APPARATUS AND METHOD USABLE WITH AN INJECTION MOLDER FOR PRODUCING ARTICLES
An apparatus usable with an injection molder for producing articles includes a first mold support including a first mold, and a second mold support including a second mold and a first die. The first mold support is movable relative to the second mold support between a first and a second position. In the first position, the first mold and the second mold being brought together to form an injection molded article having at least one protrusion extending outwardly from the body and facing the second mold. In the second position, the first mold and the first die being brought together to subsequently form the article, the first die selectively subsequently forming an altered cross sectional region in the protrusion, forming an undercut in the altered cross sectional region or between the altered cross sectional region of the subsequently formed protrusion and the body, each article being separate and non-interlocking.
This application claims the benefit of and priority to U.S. Provisional Application No. 61/751,591 filed Jan. 11, 2013, and to U.S. Non-provisional application Ser. No. 14/153,269 filed Jan. 13, 2014, each of which is hereby incorporated by reference in its entirety.
FIELDThe present invention relates to orthodontic articles and more particularly to orthodontic brackets.
BACKGROUNDIn the past, various difficulties have been encountered in connection with the orthodontic necessity to apply corrective appliances to human teeth pursuant to which certain teeth are displaced to a position of better alignment, and/or occlusion.
One primary need in orthodontic corrections is the maintenance of relatively high tensile forces on the teeth, particularly in cases where substantial displacements are required.
In response, brackets have been utilized, i.e., wire guiding and wire anchoring means which do not encircle individual teeth. However, there continue to be challenges associated with such brackets, which are difficult to apply since the cold curing cement used to affix the brackets to the teeth does not adhere well to the brackets. In practice, this inadequate adhesion has resulted in the application of reduced forces, reducing the effectiveness of orthodontic corrective treatment.
There is a need in the art for an apparatus and method for reliably increasing adherence of orthodontic brackets to teeth surfaces for use in orthodontic corrective treatment.
SUMMARYIn an exemplary embodiment, an apparatus usable with an injection molder for producing articles, includes a first mold support comprising a first mold, and a second mold support comprising a second mold and a first die. The apparatus further includes the first mold support movable relative to the second mold support between a first position and a second position. The apparatus further includes in the first position, the first mold and the second mold being brought together to form an injection molded article comprising a body having at least one protrusion extending outwardly from the body and facing the second mold. The apparatus further includes in the second position, the first mold and the first die being brought together to form a subsequently formed article, the first die selectively subsequently forming a first altered cross sectional region in at least a first portion of the protrusion, forming a first undercut in the first altered cross sectional region or between the first altered cross sectional region of the protrusion and the body. The apparatus further includes the first undercut proximate to an end of the protrusion, the first die adapted to form a second altered cross sectional region in at least a second portion of the protrusion, forming a second undercut, the second undercut non-proximate to the end of the protrusion. The apparatus further includes each article being separate and non-interlocking relative to one another.
In another exemplary embodiment, an apparatus usable with an injection molder for producing articles, includes a first mold support comprising at least two first molds. The apparatus further includes a second mold support comprising at least two second molds and at least two first dies. The apparatus further includes the first mold support rotatably movable relative to the second mold support between a first position and a second position. The apparatus further includes in the first position, each of the corresponding first molds and second molds being brought together to form an injection molded article comprising a body having at least one protrusion extending outwardly from the body and facing the second mold. The apparatus further includes in the second position, each of the corresponding first molds and first dies being brought together to form a subsequently formed article, each first die selectively subsequently forming a first altered cross sectional region in at least a first portion of the protrusion. The apparatus further includes forming a first undercut in the first altered cross sectional region or between the first altered cross sectional region of the protrusion and the body, the first undercut proximate to an end of the protrusion. The apparatus further includes the first die adapted to form a second altered cross sectional region in at least a second portion of the protrusion, forming a second undercut, the second undercut non-proximate to the end of the protrusion. The apparatus further includes each article being separate and non-interlocking relative to one another.
