Technical Field

The present invention relates to a method for making a tooth protector in which a tooth model is created by scanning the tooth structure of the user specific to the user, the same is manufactured by using the created tooth model via a three- dimensional (3D) printer, the mouth and the teeth are protected when the user is in physical action.

Prior Art

It is possible for the user who is interested in sports to be hit on the head, depending on the types of sports performed during some sportive activities. Particularly in combat sports, a blow to the head and teeth during competitions is seen. The tooth protector and similar equipment can be used during competition or training, since punching or kicking is used for example in combat sports such as boxing, kickboxing, and Mau Thai. In case a blow is received to the head in these sports, some equipment for protecting the mouth for preventing the teeth and the gum from being affected by the blow is used within the mouth. Today, equipment or apparatuses which contain said mouth protector can be used not only in sports events but also in the operations in various health fields in terms of the mouth, tooth and gum health of the patient. The mouth protectors used for the protection of mouth and teeth are preferably manufactured from elastic material such as silicone and have a feature that can be shaped according to the mouth and teeth of the user.

The mouth protectors used in the current state of the art are manufactured by three different methods mainly silicone,“boil-bite” and specific designs. The silicone mouth protectors do not protect the teeth and the tooth roots against impacts due to their structure. The“Boil-Bite” mouth protectors provide better protection compared to the silicone mouth protectors however after the boiling process as a method of use, when the person gives form to the soft tissue by means of biting, depending on more or less biting; it can cause the tooth protector unable to perform its task completely. The tooth protectors manufactured specifically for the person is manufactured by means of taking the mouth model of the person by a dentist with the help of a tooth spoon and by using this model as a mold and it provides the best protection but it is very expensive and has a long manufacturing process compared to the other tooth protectors. For this reason, the mouth protector is required to be specific to the user, at the same time it is also required to have a low cost and to be formed in a fast manner. Different from said three methods, the tooth protector can be designed parametrically in the computer environment by means of scanning the tooth structure of the user.

In the United States document numbered US2003096210 (Al) having priority date 28.04.2000, a three-dimensional (3D) scanning and model formation system is described. In the study included in said document, a system which performs scanning in STL format for determining the treatment to be used for tooth treatments and for forming the tooth model and creates a three-dimensional (3D) model is developed. The measurements obtained in this system are transferred to the matrixes and curves that form the 3D model are achieved by using said matrixes. In the invention subject to application, the solid model of the mouth and teeth is created in the computer with a three-dimensional (3D) scanning. After a solid model is created in the computer, a parametric distance from the teeth to the protection part (protector) surface and the other boundaries is achieved. After the computer model is created, the parametric modeling (STL format) is performed. During the parametric modeling process, the internal and external boundaries are determined by reading the values in minimum and maximum range of the parametric values. In the invention subject to application, curves are obtained from said boundary values and internal and external boundary points included in the software program with the curve tool that obtains proper curves and the translation angles are calculated. In the invention of said document, the parametric distance calculation process for a protection part is lacking.

In the United States patent document numbered US2014124968 (Al) having priority date 16.06.2011 in the state of the art, a transparent tooth plate production method is described. In the study included in said document, the intraoral and tooth models are obtained with a three-dimensional (3D) scanning device. The mold of the transparent protective plate is manufactured by using a three- dimensional (3D) printer with the obtained three-dimensional (3D) data. A plate with a desired thickness can be manufactured with the mold produced by means of the vacuum method. In the study, required gaps are left between the upper and lower jaw, and the plates are enabled to work. The amount of the movement for the tooth to be moved is determined and positioned properly. In the invention subject to application, the solid model of the mouth and teeth is created in the computer with a three-dimensional (3D) scanning. After a solid model is created in the computer, a parametric distance from the teeth to the protection part (protector) surface and the other boundaries is achieved. After the computer model is created, the parametric modeling (STL format) is performed. During the parametric modeling process, the internal and external boundaries are determined by reading the values in minimum and maximum range of the parametric values. In the invention subject to application, curves are obtained from said boundary values and internal and external boundary points included in the software program with the curve tool that obtains proper curves and the translation angles are calculated. In the invention of said document, the software details are not mentioned. Also in the invention of said document, the mold of the plate is formed instead of the plate.

