1111111111111111 IIIIII IIIII 111111111111111111111111111111 IIIII IIIII IIIII IIIIII IIII 11111111
`US 20070031774Al
`
`c19) United States
`02) Patent Application Publication
`Cinader, JR. et al.
`
`(10) Pub. No.: US 2007/0031774 Al
`Feb. 8, 2007
`(43) Pub. Date:
`
`(54) REGISTERING PHYSICAL AND VIRTUAL
`TOOTH STRUCTURES WITH MARKERS
`
`(22) Filed:
`
`Aug. 3, 2005
`
`(75)
`
`Inventors: David K. Cinader JR., Yorba Linda,
`CA (US); .James D. Cleary, Glendora,
`CA (US); Oliver L. Puttler, La
`Crescenta, CA (US); Richard E. Raby,
`North St. Paul, MN (US)
`
`Correspondence Address:
`3M INNOVATIVE PROPERTIES COMPANY
`PO BOX 33427
`ST. PAUL, MN 55133-3427 (US)
`
`(73) Assignee: 3M Innovative Properties Company
`
`(21) Appl. No.:
`
`11/195,952
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`A61C 3/00
`(2006.01)
`(52) U.S. Cl. .......... ,,,, ...................... ,, ........ 433/24; 433/213
`
`(57)
`
`ABSTRACT
`
`In general, the invention relates to techniques for registering
`a three-dimensional (3D) coordinate system of a physical
`model of a patient's tooth stmcture to a 3D coordinate
`system of a virtual model of the same tooth structure.
`Techniques are described to register the complex geometries
`of the physical and virtual tooth structures by using regis(cid:173)
`tration markers associated with the physical model.
`
`COLLECT PATIENT IDENTITY AND BASIC
`PATIENT INFORMATION AND CREATE PATIENT
`RECORD IN DATABASE
`
`ACCESS DATABASE AND CREATE MODEL
`RECORD FOR NEW MODEL
`
`110
`
`112
`
`SELECT DENTAL IMPRESSION TRAY
`
`114
`
`UPDATE DATABASE TO ASSOCIATE PATIENT
`RECORD WITH MODEL RECORD
`
`116
`
`PLACE MARKERS ON PATIENT'S TEETH
`
`118
`
`FORM IMPRESSION OF PATIENT'S TOOTH
`STRUCTURE
`
`120
`
`REMOVE MARKERS FROM PATIENT'S TEETH
`
`122
`
`UPDATE MODEL RECORD TO
`IMPRESSED STATUS
`
`124
`
`STERILIZE DENTAL IMPRESSION TRAY AND
`SHIP TO MANUFACTURING FACILITY
`
`126
`
`0001
`
`Exhibit 1031 page 1 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 1 of 17
`
`US 2007/0031774 Al
`
`~ Oz>-
`
`r (!)
`~o~ col
`- z
`o 0 r
`Zea
`
`T"""
`
`r
`z
`w col
`~
`a..
`
`(.)
`~
`z rol
`....J
`()
`
`c=;>
`~
`
`z
`...Jo
`<(Cl)>-
`rCl)<Col
`z w a: T"""
`WCI:r
`oa..
`~
`
`~
`
`(!)
