changed when heated to the temperature required to soften the moldable material ofmoldable tray730. For example, in some embodiments,arched frame700 may be composed of a material that substantially maintains its shape when heated up to at least 100 degrees Celsius. Such materials may include polycarbonate, Nylon, acrylonitrile butadiene styrene (ABS), or polyethylene. In certain embodiments,arched frame700 may be composed of a semi-flexible material, for example liquid silicone rubber (LSR), approximately having a Shore 30-90 hardness, although this particular hardness is not required.
FIGS. 10A through 10C illustrate an examplemoldable tray730 substantially surrounding an examplearched frame700. As shown inFIG. 10A, examplemoldable tray730 may includeocclusal surface732,outer rim734, andinner rim736; andarched frame700 may includeocclusal surface702 andflange706. As shown inFIG. 10A, in certain embodiments the labial edge ofouter rim734 may extend outward beyond the labial edge offlange706. The lingual edge ofinner rim736 may also extend inward beyond the labial edge ofocclusal surface702. As seen inFIG. 10B, in certain embodiments the distal end ofmoldable tray730 may extend distally beyond the distal end ofarched frame700. In certain embodiments, the distal end ofarched frame700 may extend approximately to the user's first molar, while the distal end ofmoldable tray730 extends approximately to the user's second or third molar. In alternative embodiments, the distal end ofarched frame700 may extend approximately to the user's second molar, while the distal end ofmoldable tray730 extends approximately to the user's third molar. In still other embodiments, the distal ends ofarched frame700 andmoldable tray730 may be approximately coextensive.
In certain embodiments, whenmoldable tray730 is oriented for placement on, for example, a user's maxillary arch, the superior surface ofouter rim734 may extend beyond the superior surface offlange706 by approximately 2.5 millimeters while the inferior surface ofmoldable tray730 may extend below the inferior surface ofarched frame700 by approximately 1.5 millimeters, although these dimensions are not required. In certain embodiments,moldable tray730 may extend outward beyond the labial edge ofarched frame700 by approximately 1.5 millimeters, though other dimensions are possible. In certain embodiments,moldable tray730 may extend inward beyond the lingual edge ofarched frame700 by approximately 1.5 millimeters, though other dimensions are possible.
In certain embodiments,flange706 may help maintain the shape ofouter rim734. Moldable trays that substantially surround an arched frame may allow for reduced bulk between a user's incisors when the tray(s) are inserted into the user's mouth. By providing moldable trays with less material between the user's incisors, certain embodiments may allow users to close their mouths further with the trays inserted, which may improve comfort and/or effectiveness. Furthermore, moldable trays that substantially surround arched frame may allow for mouth pieces where only the moldable material touches the inner surfaces of the user's mouth, such as the user's gums, lips, and tongue. Such moldable trays may also allow for improved molding to the user's front teeth. Havingarched frame700 substantially surrounded bymoldable tray730 may also reduce the chances of damage toarched frame700 and may help hold any broken pieces ofarched frame700 in place, preventing any such broken pieces from contacting the user's mouth or entering the user's airway.
In certain embodiments,arched frame700 may include apertures inocclusal surface702 and/orflange706, though such apertures are not required. Such apertures may allow the moldable material to flow througharched frame700 during the molding process, which may provide greater stiffness following the molding process and may allow for improved alignment ofarched frame700 withmoldable tray730.
FIGS. 10D through 10G illustrate an example dental device. The dental device includes afirst arch750, asecond arch755, afirst coupler760, asecond coupler770, and aflexible tension element780. When inserted and/or positioned within a user's mouth, the dental device maintains a forward position of the user's lower dental arch relative to the user's upper dental arch. As a result, the user's breathing may be improved while sleeping.
First arch750 includesarched frame700 andmoldable tray730.First arch750 may be configured to engage at least some of the teeth of a user's dental arch, such as for example, the user's lower dental arch. The midline offirst arch750 may align substantially with the anterior midline of the user's mouth whenfirst arch750 is inserted and/or positioned in the user's mouth. In some embodiments,moldable tray730 is coupled toarched frame700 and is configured to receive the user's teeth. Likewise,second arch755 includesarched frame700 andmoldable tray730.
Second arch755 may be configured to engage at least some of the teeth of a user's dental arch, such as for example, the user's upper dental arch. The midline ofsecond arch755 may align substantially with the anterior midline of the user's mouth whensecond arch755 is inserted and/or positioned in the user's mouth. In some embodiments,moldable tray730 is coupled toarched frame700 and is configured to receive the user's teeth.
First coupler760 is coupled tofirst arch750. In some embodiments,first coupler760 is coupled tofirst arch750 along the midline offirst arch750.First coupler760 is positioned such that a portion offirst coupler760 is inside a user's mouth whenfirst arch750 is inserted and/or positioned within the user's mouth.First coupler760 may engagetension element780 such thattension element780 exerts a tensile force oncoupler760. The tensile force may pullfirst arch750 forward relative tosecond arch755. As a result, a user's jaw may be pulled forward to improve snoring and/or sleep apnea during sleep. In the embodiments shown,first coupler760 includes apost765 and acap785.Cap785 removably engagespost765. In some embodiments,cap785 is coupled tofirst coupler760,first arch750, and/or post765 by a tether such thatcap785 does not uncouple fromfirst arch750 whencap785 is disengaged frompost765. In this manner, it is more difficult for a user to lose and/or misplacecap785. In alternative embodiments,first coupler760 is coupled tosecond arch755 and is configured to be within the user's mouth whensecond arch755 is positioned within the user's mouth along the user's upper dental arch.Tension element780 engagesfirst coupler760 to anchor tosecond arch755.
Second coupler770 is coupled tosecond arch755. In some embodiments,second coupler770 is coupled tosecond arch755 along the midline ofsecond arch755.Second coupler770 is positioned such that a portion ofsecond coupler770 extends anterior to a user's dental arch whensecond arch755 is inserted and/or positioned in the user's mouth.Second coupler770 engages withtension element780 such thattension element780 anchors tosecond coupler770.Tension element780 then exerts a tensile force that pullsfirst arch750 forward relative tosecond arch755. As a result, a user's jaw may be pulled forward to improve snoring and/or sleep apnea during sleep. In some embodiments, a portion ofsecond coupler770 extends outside the user's mouth whensecond arch755 is inserted and/or positioned in the user's mouth.Second coupler770 includes aflange773, apost775, and acap790.Flange773 extends anterior to the user's dental arch whensecond arch755 is inserted and/or positioned in the user's mouth. In some embodiments, a portion offlange773 extends outside of the user's mouth whensecond arch775 is inserted and/or positioned in the user's mouth.Cap790 removably engagespost775. In some embodiments,cap790 is coupled tosecond coupler770,second arch755, and/or post775 by a tether such thatcap790 does not uncouple fromsecond arch755 whencap790 is disengaged frompost775. In this manner, it is more difficult for a user to lose and/or misplacecap790. In alternative embodiments,second coupler770 is coupled tofirst arch750 and is configured to extend anterior to the user's lower dental arch whenfirst arch750 is positioned in the user's mouth.Tension element780 engagessecond coupler770 to exert a tensile force that pullfirst arch750 forward relative tosecond arch755.