In another exemplary embodiment, a method of producing injection molded articles, includes providing a first mold support comprising a first mold, a second mold support comprising a second mold and a first die. The method further includes bringing the first mold support and the second mold support together in a first position, the first mold and the second mold being brought together to form an injection molded article therebetween, each article being separate and non-interlocking relative to one another, the article having at least one protrusion facing the second mold. The method further includes moving the first mold support away from the second mold support, and moving the first mold support relative to the second mold support. The method further includes bringing the first mold support and the second mold support together in a second position, the first mold and the first die being brought together to form a subsequently formed article, the first die selectively subsequently forming a first altered cross sectional region in at least a first portion of the protrusion, forming a first undercut in the first altered cross sectional region or between the first altered cross sectional region of the protrusion and the body, the first undercut proximate to an end of the protrusion, the first die adapted to form a second altered cross sectional region in at least a second portion of the protrusion, forming a second undercut, the second undercut non-proximate to the end of the protrusion.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
Exemplary embodiments are directed to apparatus and method usable with an injection molder for producing articles, such as orthodontic brackets comprising bodies having at least one protrusion extending outwardly from the corresponding bodies. An altered cross sectional region is formed in at least a portion of at least one protrusion, forming an undercut in the altered cross sectional region or between the altered cross sectional region of the at least one protrusion and the body, as will be discussed in further detail below. The undercut provides enhanced adherence of the subsequently formed orthodontic brackets to teeth surfaces for use in orthodontic corrective treatment.
For purposes herein, an undercut is intended to correspond to an altered cross sectional region formed in a protrusion that is positioned in the altered cross sectional region or between the altered cross sectional region of the protrusion and the body of an article. Stated another way, in or coincident with the altered cross sectional region or between the body of an article and the altered cross sectional region of a protrusion extending outwardly from the body, the protrusion of a subsequently formed article includes a subsequently formed portion having at least a localized altered cross sectional area relative to the cross sectional area of the protrusion. When the localized altered cross sectional region is greater than the cross sectional area of the protrusion, the undercut or region of reduced cross sectional area is positioned between the localized altered cross sectional region and the body. However, when the localized altered cross sectional region is less than the cross sectional area of the protrusion, the undercut corresponds to the localized altered cross sectional region itself, such as at least a partial recess formed in the side surface of the protrusion.
Neither arrangement can be produced by conventional molds of an injection molder, as a die constructed to produce protrusions having undercuts cannot be nondestructively separated from corresponding injection molded articles (i.e., the corresponding rigid injection molded articles would be destroyed while separating the molds producing the article).
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In one embodiment, mold support 20 structurally supports one mold 44 and one die 48, while in another embodiment, mold support 20 structurally supports more than two molds 44 and more than two dies 48.
In operation, as shown in
In one embodiment, while mold 32 associated with the 12 o'clock position (
Once injection molded article 14 has been formed as discussed above, as further shown in
Once mold 32 associated with numeral 1 has been rotated clockwise from the 12 o'clock position (
In one embodiment, while mold 32 associated with the 3 o'clock position (
In one embodiment, while molds 32 are brought together with corresponding molds 44 to form injection molded articles 14, substantially simultaneously, the remaining molds 32 are brought together with corresponding dies 48 to create subsequently formed articles 16. In other words, apparatus 12 can operate continuously to form or create subsequently formed articles 16 (from previously formed injection molded articles 14) while substantially simultaneously forming additional articles 14. That is, with each 90 degree rotation of mold support portion 22 of mold support 18 relative to mold support 20, one pair of injection molded articles 14 are created, and one pair of subsequently formed articles 16 are formed or created continuously by the apparatus of the present disclosure.
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In one embodiment, protrusions 17 can define a closed geometry, such as a substantially circular or substantially ovular profile, while in another embodiment, protrusions 17 can define an open geometry, such as a profile similar to a crescent moon, or any suitable shape. The protrusions may be positioned in any suitable arrangement relative to one another, singly or collectively.
It is to be understood that the profile of the die surface of the die is not limited to closely resemble the protrusion profile formed in the injection molded article 14, so long as the profiles of the subsequently formed protrusions 17 have a desired undercut profile. That is, in one embodiment, the position of altered cross sectional regions can be formed in a position other than the end or in close proximity to the end of the subsequently formed protrusions, if desired. In another embodiment, the position of the die surface is movable relative to the mold support. That is, the die surface may be positioned at a desired spacing from the protrusion surface of the injection molded article when the corresponding mold supports are brought together, which spacing includes positioning the die surface such that a selective amount of interference or abutment occurs between ends of one or more protrusions of the injection molded article 14 and the die surface, such that the subsequently formed protrusion(s) is selectively controllable. In one embodiment, a non abutting spacing remains between the die surface and the corresponding surface of the injection molded article 14 when the mold supports are brought together.