`z
`~~
`r -
`()~ C\11
`<( () T"""
`LL<(
`::) LL
`z
`<(
`~
`
`c=;>
`
`~
`
`0002
`
`Exhibit 1031 page 2 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 2 of 17
`
`US 2007/0031774 Al
`
`COLLECT PATIENT IDENTITY AND BASIC
`PATIENT INFORMATION AND CREATE PATIENT
`RECORD IN DATABASE
`
`+
`
`ACCESS DATABASE AND CREATE MODEL
`RECORD FOR NEW MODEL
`
`t
`
`SELECT DENTAL IMPRESSION TRAY
`
`t
`
`UPDATE DATABASE TO ASSOCIATE PATIENT
`RECORD WITH MODEL RECORD
`
`+
`
`FORM IMPRESSION OF PATIENT'S TOOTH
`STRUCTURE
`
`t
`
`UPDATE MODEL RECORD TO
`IMPRESSED STATUS
`
`t
`
`STERILIZE DENTAL IMPRESSION TRAY AND
`SHIP TO MANUFACTURING FACILITY
`
`20
`_/
`
`2
`2
`_./
`
`2 4
`_/
`
`2
`6
`L,/
`
`28
`_./
`
`30 v
`
`32
`
`/
`
`Fig. 2
`
`0003
`
`Exhibit 1031 page 3 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 3 of 17
`
`US 2007/0031774 Al
`
`RECEIVE DENTAL IMPRESSION TRAY AT
`MANUFACTURING FACILITY
`
`+
`
`STERILIZE AND FORM CASTING
`
`+
`
`UPDATE MODEL RECORD
`
`+
`
`CURE AND TRIM CASTING
`
`+
`
`ATTACH CASTING TO PEDESTAL
`
`+
`
`SCAN CASTING TO GENERATE 3D DIGITAL MODEL
`
`i
`
`EXECUTE BEST FIT ALGORITHM TO REGISTER
`COORDINATE SYSTEMS OF CASTING
`TO DIGITAL MODEL
`
`i
`
`SEGMENT 3D DATA INTO INDIVIDUAL
`COMPONENTS
`
`4
`0
`l-/
`
`4 2
`_,/
`
`4 4
`_,/
`
`4 6
`_,/
`
`4 8
`_,/
`
`5 0
`
`/
`
`52
`L/
`
`54
`_,/
`
`A
`
`Fig. 3A
`
`0004
`
`Exhibit 1031 page 4 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 4 of 17
`
`US 2007/0031774 Al
`
`A
`
`IMPORT 3D DATA FOR EACH COMPONENT
`INTO MODEL RECORD
`
`+
`
`COMMUNICATE MODEL TO CLINICIAN COMPUTER
`
`t
`
`RECEIVE PRESCRIPTION DATA AND
`VIRTUAL BRACKET PLACEMENT DATA
`
`t
`
`PLACE APPLIANCES ON CASTING
`
`+
`
`FORM INDIRECT BONDING TRAY
`
`!
`
`TRIM INDIRECT BONDING TRAY
`
`t
`
`UPDATE MODEL RECORD
`
`t
`
`SHIP INDIRECT BONDING TRAY TO CLINIC
`
`Fig. 3B
`
`6
`5
`l-/
`
`5 8
`
`J
`
`60 v
`
`6 2
`v
`
`6 4
`
`6 6
`
`6 8
`
`7 0
`
`J
`
`J
`
`J
`
`J
`
`0005
`
`Exhibit 1031 page 5 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 5 of 17
`
`US 2007/0031774 Al
`
`81
`
`Fig. 4
`
`83
`
`Fig. 5A
`
`Fig. 5B
`
`84
`
`86 cl
`
`0006
`
`Exhibit 1031 page 6 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 6 of 17
`
`US 2007/0031774 Al
`
`Fig. 6
`
`Fig. 7
`
`0007
`
`Exhibit 1031 page 7 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 7 of 17
`
`US 2007/0031774 Al
`
`106
`
`✓100
`
`108
`
`104
`
`Fig. 8
`
`0008
`
`Exhibit 1031 page 8 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 8 of 17
`
`US 2007/0031774 Al
`
`Scan
`Impression
`I
`
`-150 Scan Patient's -152
`Teeth
`
`Pre-existing
`154
`3D Tooth Data,_.
`I
`
`Attach Pedestal to Tooth
`Structure in Virtual ~ 1 s6
`Space
`
`Generate Physical Model -158
`With Attached Pedestal
`
`'
`Mate Pedestal to Robotic
`Device for Automatic -160
`Bracket Replacement
`
`Fig. 9
`
`0009
`
`Exhibit 1031 page 9 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 9 of 17
`
`US 2007/0031774 Al
`
`~90
`
`92
`
`+z
`
`+x_j+y
`
`(0, 0, 0)
`
`Fig. JOA
`
`~90
`
`-y
`
`+zL+x
`
`(0, 0, 0)
`
`Fig. JOB
`
`0010
`
`Exhibit 1031 page 10 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 10 of 17