Flexible tension element780 engagesfirst coupler760 andsecond coupler770 to exert a tensile force onfirst arch750 andsecond arch755. In the embodiments shown,flexible tension element780 removably engagesfirst coupler760 andsecond coupler770 viapost765 and post775 respectively to couplefirst arch750 tosecond arch755.Flexible tension element780 may also be referred to as a strap.Flexible tension element780 may include elastic or substantially elastic plastic, rubber, silicone, or any other material used to formarched frames700.Flexible tension element780 defines one or more apertures (e.g. a first aperture and a second aperture) through whichflexible tension element780 engages withfirst coupler760 and/orsecond coupler770 viapost765 andpost775. Whenflexible tension element780 is engaged withpost765 and post775, caps785 and790 may be placed ontoposts765 and775 to engageposts765 and775. In this manner, caps785 and790 preventflexible tension element780 from disengaging fromposts765 and775. As a result,flexible tension element780 couplesfirst arch750 tosecond arch755 and exert a tensile force that pullsfirst arch750 forward relative tosecond arch755. In this manner,flexible tension element780 maintains a forward position offirst arch750 relative tosecond arch755.
In some embodiments,flexible tension element780 allows for lateral movement offirst arch750 relative tosecond arch755 whenflexible tension element780 is engaged with bothfirst arch750 andsecond arch755. In this manner, when the dental device is inserted and/or positioned in the user's mouth, the dental device may still allow for the user's jaw to move laterally.
In some embodiments, the length (and/or flexibility or elasticity) oftension element780 determines the magnitude of the tensile force exerted onfirst arch750 andsecond arch755. For example, along tension element780 may exert less tensile force than ashort tension element780. This disclosure contemplates the example dental device and/or the components of the example dental device including more than one tension element780 (e.g., as a kit). Eachtension element780 may have a different length so the user can adjust the magnitude of the tensile force by selecting atension element780 of a different length. In some embodiments, the more than onetension element780 being made using different materials to adjust the elasticity and/or flexibility of each tension element. For example, atension element780 may be made of plastic while anothertension element780 is made of rubber. The twotension elements780 may exert different tensile forces because different materials are used to form them. In this manner, the user can adjust the magnitude of the tensile force by selecting atension element780 of a different material. This disclosure contemplates the example dental device or the components of the example dental device being included in a kit that includesmultiple tension elements780. The lengths of thetension elements780 may be different. The materials used to form thetension elements780 may be different. This disclosure contemplatestension element780 being formed from any material (e.g., a semi-rigid material such as nylon).
FIG. 10E illustrates the example dental device ofFIG. 10D withfirst arch750 coupled tosecond arch755. As illustrated inFIG. 10E,flexible tension element780 may couplefirst arch750 tosecond arch755 by engagingposts765 and775 (not shown).Caps785 and790 also engageposts765 and775 to preventflexible tension element780 from disengaging fromposts765 and755.Post765 offirst arch750 engagesflexible tension element780 through an aperture from a bottom surface offlexible tension element780 through a top surface offlexible tension element780.Post775 ofsecond arch755 engagesflexible tension element780 through an aperture from the top surface offlexible tension element780 through the bottom surface offlexible tension element780.
FIG. 10F illustrates the example dental device ofFIG. 10D inserted and/or positioned within a user's mouth. As illustrated inFIG. 10F,first arch750 is positioned on the user's lower dental arch andsecond arch755 is positioned on the user's upper dental arch. First arch750 couples tosecond arch755 viaflexible tension element780. As shown,flange773 extends anterior tosecond arch755 and out of the user's mouth.Flexible tension element780 engagesfirst arch750 andsecond arch755 and caps785 and790 preventflexible tension element780 from disengaging. In certain embodiments,cap785 and the point at whichflexible tension element780 engagesfirst arch750 is located within the user's mouth.Flexible tension element780 exerts a tensile force that pulls thefirst arch750 forward relative tosecond arch755. As a result, the user's jaw is pulled forward which may improve breathing when the user is sleeping.
FIG. 10G illustrates an alternative embodiment of the example dental device ofFIG. 10D. As illustrated inFIG. 10G,upper arch755 includes more than one coupler/flange773. The couplers may be spaced symmetrically about the midline ofsecond arch755. This disclosure contemplates arranging multiple couplers on any portion ofsecond arch755 according to a user's needs. Each coupler couples to the coupler offirst arch750 via aflexible tension element780. For example, a firstflexible tension element780 couples a first coupler ofsecond arch755 to the coupler offirst arch750. A secondflexible tension element780 couples the second coupler ofsecond arch755 to the coupler offirst arch750. Eachflexible tension element780 is prevented from disengaging the couplers bycaps790 andcap785. Eachflexible tension element780 exerts a tensile force that pulls thelower arch750. The position of each coupler ofsecond arch755 may be adjusted to adjust the direction of the resultant tensile force applied. This disclosure contemplatessecond arch755 andfirst arch750 each including any number of couplers. This disclosure further contemplates coupler/flange773 being coupled tolower arch750 rather thanupper arch755 and the illustrated coupler offirst arch750 being instead coupled tosecond arch755.
FIG. 10H illustrates the components of the alternative embodiment of the example dental device ofFIG. 10G. As illustrated inFIG. 10H, the dental device is similar to the example dental device ofFIG. 10D, except the embodiment ofFIG. 10H includes anadditional flange773 andcorresponding post775 onsecond arch755, anadditional cap795, andstrap780 is configured to engage anadditional flange773 and post775 ofsecond arch755. This disclosure contemplates the dental device including any number of caps andflanges773 on any offirst arch750 and/orsecond arch755. This disclosure also contemplatesflanges773 being positioned on any portion offirst arch750 and/orsecond arch755. For example,flanges773 may be placed symmetrically about a midline ofsecond arch755. However, the positions offlanges773 may be adjusted and/or changed to adjust the direction of the tensile force exerted bystrap780 when engaged withfirst arch750 andsecond arch755. This disclosure also contemplatesstrap780 including defining any number of holes. A user of the dental device an select which holes to use to engage first andsecond arches750 and755 to adjust the amount of tensile force applied bystrap780. As a result, the relative forward positions of the arches can be adjusted by selecting different holes.
This disclosure contemplatesstrap780 comprising two or more separate straps/tension elements780. The separate straps/tension elements780 may overlap apertures to engage the same post/flanges773. This disclosure also contemplatesstrap780 comprising two or more straps/tension elements780 coupled together in one piece, like the example illustrated inFIG. 10H. Althoughstrap780 is one piece, it can be contemplated as afirst tension element780 coupled to asecond tension element780.
Although this disclosure describescaps785,790, and795 being separate and distinct from other components of the example dental devices, this disclosure contemplates one or more ofcaps785,790, and795 being formed internally withtension element780. Furthermore, this disclosure contemplates embodiments that do not include one or more ofcaps785,790, and795.