In the International patent document numbered WO2018141325 (Al) having priority date 03.02.2017 in the state of the art, a tooth protector which can be used with a three-dimensional (3D) printer is described. In the study included in said document, the tooth structure is transferred to the system via the scanning method; a tooth protector plate is manufactured by using a three-dimensional (3D) printer with the obtained model. At the same time, sufficient distance in the palate section can be obtained with this system. In the invention subject to application, the solid model of the mouth and teeth is created in the computer with a three-dimensional (3D) scanning. After a solid model is created in the computer, a parametric distance from the teeth to the protection part (protector) surface and the other boundaries is achieved. After the computer model is created, the parametric modeling (STL format) is performed. During the parametric modeling process, the internal and external boundaries are determined by reading the values in minimum and maximum range of the parametric values. In the invention subject to application, curves are obtained from said boundary values and internal and external boundary points included in the software program with the curve tool that obtains proper curves and the translation angles are calculated. In the invention of said document, there is no information regarding the used software program and used calculation methods.

In the invention subject to application, the solid model of the mouth and teeth is created in the computer with a three-dimensional (3D) scanning. A parametric distance from the teeth to the protection part (protector) surface and the other boundaries is achieved, after a solid model is created on the computer. After the computer model is created, the parametric modeling (STL format) is performed. During the parametric modeling process, the internal and external boundaries are determined by reading the values in minimum and maximum range of the parametric values. In the invention subject to application, curves are obtained from said boundary values and internal and external boundary points included in the software program with the curve tool that obtains proper curves and the translation angles are calculated. Thus, the tooth protector can be manufactured with fast production specific to the user. In the state of the art, there is no explanation regarding the technical features and the technical effects provided by the invention of the present application. In the existing applications, a tooth protector and a production method thereof wherein solid models of mouth and teeth are formed with three-dimensional (3D) scanning, the parametric distance from the teeth to the protection part (protector) surface and the other boundaries is obtained after creating the solid model on the computer, parametric modeling process (STL format) is realized after the computer model is created, the internal and external boundaries are determined by reading the values between minimum and maximum values of the parametric values that are read during parametric modeling process and curves are obtained with these boundary values and smooth curve obtaining tool from the internal and external boundary points in the software program and translation angles are calculated, is not seen.

Aims of the Invention

The aim of this invention is to realize a method of producing a tooth protector in which a solid model is created parametrically and manufacturing is made in a faster and user-specific manner by a three-dimensional (3D) printer.

Another aim of this invention is to realize a method of producing a tooth protector which allows for determining the parallel surface distance of the tooth protector from the teeth to the transverse plane and the distance from the teeth to the other surfaces.

Another aim of this invention is to realize a method of producing a tooth protector which is low cost and enables fast production due to the parallel surface distance of the tooth protector from the teeth to the transverse plane and the distance from the teeth to the other surfaces is parametric.

Brief Description of the Invention As defined in the first claim and the other dependent claims, in order to achieve the aim of this invention, a method for producinga tooth protector is described. First of all, the solid model of the tooth structure is generated. Then three- dimensional computer model of the said solid model is prepared. Parametric tooth modeling is made after the preparation of three-dimensional computer tooth model. After the parametric tooth modeling is made, the process of obtaining the boundary curves on the parametric model surface is carried out. Then the coordinates of X, Y, and Z axes on the parametric tooth model are determined. The inner and outer boundary points are determined depending on the said coordinates. Suitable curves are created for the obtained inner and outer boundary points. The formed boundary curves are translated such that from each point they are perpendicular to the curve. Consequently, the shell model is formed from the translated curves, and the formed shell model is manufactured by a three- dimensional printer.

Detailed Description of the Invention

The method for manufacturing a tooth protector which is realized to fulfill the aims of the present invention is illustrated in the accompanying figures, in which:

Figure 1. Is a schematic view of the tooth protector production method.

Figure 2. It is the view of the formed three-dimensional tooth model in the coordinate plane.

Figure 3. It is the view of the ceiling and floor points on the surface of the tooth model in a separated manner on the graph.

Figure 4. It is the view of the internal and external boundary points obtained from the surface points of the tooth model on the graph.

Figure 5. It is the view of the curves obtained according to the inner and outer boundary points obtained from the tooth model on the graph. Figure 6. It is the view of the slope taken from a point of the curve obtained from the tooth model, perpendicular translation slope and the angular equivalents on the graph.