`
`US 2007/0031774 Al
`
`y-93
`
`+z l
`
`958
`
`b
`0
`0
`'.:::t
`
`&_948
`
`094A
`
`+y
`.......... _Ol9----------------.I --+x
`(o. o. o) I
`4.000"
`
`Fig. llA
`
`-y
`
`~
`
`l
`LO
`N
`0 +z
`(o. o, o) I
`
`94A
`
`94B
`
`94C y-93
`
`+x
`
`4.000"
`
`Fig. JIB
`
`0011
`
`Exhibit 1031 page 11 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 11 of 17
`
`US 2007/0031774 Al
`
`+z
`
`l
`
`b
`0
`0
`""2"
`
`+y
`()18-------------------l --+x
`(0, 0,0) 1 - 1 - - - - 4.000" - - - - -
`
`Fig. 12A
`
`-y
`
`l
`
`90
`
`93
`
`0
`--'-'--~1----....L41l~--....un,;:i,__ _ _ ..um.:i..__ __ _,J ---+x
`(0, 0, 0)
`
`4.000"
`
`Fig. 12B
`
`0012
`
`Exhibit 1031 page 12 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication
`
`Feb. 8, 2007 Sheet 12 of 17
`
`US 2007/0031774 Al
`
`-y
`
`l
`
`I
`
`0
`LC)
`r---
`i:o T"""
`N
`
`90
`
`96
`
`~ l _ + z& - - - ~ - - - = - - - - ~ - - t - ~ _ _ +x
`(0, 0, 0) 1 - - - - - - 4.000" --------i
`Fig. 13
`
`+z l
`--
`
`0
`0
`0
`"'-f"
`
`"'98
`©@ ©i
`
`@@@ 0
`@@ @@
`@
`®
`@
`@
`@@
`@@
`®
`@)
`@@
`@@
`©
`@
`
`+y
`
`(o, o, o) I
`
`4.000"
`Fig. 14
`
`r--97
`
`99
`
`+x
`
`0013
`
`Exhibit 1031 page 13 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 13 of 17
`
`US 2007/0031774 Al
`
`-y
`
`r
`
`0
`LO
`r-,,..
`N
`
`105
`
`101
`
`96
`
`103
`
`(0, 0, 0)1--1 - - - 4.000"
`Fig. 15
`
`103
`
`0
`
`LO
`r-,,..
`00
`0
`
`105
`
`4.000"
`Fig. 16
`
`+y
`
`(0, 0, 0)
`
`+x +------«l+r
`
`-y
`
`0
`LO
`r-,,..
`N
`
`97
`
`0014
`
`Exhibit 1031 page 14 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 14 of 17
`
`US 2007/0031774 Al
`
`COLLECT PATIENT IDENTITY AND BASIC
`
`PATIENT INFORMATION AND CREATE PATIENT - 110
`
`RECORD IN DATABASE
`
`,,
`ACCESS DATABASE AND CREATE MODEL
`RECORD FOR NEW MODEL
`,,
`SELECT DENTAL IMPRESSION TRAY
`
`i - - - 112
`
`114
`
`1W
`
`UPDATE DATABASE TO ASSOCIATE PATIENT
`RECORD WITH MODEL RECORD
`
`- 116
`PLACE MARKERS ON PATIENT'S TEETH - 118
`
`,,
`
`,,
`FORM IMPRESSION OF PATIENT'S TOOTH _1
`20
`STRUCTURE
`
`1'
`
`REMOVE MARKERS FROM PATIENT'S TEETH - 122
`
`UPDATE MODEL RECORD TO
`IMPRESSED STATUS
`
`24
`r---1
`
`1•
`STERILIZE DENTAL IMPRESSION TRAY AND
`SHIP TO MANUFACTURING FACILITY
`Fig. 17
`
`- 1
`26
`
`0015
`
`Exhibit 1031 page 15 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 15 of 17
`
`US 2007/0031774 Al
`
`~128
`
`Fig. 18
`
`130~
`
`132
`
`Fig. 19
`
`0016
`
`Exhibit 1031 page 16 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 16 of 17
`
`US 2007/0031774 Al
`
`133
`
`Fig. 20
`
`~134
`
`Fig. 21
`
`0017
`
`Exhibit 1031 page 17 of 29
`DENTAL IMAGING
`
`

`

`Patent Application Publication Feb. 8, 2007 Sheet 17 of 17
`
`US 2007/0031774 Al
`
`138~ 0 d'
`0
`(}
`0
`0 0
`~00<>
`
`Fig. 22
`
`139
`
`138
`
`131 Fig. 23
`
`Fig. 24
`
`140
`
`137
`
`0018
`
`Exhibit 1031 page 18 of 29
`DENTAL IMAGING
`
`

`

`US 2007 /0031774 Al
`
`Feb. 8,2007
`
`1
`
`REGISTERING PHYSICAL AND VIRTUAL TOOTH
`STRUCTURES WITH MARKERS
`
`TECHNICAL FIELD
`
`[0001] The invention relates to orthodontics and, more
`particularly, computer-based techniques for assisting orth(cid:173)
`odontic diagnosis and treatment.