FIG. 11A illustrates another examplemoldable tray730 havingocclusal surface732,outer rim734,inner rim736, andnotches742. In this embodiment,moldable tray730 is attached to apost802 havingslot804,channels806, andtension element channel834.FIG. 11B also illustrates a lower isometric view of the same embodiment showingouter rim734,notch742, and alower surface744. As shown inFIG. 11A, in certain embodimentsmoldable tray730 may be custom molded to fit a particular user's dental arch. In particular embodimentsmoldable tray730 may include one ormore notches742 which may facilitate grasping the moldable tray for improved insertion into and removal from the user's mouth. As shown inFIG. 11B, in certain embodimentslower surface744 of themoldable tray730 may also be molded to fit the user's second dental arch. In certain embodiments, moldinglower surface744 to the user's mandibular dental arch may be performed with the user's mandibular dental arch placed in a particular position relative to the user's maxillary dental arch. For example, the user's mandibular dental arch may be extended in the anterior direction, which may help open a user's airway allowing for improved breathing. Moldinglower surface744 to the user's mandibular dental arch may also help hold the user's jaw in a desired position, such as, for example, when upward force is applied to the user's mandible by a chin strap or other device.
In certain embodiments, a second moldable tray configured to engage with the user's second dental arch may be fused withmoldable tray730, locating the user's mandibular arch in a particular position relative to the user's maxillary arch. In such embodiments, the second moldable tray may be fused tomoldable tray730 prior to forming a mold of the user's dentition. In alternative embodiments, the second moldable tray may form a separate piece prior to being molded to the user's dentition. In such embodiments, the second moldable tray andmoldable tray730 may be heated and fused together during the molding process.
Alternative embodiments may utilize a custom-made tray rather than a moldable tray. In some embodiments, a custom-made tray may be pre-fitted and then molded from a substantially rigid material, such as, for example, acrylic. Certain embodiments may have two separate custom-made trays coupled together via an adjustment mechanism, such as, for example, those described in U.S. Pat. No. 7,748,386, which is incorporated herein by reference. In certain embodiments, such an adjustment mechanism may have wedges in the side that interact to move the user's lower jaw forward.
FIG. 12 illustrates twomoldable trays730, amask850, and acoupler800.FIG. 13 illustrates a side view of the components shown inFIG. 12. As shown,moldable trays730 includeocclusal surface732,outer rim734, andinner rim736.Mask850 is a device for directing the flow of air and/or other gases to a user.Coupler800 adjustably couples mask850 to at least onemoldable tray730. In the embodiment shown, twomoldable trays730 cooperate to form an adjustable oral appliance configured to adjustably position the lower arch of a user relative to the user's upper arch. As shown, uppermoldable tray730, includespost802 that extends anterior to the user's mouth when uppermoldable tray730 is positioned proximate to the user's maxillary dentition. Similarly, lowermoldable tray730 includestension element830 that extends anterior to the user's mouth when lowermoldable tray730 is positioned proximate to the user's mandibular dentition. In this embodiment, post802 includes atension element channel834 to receivetension element830. In certain embodiments,tension element830 may be threaded and may be coupled toadjustment knob832, which may be turned to adjust the position of lowermoldable tray730 relative to uppermoldable tray730. Althoughtension element830 is described as being threaded, other configurations may be used to adjust the relative positions of upper and lowermoldable trays730. In alternative embodiments,tension element830 may attach to an adjustable oral appliance, such as the oral appliance described in U.S. Pat. No. 7,748,386. In certain embodiments, uppermoldable tray730 and lowermoldable tray730 may be used with or without a mask. In these embodiments,moldable trays730 may function as an oral appliance only or may be used during surgery or post-surgery to maintain the user's airway during the administering of anesthetics or during ventilation, or they may be in place in the event that resuscitation becomes necessary.
Mask850 includes one ormore flanges822, with eachflange822 including aslot824.Flange822 may be fixed to or integrally formed withmask850; orflange822 may be removably coupled tomask850. However, it should be appreciated thatflange822 may be fixed to or integrally formed with other mask types, orflange822 may be removably coupled to and/or interchangeable with other mask types. In embodiments in which asingle flange822 is used,flange822 may have a thickness of between 10-22 millimeters, though such dimensions are not required. In other embodiments,flange822 may have a thickness of between 12-18 millimeters. In a particular embodiment,flange822 may have a thickness of approximately 14 millimeters. In embodiments havingmultiple flanges822, eachflange822 may have a thickness of between 1-4 millimeters, though this range is not required. In a particular embodiment having amultiple flanges822, one or more of theflanges822 may have a thickness of approximately 3 millimeters. In certain embodiments havingmultiple flanges822, when the mask is oriented to the user's face, the distance between the right edge of therightmost flange822 and the left edge of theleftmost flange822 may be similar to the ranges described above for asingle flange822. For example, in a particular embodiment having twoflanges822, the span between the inner edges of the flanges may be approximately 6 millimeters and the span between the outer edges of the flanges may be approximately 14 millimeters, though other dimensions may be used. Such embodiments may improve the ability ofcoupler800 to prevent deformation outside of the sagittal plane.
As shown inFIG. 12,mask850 is a pillow mask withnasal inserts852 that may be configured to seal against the user's nostrils. In certain embodiments,nasal inserts852 may be fitted independently to mask850 and may be capable of rotating independently to the angle of the user's nostrils. In certain embodiments,nasal inserts852 may be removeably coupled tomask850 and may be interchangeable with different sizes of nasal inserts852. In some embodiments, the user may select different sizes ofnasal inserts852 for each nostril. In alternative embodiments,nasal inserts852 may be formed together as a pair and attached as one unit to mask850. In other embodiments,nasal inserts852 may be fixed permanently to mask850. In certain embodiments,mask850 may have an inlet that is fixed on the top of the frame for delivering air and/or other gases to mask850. In some embodiments,mask850 may have a ball joint, elbow, or a combination thereof delivering air and/or other gases to mask850. In alternative embodiments, air and/or other gases may be delivered in the side or the bottom ofmask850. In certain embodiments, air and/or other gases may be delivered through several different tubes. In certain embodiments, the user may be able to select one or more connection points for delivery of air and/or other gases and plug or otherwise disable other connection points. In other embodiments, a main hose may attach directly to mask850 or to an elbow joint or a ball joint. In certain embodiments,mask850 may have a length of flexible tubing that may connect with a main hose. In certain embodiments, the optional flexible tubing may be approximately 50-300 millimeters long, though this is not required. In one example embodiment,mask850 may have a 250 millimeter-long flexible tube. In certain embodiments, such tubing may be light, flexible, and have a smaller diameter than the main hose. In some embodiments, the flexible tubing may have a diameter of approximately 12-19 