Figure 7. It is the view of the perpendicular translation slope obtained from the tooth model and the translated slopes formed with their angular equivalents on the graph.

Figure 8. It is the view of the formed distances on geometry.

Figure 9. It is the perspective view of the formed parametric tooth model.

Figure 10. It is the top view of the formed shell models and the tooth model used in the calculations.

The parts in the figure are enumerated one by one and the parts correspond to these numbers are given in the following.

100. Tooth protector production method

The method (100) for making a tooth protector which enables the impact to the mouth and the teeth of the user to be dampened in which a tooth model is created by scanning the tooth structure of the user specific to the user, is manufactured by using the created tooth model via a three-dimensional (3D) printer, mainly comprises the following process steps;

creating the solid tooth model of the user (101),

transforming the achieved solid tooth model into three-dimensional computer model (102),

making the parametric modeling of the tooth model which is transformed into three-dimensional computer model and achieving the boundary curves on the parametric model surface (103),

determining the coordinates of X, Y and Z axes on the parametric tooth model surface and determining the inner and outer boundary points based on the said coordinates (104), creating curves suitable for the obtained inner and outer boundary points (105),

translating the formed boundary curves such that from each point they are perpendicular to the curve (106),

forming shell model by the translated curves and manufacturing the tooth protector by the three-dimensional printer with the formed shell model (107).

In the inventive tooth protector production method (100), in general, the tooth protector, which is used for protecting the teeth against impacts in the combat sports, is provided to be specific to the user. In the tooth protector production method (100), a tooth model is formed by means of scanning the tooth structure of the user specific to the user. In the tooth protector production method (100), the tooth protector is manufactured using the created tooth model via a three- dimensional (3D) printer. The impact on the mouth and teeth of the user is enabled to be dampened by using the tooth protector which is produced by using the tooth protector production method (100).

In the tooth protector production method (100) in an embodiment of the invention, first of all, the solid tooth model of the user who will use the tooth protector is formed (101). In creating the solid tooth model of the user, preferably“Boil-Bite” type mouthpiece is used. The said mouthpiece is heated and thus it is made elastic. The heated mouthpiece is received by the user in his/her mouth and is bitten by the user such that the whole chin is compressed. When the user bites the mouthpiece, the model of the tooth and gums are formed on the mouthpiece. After some time, said mouthpiece hardens and the model of the teeth and the gums of the user remain by means of hardening. Thus, the solid tooth model of the user can be created (101). In different embodiments of the invention, the solid tooth model of the user can also be obtained by means of using different methods.

In one embodiment of the invention, after forming the solid tooth model of the user (101), the achieved solid tooth model is transferred into a three-dimensional computer model (102). Converting said solid model into a computer model can be realized with different programs. A computer model can be formed based on the program used during the conversion of the solid model to a computer model. The created computer model can be adjusted by preferably the three-dimensional drawing based on the computer program used. The user can use different methods for achieving the three-dimensional tooth model. In one embodiment of the invention, the mouth and tooth structure of the user is scanned by using a three- dimensional scanner. In another embodiment of the invention, preferably the mold of the tooth structure of the user is formed by using a tooth measurement spoon. After the mold of the tooth structure of the user is formed, said mold is filled and the solid tooth model is formed. The achieved solid tooth is scanned in the three- dimensional scanner and the computer model is formed. By using the above- mentioned methods, the solid tooth model is transferred into a three-dimensional computer model (102).

In one embodiment of the invention, after transforming the achieved solid tooth model into the three-dimensional computer model (102), the process step of making the parametric modeling of the tooth model and achieving the boundary curves on the parametric model surface (103) is initiated. In this embodiment of the invention, the parametric modeling process with the STL extension to be used in the three-dimensional printers is realized. Said parametric modeling process is the modeling process of the surfaces of the solid tooth model converted into a computer model with preferably the triangular surface elements. In this case, in the process of making parametric modeling of the tooth model that is transformed into a three-dimensional computer model (102), while carrying out the parametric modeling process with STL, the parametric modeling of the surface of the computer model is performed (Figure 2). The surface geometry of the three- dimensional computer model is illustrated by said parametric modeling. While the parametric modeling of the three-dimensional computer model is made, the surface geometry of the computer tooth model is divided into triangles or combined as triangles. In said STL parametric model, the triangles of which the surface of the tooth model is divided comprise points on X, Y, and Z axes in the coordinate plane and the normal of the points. The tooth model formed in the computer environment is viewed as a point cloud on the scanned surface. A sufficient similarity with the tooth structure of the user can be obtained by means of forming surfaces between the points which are seen in the coordinate plane.