In addition, the die can be brought into a predetermined range of at least one position relative to the protrusion(s) of the injection molded article for a corresponding predetermined range of time for subjecting at least a portion of the protrusion(s) to one or more of a predetermined temperature range and a predetermined pressure range for forming the undercut. That is, the temperature of the die (of course, including the die surface) can be selectively controlled as a function of distance or proximity of the die from the protrusion(s) of the injection molded article in combination with a predetermined rate of time. In addition, the temperature of portions of the die can be selectably controlled over a predetermined range of temperatures as well as a predetermined rate of time. In other words, the temperature of the die (and even portions of the die) can be selectively controlled in combination with the speed of travel of the die (toward and/or away from protrusion(s) of the injection molded article; such speeds not limited to being the same in either direction) and/or the amount of proximity or spacing from the protrusion(s), including a range of abutment between the die and the protrusion(s) of the injection molded article. Stated another way, the die can be selectively controlled over a broad range of temperatures, such temperatures also being selectively controllable relative to the speed and/or distance from the protrusion(s), including interference or abutment, as well as selective control of time. In one embodiment, the die may be configured to remain in a non-moving position (also referred to as dwell time) for at least a portion of the time that the mold supports are brought together. In one embodiment, the die selectively controls a surface feature of at least a portion of the protrusion(s). For example, if the die surface contacts the protrusion(s), the surface roughness of the die may be transferred at least to the extent of the amount of contact of the protrusion(s) and the die surface. As a result of the extent of control of the die relative to the protrusion(s) of the injection molded article, at least the position and magnitude of undercut may be selectively controlled for the protrusion(s), and the amount of subsequent forming of the protrusion(s) may be altered during production.
It is also to be understood that materials which may be used in the apparatus can be liquid or powdered forms of ceramic, metal, plastic material or a combination thereof, depending upon the application.
It is also to be understood that while the article disclosed is an orthodontic bracket, the apparatus of the present disclosure may also be used for any number of other injection molded articles in which a secondary forming operation subsequent to production of the injection molded article can provide beneficial effects, not being limited to forming undercuts, such as surface features or other beneficial properties derivable from such secondary forming operations.
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While the foregoing specification illustrates and describes exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material including dopants to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims
1. An apparatus usable with an injection molder for producing articles, comprising:
- a first mold support comprising a first mold;
- a second mold support comprising a second mold and a first die;
- the first mold support movable relative to the second mold support between a first position and a second position;
- wherein in the first position, the first mold and the second mold being brought together to form an injection molded article comprising a body having at least one protrusion extending outwardly from the body and facing the second mold;
- wherein in the second position, the first mold and the first die being brought together to form a subsequently formed article, the first die selectively subsequently forming a first altered cross sectional region in at least a first portion of the protrusion, forming a first undercut in the first altered cross sectional region or between the first altered cross sectional region of the protrusion and the body, the first undercut proximate to an end of the protrusion, the first die adapted to form a second altered cross sectional region in at least a second portion of the protrusion, forming a second undercut, the second undercut non-proximate to the end of the protrusion;
- wherein each article being separate and non-interlocking relative to one another.
2. The apparatus of claim 1, wherein the first mold support is rotatably movable about an axis relative to the second mold support.
3. The apparatus of claim 1, wherein the first mold support is movable along a line relative to the second mold support.
4. The apparatus of claim 1, wherein at least the first mold support comprises a plurality of first molds and the second mold support comprises at least one second mold and at least one first die, the apparatus operable such that once at least one first mold and at least one second mold have been brought together to form the article (the first position), when the at least one first mold and the at least one first die are then brought together to form the subsequently formed article (the second position), another of the at least one first mold and another of the at least one second mold are substantially simultaneously brought together to form another article (a third position).
5. The apparatus of claim 4, wherein the corresponding first molds, second mold(s) and first die(s) of the apparatus operate continuously to form subsequently formed articles while substantially simultaneously forming additional articles.