millimeters, while the main hose may have a diameter of approximately 22 millimeters, though these dimensions are not required. In one example embodiment, the flexible tubing may have an internal diameter of approximately 17 millimeters. In certain embodiments, there may be a connector between the short flexible tube and the main tube, and in some embodiments this connector may be capable of swiveling. In particular embodiments, the connector may be a ball joint or a straight connector. In certain embodiments, optional headgear may be supplied that attaches to mask850,coupler800, and/ormoldable tray730. Such headgear may pass along the side of the user's face and may be capable of holding the main hose or other air-delivery device in a particular position. For example, in certain embodiments, such headgear may hold the main hose in place on top of the user's head or to one or both sides of the user's head. In certain embodiments, such headgear may also be configured to help holdmoldable tray730, or any other oral appliance, in the user's mouth. In some embodiments, such headgear may be adjustable at a connection point onmask850 and/or at one or more places around the user's head. In alternative embodiments, the headgear may be formed from a stretchable material and may require little or no manual adjustment. In one example embodiment, the headgear may be at least partially made from Breath-o-prene®, which is a soft, breathable laminate. In another example embodiment, the headgear may be at least partially made from silicone or a molded thermoplastic/fabric composite. In other embodiments, the headgear may be formed from a combination of these materials, or from a combination of these and other materials. In certain embodiments, a chin strap may attach to mask850, headgear, ormoldable tray730 or any other oral appliance. In some embodiments,mask850 may have bias flow (vent holes) to flush out the user's exhaled breath. In such embodiments,mask850 may have a plurality of holes to enable bias flow. In certain embodiments,mask850 may have approximately 10-50 holes, though this is not required. In one example embodiment,mask850 may have approximately 35 holes. In these embodiments, the holes may be approximately 0.75 millimeters in diameter, though these dimensions are not required. In certain embodiments, the holes may have non-uniform cross-sectional shapes throughout the length of the holes. In one example embodiment, one or more of the holes may be rounded and have an opening diameter of approximately 1.2 millimeters, the diameter of the hole falling to approximately 0.75 millimeters when moving through the hole and then expanding again to a diameter greater than 0.75 millimeters when moving through to the other end of the hole. In alternative embodiments, the holes may be tapered from one side or the other, or the holes may be straight throughout. In certain embodiments, having many small holes may slow the flow of gas and may reduce the draft and noise of such flow. In other embodiments,mask850 may have no holes, which may enable closed-loop ventilation. In certain embodiments,mask850 may be first formed in two or more distinct pieces and then joined, for example, by welding, gluing, clipping, screwing, latching, strapping, or otherwise fixing the pieces together. In other embodiments, the mask may initially be formed as a single piece. Furthermore, those skilled in the art will appreciate that the headgear, tubes, bias holes, chin straps, attachments, assembly features, and other aspects described above may also apply to other masks described herein.
Post802 may include one ormore channels806 and aslot804. In the embodiment shown,coupler800 is formed by twoflanges822 engaging twochannels806. The movement offlanges822 relative tochannels806 is limited byfastener805 inslot804.Fastener805 may represent any structure that can restrict the movement offlanges822 relative tochannels806. In certain embodiments,fastener805 may be a pin, screw, or bolt. In the embodiment shown,fastener805 is a threaded hex-head bolt that engages a hex-head counter sink807 on one side ofpost802 and a tighteningknob808 on the other side ofpost802. In certain embodiments, a hex-head (or other appropriately shaped) countersink may prevent rotation offastener805 while tighteningknob808 or other appropriate structure is fixing the position offastener805. In a particular embodiment, both sides ofpost802 may include a countersink, such that a user may select to position tighteningknob808 on either side ofpost802. This flexibility may make the use of tighteningknob808 equally convenient to left-handed and right-handed users. In alternative embodiments, post802 may include an additional tightening knob opposite tighteningknob808, enabling adjustment from either side ofpost802.
FIG. 14A illustrates the anterior end of anexample post802 andFIG. 14B illustrates an example anterior view of an examplearched frame700 with atension element830. As shown inFIG. 14B, in certain embodiments at least a portion of the tension element may be threaded, and the threaded portion may engage with thetension element adjustor832. In the embodiments shown,post802 includes D-shapedslot834 andtension element830 has a corresponding D-shaped cross-section. In certain embodiments, the D-shapedslot834 andtension element830 may substantially preventtension element830 from rotating whenadjustment knob832 is used to adjusttension element830. Although a D-shape is illustrated, other cross-sections may be used to prevent the rotation oftension element830 inslot834. As one example, slot834 may have a “key” structure that corresponds with a channel intension element830.
FIGS. 15A and 15B illustrateexample flanges822. As shown inFIG. 15A,flange822 may include aslot824. WhileFIG. 15B depicts twodistinct flanges822, alternative embodiments may have a single flange, multiple flanges, or any other structure which may be secured in place relative to post802 byfastener805. In alternative embodiments,slot824 may have various shapes, sizes, and orientations. In certain embodiments,flanges822 may be formed and/or molded as one part. In other embodiments,flanges822 may be formed from multiple parts that may be assembled, clipped, screwed, or overmolded. In various embodiments,flanges822 may consist of plastic and/or metal such as stainless steel.
FIGS. 16A and 16B illustrate anexample post802 having afastener805,channels806, countersink807, tighteningknob808, and atension element channel834. As shown inFIG. 16A, an end offastener805 may be configured to engage withcountersink807. In certain embodiments, as shown inFIG. 16B, at least a portion offastener805 may be threaded. As shown inFIG. 16B, in some embodiments slot804 (not shown) may cross laterally throughpost802, allowingfastener805 to pass laterally throughpost802 acrosschannels806. In some embodiments, whenflanges822 are disposed inchannel806,slots824 may substantially align withslot804, allowingfastener805 to pass through bothslot804 andslots824. In such an embodiment, tighteningknob808 may be adjusted to increase or decrease lateral force exerted along the long axis offastener808. Adjusting tighteningknob808 in such an embodiment may operate to secureflanges822 in place relative to post802. In certain embodiments, an attached mask or breathing device may be moved into the desired position relative to the user's face and then fixed into that position by adjusting tighteningknob808.
In certain embodiments, post802 may be formed and/or molded as one part. In other embodiments, post802 may be formed from multiple parts that may be assembled, clipped, screwed, or overmolded. In various embodiments, post802 may consist of plastic and/or metal such as stainless steel.