In one embodiment, after the process step of making the parametric modeling of the tooth model which is transformed into three-dimensional computer model and achieving the boundary curves on the parametric model surface (103), the process step of determining the coordinates of X, Y and Z axes on the parametric tooth model surface and determining the inner and outer boundary points based on said coordinates (104) is realized. All points on the surface of the parametric tooth model have equivalents on X, Y, and Z axes in the coordinate plane. In the obtained STL tooth parametric model, a matrix is formed with the points on said X, Y, and Z axes. The matrix formed with the points on said X, Y, and Z axes completely constitute the parametric tooth model. While the parametric modeling of the tooth model is performed, software programs with different functions can be used in order to arrange the matrix constituted by the points on the X, Y, and Z axes. The sequencing of the points on X, Y, and Z-axes in the coordinate points matrix that do not have a specific order from the minimum value to maximum value can be realized with said software functions. The points in X, Y, and Z axes in the matrix of the coordinate points of the parametric tooth model is sequenced by means of said software function and are gathered in two planes as the ceiling and the floor. In the process step of making the parametric modeling of the tooth model which is transformed into a three-dimensional computer model and achieving the boundary curves on the parametric model surface (103), the tooth protector whose parametric model will be created can have different parameters for ceiling and floor.

In one embodiment of the invention, in the process step of making the parametric modeling of the tooth model which is transformed into three-dimensional computer model and achieving the boundary curves on the parametric model surface (103), while the parametric modeling of the tooth model is performed, preferably“stlread” function is used for arranging the matrix formed by the points in said X, Y and Z- axes.

In one embodiment of the invention, in the process step of making the parametric modeling of the tooth model which is transformed into three-dimensional computer model and achieving the boundary curves on the parametric model surface (103), different methods can be used to obtain the ceiling and floor curves of the tooth protector whose parametric model will be created. In one embodiment of the invention, after the sequencing of the maximum and minimum values of the points on the matrix formed by the points on X, Y, and Z-axes, the ceiling and floor points of the tooth model on the Z-axis can be determined. After the ceiling and floor points on the Z axis of the tooth model are determined, the midpoint on the Z-axis of the tooth model can be calculated by said software function. The points between the midpoint determined on the Z-axis on the parametric tooth model and the ceiling point are enabled to be positioned on a ceiling matrix; the points between the midpoint and the floor point are enabled to be positioned on a floor matrix. In this way, after the parametric tooth model is formed, the tooth model is enabled to be shaped with the points separated as floor and ceiling (Figure 3).

In one embodiment of the invention, in the process step of making the parametric modeling of the tooth model which is transformed into a three-dimensional computer model and achieving the boundary curves on the parametric model surface (103), the process of forming the surfaces of the tooth protector is initiated by separating the parametric tooth model into matrixes such as the ceiling and the floor. In total, four curves are formed, two of which are on the ceiling, and two of which are on the floor, in order to create surfaces that belong to the tooth protector. The ceiling and floor matrixes which are directly taken from the surface of the tooth model formed on the parametric tooth model are used in order to create two curves on the ceiling and floor.

The inner boundary points on the ceiling matrixes for the curve which will remain on the tongue portion of the teeth, the outer boundary points on the ceiling matrixes for the curve which will remain on the cheek part of the teeth are determined first of all during the formation of the ceiling curves by means of the ceiling and floor matrixes taken directly from the tooth model surface which is formed on the said parametric tooth model. The process of forming the above- mentioned ceiling curves is also used in the process of forming the floor curves. An average value in the X-axis according to the minimum and maximum values in the ceiling and floor point matrixes is found in order to determine the inner boundary points. The points that are smaller and greater than the value in the X- axis whose average is determined for each value defined in Y-axis in the ceiling and floor point matrixes are separated for determining the outer boundary points. The minimum and maximum values of the points that are smaller and larger than the average values taken according to X-axis are separated for each value in Y- axis separately. The inner and outer boundary points are obtained for the values on the determined X and Y- axes (Figure 4).

