Abstract: An orthodontic appliance such as a bracket has bonding structure that provides a greater bond strength to the tooth in regions beneath an occlusal edge portion of the base in comparison to regions beneath at least one of a mesial edge portion, distal edge portion and occlusal edge portion of the base. The weaker bond strengths beneath the mesial edge portion, the distal edge portion and/or the gingival edge portion facilitate removal of the appliance by the orthodontist when desired. The higher bond strength beneath the occlusal edge portion is sufficient to securely retain the appliance on the tooth and safely resist the forces normally encountered during orthodontic treatment.

Abstract: Orthodontic archwires are packaged between pairs of flexible sheets that are releasably fixed to each other. The archwires are spaced apart from each other between the sheets and arranged in a nested array wherein a portion of one archwire is received within the U-shaped configuration of another archwire. Lines of weakness extend between adjacent pairs of the archwires for enabling detachment of one archwire from remaining archwires of the assembly when desired.

Abstract: A force module useful in moving individual malpositioned teeth or entire dental arches during orthodontic therapy includes an elongated body made of art elastomeric material, with couplings at each end of the body for connection to selected orthodontic appliances. The couplings are preferably spaced inwardly from opposite ends of the body to reduce bending stresses, and optionally an enlarged head of the body is provided to retain each coupling in place. In certain embodiments, the body has an enlarged middle section to reduce likelihood of fracture. A resilient core made of a metallic material is optionally received in the body to enhance the stiffness of the force module.

Abstract: Orthodontic adhesive is cooled below ambient temperature in order to facilitate applying the adhesive to the base of an orthodontic appliance. The adhesive is placed on a carrier and formed into a certain shape on the carrier, and then released from the carrier while cool. In one embodiment, a quantity of adhesive is placed on the base of the appliance, and the appliance is then moved to a cut-off die while the adhesive remains cool and relatively brittle; next, a stream of pressurized air fractures and removes excess adhesive from the appliance base.

Abstract: A package for an adhesive precoated dental appliance such as an orthodontic bracket includes a container having a well and a flange, and a cover that extends over an opening of the well. A pressure sensitive adhesive releasably connects the cover to the flange along a first region, and a hermetic seal extends between the cover and the flange along a second region that is located between the first region and the opening of the well. The hermetic seal cooperates with the pressure sensitive adhesive to provide a reliable, easily openable package. The hermetic seal also prevents volatile components of adhesive on the dental appliance from contacting the pressure sensitive adhesive and thereby decreases loss of the volatile components from within the package in order to extend the expected shelf life of the adhesive precoated appliance.

Abstract: Bond strengths of orthodontic appliances are enhanced by applying heat to heat softenable projections of a bonding base of the appliance, and then moving outer portions of the projections in lateral directions to present overhanging regions. The overhanging regions provide undercut areas that mechanically interlock with adhesive when the appliance is bonded to a tooth and the adhesive hardens. The method is useful for plastic appliances as well as other appliances that are made of materials exhibiting thermoplastic characteristics during at least one phase of their manufacture.