FIGS. 17A through 17F illustrate various positions of anexample coupler800. As shown inFIG. 17A,coupler800 may include aflange822 withslot824 and apost802 having afastener805 and countersink807. As shown inFIGS. 17A through 17F, in certain embodiments,flange822 may be capable of moving in the superior-inferior direction relative to post802, moving in the anterior-posterior direction relative to post802, and rotating aroundfastener805. In alternative embodiments,flange822 may be capable of moving in the superior-inferior direction relative to post802 and rotating aroundfastener805. In certain embodiments,flange822 may be limited to adjustment, rotation, and/or movement within the sagittal plane. In some embodiments, post802 may include an additional joint that may provide adjustment, rotation, and/or movement in one or more additional directions. In certain embodiments,flange822 may be adjusted vertically approximately +/−10 mm, though other ranges may be used. For example, other embodiments may have vertical adjustment ranges of between +/−7 mm and +/−14 mm. In certain embodiments,flange822 may be adjusted in the anterior-posterior direction approximately +/−5 mm, though other ranges may be used. For example, other embodiments may have horizontal adjustment ranges of between +/−3 mm and +/−8 mm. In certain embodiments, whenflange822 has a desired position and orientation, tighteningknob808 may be adjusted to secureflange822 in place relative to post802.
FIG. 18 illustrates another example post882 having afastener805,plates884,channels806, tighteningknob808, andplate886. In particular embodiments,plates884 may definechannels806, which are configured to receiveflanges822. As shown inFIG. 18, post882 may be cylindrical and hollow. In a particular embodiment, post882 may consist of metal, such as stainless steal. In alternative embodiments, post882 may have various structures, shapes, and densities and can be made from a wide variety of rigid materials. In some embodiments,plate886 may be attached at the posterior end of post882.Plate886 may be configured to couple to the front of an oral appliance such as those described, for example, in U.S. Pat. No. 7,748,386, which is incorporated herein by reference.
FIG. 19A illustrates anexample mask890 havingflanges822 withslots824 and ahose coupler854 coupled to ahose870.FIG. 19B illustrates a side view ofmask890, showingopening856 andflanges822. In certain embodiments, as shown inFIG. 19B,flanges822 may be fixed to or integrally formed withmask890. In alternative embodiments,flanges822 may be removably coupled to the anterior surface ofmask890. In some embodiments, opening856 may allow structures, such aspost802 or post882, to pass through the front ofmask890 and couple withflanges824. In certain embodiments, opening856 may be sized to accommodate various positions and orientations ofpost802 relative to mask890.
FIG. 20 illustrates anexample mask892 coupled to anexample post802. As shown,mask892 includes aseal860, opening856,flanges822, and ahose coupler854. As shown,post802 is attached tomoldable tray730 inside the user's mouth, allowingmask892 to be adjustably oriented to the user's face. In certain embodiments,mask892 may be adjusted vertically, adjusted in the anterior-posterior direction, and/or rotated in the sagittal plane. In certain embodiments, as shown inFIG. 20,seal860 may includeflexible gasket862 which may be configured to allowpost802 to pass through it and couple withflanges824, forming an air-tight seal aroundpost802.Flexible gasket862 may also allowmask892 to be adjusted to various positions and orientations relative to the user's face without significantlydisturbing post802 or breaking the airtight seal ofseal860. In some embodiments, as shown inFIG. 20,flexible gasket862 may incorporate or be surrounded by creases, which may improve the ability offlexible gasket862 to accommodate various positions ofpost802, though such creases are not required. In certain embodiments,post802, or another suitable post such as post882, may attach to various oral appliances, allowing for various combinations of oral appliances, posts, and masks. In alternative embodiments,flanges822 may be contained within a mask, providing the substantially similar movement and adjustment to mask892. In such embodiments,fastener805 may pass through a gasket in the mask's seal to a position outside the mask where it could be operated by a user.
Havingmask892 secured to the user's oral appliance may obviate the need for the user to wear stabilizing headgear. Such straps may shift accidentally, may be uncomfortable for the user, may leave marks on the user's face, and may irritate the user's face and scalp. Furthermore, since havingmask892 secured to the user's oral appliance may prevent substantial movement ofmask892 relative to the user's face and prevent leakage, these embodiments may reduce the need to tighten the mask to the user's face, which may result in reduced pressure on the user's face and reduced pressure sores. These embodiments may also provide greater mask stability during sleep for users who exhibit substantial movement during sleep. It should be appreciated that all such embodiments and advantages described with respect to mask892 may also apply to other mask described herein, such as, for example, masks850 and/or894.
In alternative embodiments,mask892 may be held in place by a tension element attached to an oral appliance, with the tensionelement pulling mask892 toward the oral appliance and the user's face. In certain embodiments, the pull of the tension element may be adjusted by a screw, tightening knob, or other adjustment mechanism. Following adjustment, in certain embodiments mask892 may be secured via a fastener, such as a hook.
WhileFIG. 20 shows mask892 as a full face mask covering the user's nose and mouth,FIGS. 21A and 21B illustrate analternative mask894 covering the user's mouth and delivering air and/or other gases to the user's nose via nasal inserts852. In certain embodiments, as shown inFIG. 21B,seal860 may extend below the user's chin. Masks with portions that extend below a user's chin may improve the function of the mask by preventing and/or reducing the occurrence of the user opening their mouth while using the mask. Still other embodiments incorporating different types of masks will be apparent to those skilled in the art. In certain embodiments, whenflanges822 ofmask894 are disposed inchannels806 ofpost802, movement ofmask894 outside of the sagittal plane is strongly resisted, which may help prevent mask leakage if a user lays on his or her side, pushingmask894 laterally against a surface such as a pillow.
Various types of masks may be used in other embodiments. For example, certain embodiments may use pillow masks, which seal against the user's nostrils; nasal masks, which cover the user's nose; full face masks, which cover both the user's mouth and nose; hybrid masks, which have one portion covering a user's mouth and another portion covering the user's nose or sealing against the user's nostrils; or oral masks, which cover the user's mouth. Such masks may be used for the delivery of pressurized air, oxygen, aerosols, gasses, or medication; and the masks may be vented or non-vented. Masks included in various embodiments may be used for continuous positive airway pressure treatment (CPAP), auto-CPAP, or bilevel or closed-loop ventilation; and masks may be custom-fitted to a particular user or they may be non-custom masks that conform to different face shapes.
In certain embodiments, a venting seal may be combined with the masks and/or oral appliances disclosed herein. In certain embodiments, the venting seal may be fixed or detachable. The venting seal may be positioned outside the user's mouth next to the user's lips or the venting seal may be positioned behind the user's lips next to the user's teeth. In certain embodiments, the venting seal may reduce or eliminate the venting of air or other gases from the user's mouth, such as for example when air or other gases are being supplied to the user's nose. An example venting seal is disclosed in U.S. Pat. No. 6,675,802, incorporated herein by reference. In certain embodiments, the venting seal may be attached to post802, post882, or other appropriate structure, either removably or permanently.