In one embodiment of the invention, after the process step of determining the coordinates of X, Y, and Z- axes on the parametric tooth model surface and determining the inner and outer boundary points based on said coordinates (104) is realized, suitable curves are created for the obtained inner and outer boundary points (105). Continuously formed curves are created by using the inner and outer boundary points obtained in the process step of making the parametric modeling of the tooth model which is transformed into three-dimensional computer model and achieving the boundary curves on the parametric model surface (103) (Figure 5). Different software programs can be used in order to create continuous curves. In another embodiment of the invention, in order to form continuous curves, the “Curve Fitting Tool” in the MATLAB is used.

In another embodiment of the invention, an algorithm is created in order to form a polynomial type curve with a preferred degree for forming continuous curves. At the same time, the methods of adapting the parameters by calculating the same which is suitable for a function of the point coordinates to which a curve will be assigned based on the preferred function and forming the curve by using control points and by using fewer parameters by using methods such as Hermite, Bezier, B-Spline, and Non-Uniform Rational B-Spline, etc. can be used.

In one embodiment of the invention after the process step of creating curves suitable for the obtained inner and outer boundary points (105), the process step of translating the formed boundary curves such that from each point they are perpendicular to the curve (106) is realized. Different curves are created by translating the same at a distance determined by the user that is vertical to the curves suitable to the inner and outer boundary points at each point. Said curves are used to form the outer surfaces of the tooth protector. The inner surface of the tooth protector is formed by the created parametric tooth surface. Increasing the parametric translation distance of the curves formed according to the inner and outer boundary points also increases the thickness for the ceiling and floor of the tooth protector. While the translated curves are obtained, the slope of the curve at certain intervals on the curve is calculated. The angular equivalent of the curve is found by using the calculated slope. The vertical translation angle to be made in the determined points by taking 90“phase difference in the counterclockwise direction of the found angle is calculated (Figure 6).

In one embodiment of the invention in the process step of translating the formed boundary curves such that from each point they are perpendicular to the curve (106), for the translation process of the curves, a transformation matrix is used. The first location of said points is accepted as the origin of the translation process in the translation process to be carried out for a preferred point on the boundary curves. The preferred points are translated by the preferred translation amount on the X-axis and it is rotated around the Z-axis in an amount of the calculated translation angle. After the application of translation and rotation processes, the values on X and Y axes that belong to the point where said processes are applied can change. The coordinates of the translated points are obtained by means of adding the obtained new coordinate value on X and Y axes to the coordinate values of the points themselves (Figure 7).

In one embodiment, after the process of translating the formed boundary curves such that from each point they are perpendicular to the curve (106), the processes of forming the shell model formed by the translated curves and manufacturing the tooth protector design by the three-dimensional printer with the formed shell model (107) are realized (Figure 8-10). The process of translating the boundary curves such that from each point they are perpendicular to the curve (106) is provided by changing the Z-axis value of each point depending on the fact that the boundary curves in the tooth model are formed in XY coordinate plane. The translation distances of the curves in the XY plane and X-axis constitute the parametric measures in the design of the shell model to be formed with said curves. The process of translating the curves obtained as a result of the processes made equally to the curves of the tooth model at each point is confirmed by means of calculating the distances between said curves (Figure 8). Start and end coordinates of the formed distance are shown in Figure 8. The other curves shown in Figure 8 belong to the tooth model. Surfaces formed with two different parameter sets are shown in Figure 8.

In the process of forming a shell model obtained from the translated curves and manufacturing the tooth protector by the three-dimensional printer with the formed shell model (107), a software function is used for forming the shell model with the translated curves. In another embodiment of the invention, in the process of forming shell model formed by the translated curves and manufacturing the tooth protector by the three-dimensional printer with the formed shell model (107), preferably a “surf2stl” software function is used for forming the shell model with the translated curves. Based on the operating system of said“surf2stl” function, there is a common curve for each surface between the surface before and after it. The coordinates of the curves translated such that they fulfill the abovementioned condition in X, Y, and Z- axes are given as an input to the“surf2stl” function and a shell model is formed (Figure 9).

In another embodiment of the invention, in the process of forming the shell model from the translated curves and manufacturing the tooth protector by the three- dimensional printer with the formed shell model (107), for forming the shell model, instead of a ready code“surf2stl”, a suitable algorithm is developed and the same result is obtained (Figures 9-10). Following the creation of said shell model, the obtained three-dimensional parametric tooth protector model can be printed out from the three-dimensional printer in a user-specific manner.