US 12,409,600 B2
Methods of forming a dental appliance
Chunhua Li, Cupertino, CA (US); and Yan Chen, Cupertino, CA (US)
Assigned to Align Technology, Inc., San Jose, CA (US)
Filed by Align Technology, Inc., San Jose, CA (US)
Filed on May 23, 2024, as Appl. No. 18/673,306.
Application 18/673,306 is a continuation of application No. 17/175,554, filed on Feb. 12, 2021, granted, now 12,023,846.
Application 17/175,554 is a continuation of application No. 15/990,383, filed on May 25, 2018, granted, now 10,919,209, issued on Feb. 16, 2021.
Application 15/990,383 is a continuation of application No. 14/318,283, filed on Jun. 27, 2014, abandoned.
Application 14/318,283 is a continuation of application No. 12/583,062, filed on Aug. 13, 2009, granted, now 8,765,031, issued on Jul. 1, 2014.
Prior Publication US 2024/0308128 A1, Sep. 19, 2024
Int. Cl. B29C 51/02 (2006.01); A61C 7/08 (2006.01); B29B 11/14 (2006.01); B29B 13/02 (2006.01); B29C 35/02 (2006.01); B29C 39/00 (2006.01); B29C 39/02 (2006.01); B29C 45/00 (2006.01); B29C 51/00 (2006.01); B29K 75/00 (2006.01); B29K 101/10 (2006.01); B29L 31/00 (2006.01)
CPC B29C 51/02 (2013.01) [A61C 7/08 (2013.01); B29B 11/14 (2013.01); B29B 13/023 (2013.01); B29C 35/02 (2013.01); B29C 39/006 (2013.01); B29C 39/026 (2013.01); B29C 45/0001 (2013.01); B29C 51/002 (2013.01); B29K 2075/00 (2013.01); B29K 2101/10 (2013.01); B29L 2031/753 (2013.01); B29L 2031/7532 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of forming a dental appliance, comprising:
partially curing a prepolymer mixture into a semi-solid polymer material having a first shape, wherein the first shape is a sheet;
placing the semi-solid polymer material over a dentition mold, wherein the semi-solid polymer material takes on a second shape corresponding to a shell having one or more cavities for receiving one or more teeth; and
fully curing the semi-solid polymer material by exposure to energy until the semi-solid polymer material thermosets in the second shape.
 
16. The method of claim 1, wherein placing the sheet of semi-solid polymer material over the positive dentition mold causes a first area of the sheet to become thinner than a second area of the sheet, wherein the first area of the sheet corresponds to a thinner occlusal area of the shell.