FIGS. 22A and 22B andFIG. 23 illustrate anexample mask900 having ahose coupler902 and astrap904 with a plurality ofapertures906. As shown inFIG. 22A,hose coupler902 may be configured to attach to ahose910 which may deliver air and/or other gases to mask900. In certain embodiments, as shown inFIG. 23A,strap904 may span the opening ofhose coupler902. As shown inFIG. 23A,strap904 may have a plurality of apertures along its length. In certain embodiments, as shown inFIG. 22B, atension element920 may pass through one of the plurality ofapertures906 and attach tooral appliance930, which may be any mouthpiece configured to couple totension element920.FIG. 24 illustrates an exampleoral appliance930,mask900, andtension element920. As shown inFIG. 24,tension element920 has a threadedknob924 and ahook922.Oral appliance930 includes a receiver to engagetension element920 to pullmask900 towardsoral appliance930. In certain embodiments, the receiver inoral appliance930 may be a loop, a latch, or a slot. In a particular embodiment,tension element920 includeshook922 and threadedknob924. In alternative embodiments,tension element920 may include one or more alternative structures to pullmask900 towardsoral appliance930.
FIGS. 25A and 25B illustrate anexample mask950 andadapter960. As shown inFIGS. 26A and 26B, incertain embodiments adapter960 may include ahose coupler962, astrap904 having a plurality ofapertures906, and amask coupler968. In some embodiments,hose coupler902 may be configured to couple with ahose910. As shown inFIGS. 25A and 25B,mask coupler968 may be configured to couple withhose coupler952 ofmask950, allowingadapter960 to couple withmask950. Whenadapter960 is coupled tomask950,adapter960 may allowmask950 to interact withhose910 andtension element920 as described in the above description ofmask900.
FIG. 27 illustrates an example dental device comprising a universal coupler and an example dental attachment. As shown inFIG. 27, a dental device is provided comprising anarched frame100, amoldable tray135, a secondarched frame200, and a secondmoldable tray235.Arched frame100 may comprise a universal coupler comprising a substantiallyplanar surface145. In particular embodiments, ahook405 may be configured to engage the universal coupler. In particular embodiments, secondarched frame200 may comprise areceiving mechanism130 coupled to the lingual portion of secondarched frame200.Receiving mechanism130 may be a bar that spans the lingual portion of secondarched frame200. In particular embodiments,hook405 may engage receivingmechanism130 to adjust the forward position ofarched frame100 relative to secondarched frame200. In certain embodiments, this adjustment may help to prevent a user from snoring when the dental device is inserted in the user's mouth.
FIG. 28 illustrates an example dental device comprising a universal coupler and an example dental attachment. As shown inFIG. 28, a dental device is provided comprising anarched frame100, amoldable tray135, a secondarched frame200, and a secondmoldable tray235.Arched frame100 may comprise a universal coupler comprising a substantiallyplanar surface145. In particular embodiments, a substantially roundedprojection415 may be configured to engage the universal coupler. In particular embodiments,rounded projection415 may be the only point of contact between the user's upper and lower dental arches to prevent a user from clenching his jaw when the dental device is inserted in the user's mouth. In particular embodiments,rounded projection415 may contact an opposing arch or may contact one or more incisors of the opposing dental arch to prevent a user from clenching his jaw when the dental device is inserted in the user's mouth. The opposing arch may have a contact surface that may be planar.
The universal oral appliance comprising a universal coupler may provide several advantages for a user. In particular embodiments, a universal oral appliance comprising a universal coupler may offer more use options to a user. For example, a user's appliance may be fitted with several different dental attachment options. The user may choose which dental attachment is best suited for his situation without having to hire a lab to construct another appliance. In particular embodiments, a particular user may also adjust the dental attachment to better suit the shape and size of the user's mouth. This disclosure contemplates the universal oral appliance being created from parts in a kit. A user may purchase the kit instead of a dental device created in a laboratory.
FIG. 29 illustrates an example arch comprising a dental attachment. As shown inFIG. 29, an arch is provided that comprises anarched frame100 and amoldable tray135 coupled toarched frame100.Arched frame100 comprises anarched body105 that defines a plurality ofapertures110. The arch may further comprise a dental attachment configured to engagearched frame100. In particular embodiments, the dental attachment is configured to engagearched frame100 along the midline ofarched frame100. In particular embodiments, the dental attachment may comprise apost500 and ananchoring element505.Post500 may be coupled at a first end to anchoringelement505. In particular embodiments, a second end ofpost500 may engagearched frame100. In some embodiments, post500 may be configured to removably engagearched frame100. In particular embodiments, anchoringelement505 may include a buckle, a slot, a clasp, a clamp, and/or any other appropriate element to anchor a tension element. In some embodiments, anchoringelement505 may be configured to be outside a user's mouth when the arch is inserted in the user's mouth. In some embodiments, the dental attachment may further comprise arelease mechanism510. As an example and not by way of limitation,release mechanism510 may be a button or a latch. Although this disclosure describes certain types ofrelease mechanisms510, this disclosure contemplates anysuitable release mechanism510. Although this disclosure describes an arch comprisingarched frame100,moldable tray135, and a dental attachment, this disclosure contemplates a one-piece arch comprising a dental attachment.
FIG. 30 illustrates an example arch comprising a second anchoring element and a tension element. As shown inFIG. 30, an arch is provided that comprises anarched frame200 and amoldable tray235 coupled toarched frame200.Arched frame200 comprises anarched body205 that defines a plurality ofapertures210. The arch may further comprise asecond anchoring element245. In particular embodiments,second anchoring element245 may be coupled to the arch along the midline of the arch. The arch may further comprise atension element515. In particular embodiments,tension element515 may be flexible and may be configured to engagesecond anchoring element245. In particular embodiments,tension element515 may be further configured to couple to an anchoring element outside a user's mouth when the arch is inserted in the user's mouth. In some embodiments,tension element515 may comprise astrap520 and acoupler516.Coupler516 may be configured to engage the second anchoring element. In particular embodiments,coupler516 may be configured to removably engage the second anchoring element.Strap520 may be coupled tocoupler516. In particular embodiments,strap520 may be configured to engage the anchoring element outside the user's mouth when the arch is inserted in the user's mouth. In particular embodiments,strap520 may comprise a hard plastic, leather, or metal. In certain embodiments,strap520 may be a zip tie. In other embodiments,strap520 may be a wire, belt, string, or any other appropriate element to engage the anchoring element. Although this disclosure describes an arch comprisingarched frame200,moldable tray235, andtension element515, this disclosure contemplates a one-piece arch comprisingtension element515.