6. The apparatus of claim 1, wherein the protrusion comprises an open geometry.
7. The apparatus of claim 1, wherein the protrusion comprises a closed geometry.
8. The apparatus of claim 1, wherein the first die is brought into a predetermined range of at least one position relative to the protrusion for a corresponding predetermined range of time for subjecting the at least a first portion and the at least a second portion of the protrusion to one or more of a predetermined temperature range and a predetermined pressure range for forming the first undercut and the second undercut.
9. The apparatus of claim 8, wherein the temperature of portions of the first die is selectively controllable for the predetermined range of at least one position and the corresponding predetermined range of time.
10. The apparatus of claim 1, wherein the article is formed from a ceramic, metal, plastic material or a combination thereof.
11. The apparatus of claim 8, wherein the first die selectively controls a surface feature of at least one of the at least a first portion and the at least a second portion of the protrusion.
12. The apparatus of claim 1, wherein the article is an orthodontic bracket.
13. An apparatus usable with an injection molder for producing articles, comprising:
- a first mold support comprising at least two first molds;
- a second mold support comprising at least two second molds and at least two first dies;
- the first mold support rotatably movable relative to the second mold support between a first position and a second position;
- wherein in the first position, each of the corresponding first molds and second molds being brought together to form an injection molded article comprising a body having at least one protrusion extending outwardly from the body and facing the second mold;
- wherein in the second position, each of the corresponding first molds and first dies being brought together to form a subsequently formed article, each first die selectively subsequently forming a first altered cross sectional region in at least a first portion of the protrusion, forming a first undercut in the first altered cross sectional region or between the first altered cross sectional region of the protrusion and the body, the first undercut proximate to an end of the protrusion, the first die adapted to form a second altered cross sectional region in at least a second portion of the protrusion, forming a second undercut, the second undercut non-proximate to the end of the protrusion;
- wherein each article being separate and non-interlocking relative to one another.
14. The apparatus of claim 13, wherein the corresponding first molds, second molds and first dies of the apparatus operate continuously to form subsequently formed articles while substantially simultaneously forming additional articles.
15. The apparatus of claim 13, wherein each first die is brought into a predetermined range of at least one position relative to the corresponding protrusion for a corresponding predetermined range of time for subjecting the at least a first portion and the at least a second portion of the protrusion to one or more of a predetermined temperature range and a predetermined pressure range for forming the undercut.
16. The apparatus of claim 15, wherein the temperature of portions of the first die is selectively controllable for the predetermined range of at least one position and the corresponding predetermined range of time.
17. The apparatus of claim 13, wherein the article is formed from a ceramic, a metal, a plastic or a combination thereof.
18. The apparatus of claim 15, wherein the first die selectively controls a surface feature of the at least a first portion and the at least a second portion of the protrusion.
19. The apparatus of claim 13, wherein the article is an orthodontic bracket.
20. A method of producing injection molded articles, comprising:
- providing a first mold support comprising a first mold, a second mold support comprising a second mold and a first die,
- bringing the first mold support and the second mold support together in a first position, the first mold and the second mold being brought together to form an injection molded article therebetween, wherein each article being separate and non-interlocking relative to one another, the article having at least one protrusion facing the second mold;
- moving the first mold support away from the second mold support;
- moving the first mold support relative to the second mold support;
- bringing the first mold support and the second mold support together in a second position, the first mold and the first die being brought together to form a subsequently formed article, the first die selectively subsequently forming a first altered cross sectional region in at least a first portion of the protrusion, forming a first undercut in the first altered cross sectional region or between the first altered cross sectional region of the protrusion and the body, the first undercut proximate to an end of the protrusion, the first die adapted to form a second altered cross sectional region in at least a second portion of the protrusion, forming a second undercut, the second undercut non-proximate to the end of the protrusion.
21. The method of claim 20, wherein providing a first mold support comprises a plurality of first molds, and subsequent to moving the first mold support relative to the second mold support, bringing the first mold support and the second mold support together such that once at least one first mold and at least one second mold have been brought together to form the article, when the at least one first mold and the at least one first die are then brought together to form the subsequently formed article, another first of the at least one mold and another of the at least one second mold are substantially simultaneously brought together to form another article.
22. The method of claim 20, wherein the article is an orthodontic bracket.
Type: Application
Filed: Dec 4, 2019
Publication Date: Apr 2, 2020
Inventors: Michael ANDERSON (Bradenton, FL), David Richard MARONEY (Cedar, MN)
Application Number: 16/703,087