FIG. 31 illustrates an example dental device comprising a dental attachment, a second anchoring element, and a tension element. As shown inFIG. 31, a dental device is provided that comprises anarched frame100 and a secondarched frame200. The dental device further comprises amoldable tray135 coupled toarched frame100 and a secondmoldable tray235 coupled to secondarched frame200. The dental device may further comprise a dental attachment configured to engagearched frame100. In particular embodiments, the dental attachment may comprise apost500 and ananchoring element505. The dental device may further comprise asecond anchoring element245.Second anchoring element245 may be coupled to secondarched frame200. The dental device may further comprise atension element515.Tension element515 may be configured to engagesecond anchoring element245. In particular embodiments,tension element515 may comprise acoupler516 and astrap520. In particular embodiments,strap520 may be configured to engage anchoringelement505 outside the user's mouth when the dental device is inserted in the user's mouth. Anchoringelement505 may be configured to secure substantially the length ofstrap520 engaged to anchoringelement505. In particular embodiments, increasing the length ofstrap520 engaged to anchoringelement505 will adjust the forward position ofarched frame100 relative to secondarched frame200. In particular embodiments, the dental attachment may further comprise arelease mechanism510.
FIG. 32 illustrates an example dental attachment and tension element. As shown inFIG. 32, a dental attachment is provided comprising apost500 and ananchoring element505. Anchoringelement505 may be coupled to an end ofpost500. A tension element is also provided comprising astrap520.Strap520 may be configured to engage anchoringelement505. Anchoringelement505 may be configured to secure the length ofstrap520 engaged to anchoringelement505. In particular embodiments, the dental attachment may comprise arelease mechanism510.Release mechanism510 may be configured to releasestrap520 from anchoringelement505.
FIG. 33 illustrates an example dental device in a user's mouth. As shown inFIG. 33, a dental device is provided that comprises anarched frame100, a secondarched frame200, amoldable tray135 coupled toarched frame100, and a secondmoldable tray235 coupled to secondarched frame200.Moldable tray135 may comprise achannel140 configured to engage at least some of the teeth of the user'smaxillary arch305. Second arched frame may comprise a secondarched body205 that defines a second plurality ofapertures210. The dental device may further comprise a dental attachment. The dental attachment may comprise apost500 and ananchoring element505. Anchoringelement505 may be coupled to an end ofpost500, and a second end ofpost500 may be configured to engagearched frame100. Anchoringelement505 may be configured to be outside the user's mouth when the dental device is inserted in the user's mouth. The dental device may further comprise asecond anchoring element245 coupled to secondarched frame200. The dental device may further comprise a tension element comprising acoupler516 and astrap520.Coupler516 may be configured to engagesecond anchoring element245.Strap520 may be coupled tocoupler516 and may be configured to engage anchoringelement520 outside the user's mouth when the dental device is inserted in the user's mouth. Anchoringelement505 may be configured to secure substantially the length ofstrap520 engaged to anchoringelement505. In particular embodiments, increasing the length ofstrap520 engaged to anchoringelement505 may adjust the forward position ofarched frame100 relative to secondarched frame200. In particular embodiments, adjusting the forward position ofarched frame100 relative to secondarched frame200 may adjust the forward position of the user'smaxillary arch305 relative to the user'smandibular arch300. In particular embodiments, adjusting the forward position of the user'smaxillary arch305 relative to the position of the user'smandibular arch300 may help to improve the user's breathing and/or prevent the user from snoring.
In particular embodiments, the dental device comprising a dental attachment and a tension element may allow a third party faster access to a user's mouth and airway. For example, if the user is a patient sleeping in a sleep laboratory, a doctor in the laboratory may quickly pull on the tension element to open an airway that closed while the patient slept. As another example, if the user is a patient undergoing surgery in a hospital, a surgeon may quickly release the tension element to open the patient's mouth for intubation or for insertion of an instrument while the patient is sedated. In particular embodiments, the dental device comprising a dental attachment and a tension element may pull the user's lower jaw forward without locking the lower jaw in place. The user's lower jaw will maintain a certain range of lateral motion while the dental device is inserted in the user's mouth. This disclosure contemplates the dental device comprising a dental attachment and a tension element being created from a kit. A patient, doctor, or surgeon may purchase the kit and create the dental device quickly. In particular embodiments, the dental device may be a disposable device that may be thrown out after one or more uses.
FIG. 34 illustrates an example process for creating a dental device. Atstep600, an arched frame is formed. In particular embodiments, the arched frame may be configured to be positioned proximate to the occlusal surface of a user's dental arch such that the arched frame extends beyond the cuspids of the user's dental arch. The arched frame may define a plurality of apertures. Atstep605, an adjustment mechanism is coupled to the arched frame. In particular embodiments, the adjustment mechanism may comprise a hook and a threaded adjustor. Atstep610, a moldable tray is formed. In particular embodiments, the moldable tray may comprise a channel configured to engage at least some of the teeth of the user's dental arch. In some embodiments, the channel may be shaped to conform to the teeth of a generic user's dental arch. In other embodiments, the channel may be a smooth channel configured to cover some of the teeth of the user's dental arch. In particular embodiments, the channel may be further shaped to conform to a particular user's dental arch. Atstep615, the moldable tray is coupled to the arched frame. In particular embodiments, the moldable tray may engage the plurality of apertures. In particular embodiments the process may be repeated to form a second arched frame and a second moldable tray. In particular embodiments, the arched frame may comprise kevlar polycarbon, acryllic, polycarbonate resin thermoplastic, or any other suitable hard plastic polymer. In particular embodiments, the moldable tray may comprise polycaprolactone.
In particular embodiments, the process illustrated inFIG. 34 may lead to faster creation and production of dental devices. Users may avoid sending dental impressions to a laboratory to create a dental devices thus saving time and money.
Although example steps are illustrated and described, the present invention contemplates two or more steps taking place substantially simultaneously or in a different order. For example,step605, coupling an adjustment mechanism to the arched frame, may be performed afterstep610, forming a moldable tray. In addition, the present invention contemplates using methods with additional steps, fewer steps, or different steps, so long as the steps remain appropriate for creating a dental device.
Various embodiments disclosed herein may be used together in a variety of combinations. For example, in certain embodiments, the various posts, such asposts802 and882, may be coupled to any of the various oral appliances disclosed herein, including the oral appliances disclosed in U.S. Pat. No. 7,748,386. As another example, the various posts described herein may be coupled to any of the various masks disclosed, such as but not limited tomasks850,890,892, and894. As another example, in certain embodiments, the various adjustment mechanisms may be used with the various oral appliances disclosed herein, including the adjustment mechanisms and oral appliances disclosed in U.S. Pat. No. 7,748,386. As another example, in certain embodiments the various oral appliances may be coupled with the various dental attachments disclosed herein.
Although the present invention has been described above in connection with several embodiments, changes, substitutions, variations, alterations, transformations, and modifications may be suggested to one skilled in the art, and it is intended that the present invention encompass such changes, substitutions, variations, alterations, transformations, and modifications as fall within the spirit and scope of the appended claims.

Claims

1-118. (canceled)

119. A dental device comprising:

a first arch configured to engage at least some of the teeth of a user's dental arch, the first arch having a midline that aligns substantially with the anterior midline of the user's mouth when the first arch is inserted in the user's mouth;

a first coupler coupled to the first arch along the midline of the arch, a portion of the first coupler configured to be inside the user's mouth when the first arch is inserted in the user's mouth;

a second arch configured to engage at least some of the teeth of the user's second dental arch, the second arch having a midline that aligns substantially with the anterior midline of the user's mouth when the second arch is inserted in the user's mouth;

a second coupler coupled to the second arch along the midline of the second arch, the second coupler configured to extend anterior to the user's second dental arch when the second arch is inserted in the user's mouth; and

a flexible tension element configured to removably engage the second coupler and the first coupler, the tension element configured to maintain a forward position of the first arch relative to the second arch.

120. The dental device ofclaim 119, wherein the first coupler comprises:

a post coupled to the first arch, the tension element configured to engage the post; and

a cap configured to engage the post, the cap configured to prevent the tension element from disengaging from the post when the cap and the tension element are both engaged with the post.

121. The dental device ofclaim 119, wherein the second coupler comprises:

a flange coupled to the second arch;

a post coupled to the flange, the tension element configured to engage the post; and

122. The dental device ofclaim 121, wherein the cap is configured to removably engage the post.

123. The dental device ofclaim 119, wherein the tension element defines a first aperture and a second aperture, the first aperture configured to engage the first coupler, the second aperture configured to engage the second coupler.

124. The dental device ofclaim 119, wherein the first arch comprises:

a frame comprising:

a left occlusal portion configured to be positioned proximate at least one of a left bicuspid or a left molar of the user;

a right occlusal portion configured to be positioned proximate at least one of a right bicuspid or a right molar of the user, wherein the frame defines an open space between the left occlusal portion and the right occlusal portion, the space configured to be positioned proximate an incisor of the user; and

a flange coupled to the left occlusal portion and the right occlusal portion, the flange extending substantially perpendicular and mesial to the left and right occlusal portions; and

a thermoplastic moldable tray coupled to the frame.

125. The dental device ofclaim 124, wherein the thermoplastic moldable tray extends beyond a lingual edge of the left occlusal portion in a lingual direction and a lingual edge of the right occlusal portion in a lingual direction.

126. The dental device ofclaim 124, wherein the thermoplastic moldable tray extends beyond a posterior edge of the left occlusal portion in a posterior direction and a posterior edge of the right occlusal portion in a posterior direction.

127. The dental device ofclaim 119, wherein the tension element allows for lateral movement of the first arch relative to the second arch when the tension element is engaged with both the first and second couplers.

128. The dental device ofclaim 119, wherein the tension element is configured to exert a tensile force that pulls the first arch forward relative to the second arch when the tension element is engaged with both the first and second couplers.

129. A dental device comprising:

a first arch configured to engage at least some of the teeth of a user's dental arch and having a midline that aligns substantially with the anterior midline of the user's mouth when the first arch is inserted in the user's mouth;

a first coupler coupled to the first arch along the midline of the arch;

a second arch configured to engage at least some of the teeth of the user's second dental arch and having a midline that aligns substantially with the anterior midline of the user's mouth when the second arch is inserted in the user's mouth;

a second coupler coupled to the second arch;

a first tension element configured to removably engage the second coupler and the first coupler, the first tension element configured to maintain a forward position of the first arch relative to the second arch.

130. The dental device ofclaim 129 further comprising:

a third coupler coupled to the second arch; and

a second tension element configured to removably engage the third coupler and the first coupler, the second tension element configured to maintain a forward position of the first arch relative to the second arch.

131. The dental device ofclaim 130, wherein the second and third couplers are spaced substantially equidistant from the midline of the second arch.

132. The dental device ofclaim 129, wherein the first coupler comprises:

a post coupled to the first arch, the first tension element configured to engage the post; and

a cap configured to engage the post, the cap configured to prevent the first tension element from disengaging from the post when the cap and the first tension element are engaged with the post.

133. The dental device ofclaim 132, wherein the cap is configured to removably engage the post.

134. The dental device ofclaim 129, wherein the first tension element defines a first aperture and a second aperture, the first aperture configured to engage the first coupler, the second aperture configured to engage the second coupler.

135. The dental device ofclaim 129, wherein the first arch comprises:

a frame comprising:

a thermoplastic moldable tray coupled to the frame.

136. The dental device ofclaim 135, wherein the thermoplastic moldable tray extends beyond a lingual edge of the left occlusal portion in a lingual direction and a lingual edge of the right occlusal portion in a lingual direction.

137. The dental device ofclaim 135, wherein the thermoplastic moldable tray extends beyond a posterior edge of the left occlusal portion in a posterior direction and a posterior edge of the right occlusal portion in a posterior direction.

138. The dental device ofclaim 129, wherein the first tension element allows for lateral movement of the first arch relative to the second arch when the first tension element is engaged with both the first and second couplers.

139. The dental device ofclaim 129, wherein the first tension element is configured to exert a tensile force that pulls the first arch forward relative to the second arch when the first tension element is engaged with both the first and second couplers.