`
`BACKGROUND
`
`[0002] The field of orthodontics is concerned with repo(cid:173)
`sitioning and aligning a patient's teeth for improved occlu(cid:173)
`sion and aesthetic appearance. For example, orthodontic
`treatment often involves the use of tiny slotted appliances,
`known as brackets, which are fixed to the patient's anterior,
`cuspid, and bicuspid teeth. An archwire is received in the
`slot of each bracket and serves as a track to guide movement
`of the teeth to desired orientations. The ends of the archwire
`are usually received in appliances known as buccal tubes
`that are secured to the patient's molar teeth.
`
`[0003] A number of orthodontic appliances in commercial
`use today are constructed on the principle of the "straight
`wire concept" developed by Dr. Lawrence F. Andrews,
`D.D.S. In accordance with this concept, the shape of the
`appliances, including the orientation of the slots of the
`appliances, is selected so that the slots are aligned in a flat
`reference plane at the conclusion of treatment. Additionally,
`a resilient archwire is selected with an overall curved shape
`that normally lies in a flat reference plane.
`
`[0004] When the archwire is placed in the slots of the
`straight wire appliances at the beginning of orthodontic
`treatment, the archwire is often deflected upwardly or down(cid:173)
`wardly from one appliance to the next in accordance with the
`patient's malocclusions. However, the resiliency of the
`archwire tends to return the archwire to its normally curved
`shape that lies in a flat reference plane. As the archwire shifts
`toward the flat reference plane, the attached teeth are moved
`in a corresponding fashion toward an aligned, aesthetically
`pleasing array.
`
`[0005]
`In general, orthodontic appliances that are adapted
`to be adhesively bonded to the patient's teeth are placed on
`the teeth by either one of two methods: a direct bonding
`method, or an indirect bonding method. In the direct bond(cid:173)
`ing method, the appliance and adhesive are grasped with a
`pair of tweezers or other hand instrument and placed by the
`practitioner on the surface of the tooth in an approximate
`desired location. Next, the appliance is shifted along the
`surface of the tooth as needed until the practitioner is
`satisfied with its position. Once the appliance is in its
`precise, intended location, the appliance is pressed firmly
`onto the tooth to seat the appliance in the adhesive. Excess
`adhesive in areas adjacent the base of the appliance is
`removed, and the adhesive is then allowed to cure and fix the
`appliance firmly in place. Typical adhesives include light(cid:173)
`curable adhesives that begin to harden upon exposure to
`actinic radiation, and two-component chemical-cure adhe(cid:173)
`sives that begin to harden when the components are mixed
`together.
`
`[0006] While the direct bonding technique described
`above is in widespread use and is considered satisfactory by
`many, there are shortcomings that are inherent with such a
`technique. For example, access to surfaces of malposed teeth
`
`may be difficult. In some instances, and particularly in
`connection with posterior teeth, the practitioner may have
`difficulty seeing the precise position of the bracket relative
`to the tooth surface. Additionally, the appliance may be
`unintentionally bumped from its intended location during
`the time that the excess adhesive is being removed adjacent
`the base of the appliance.
`[0007] Another problem associated with the direct bond(cid:173)
`ing technique described above concerns the significant
`length of time needed to carry out the procedure of bonding
`each appliance to each individual tooth. Typically, the prac(cid:173)
`titioner will attempt to ensure that each appliance is posi(cid:173)
`tioned in its precise, intended location before the adhesive is
`cured, and some time may be necessary before the practi(cid:173)
`tioner is satisfied with the location of each appliance. At the
`same time, however, the patient may experience discomfort
`and have difficulty in remaining relatively motionless, espe(cid:173)
`cially if the patient is an adolescent. As can be appreciated,
`there are aspects of the direct bonding technique that can be
`considered a nuisance for both the practitioner and for the
`patient.
`[0008]
`Indirect bonding techniques often avoid many of
`the problems noted above. In general, indirect bonding
`techniques known in the past have involved the use of a
`transfer tray having a shape that matches the configuration
`of at least part of a patient's dental arch. A set of appliances
`such as brackets are releasably connected to the tray at
`certain, predetermined locations. Adhesive is applied to the
`base of each appliance, and the tray is then placed over the
`patient's teeth until such time as the adhesive hardens. Next,
`the tray is detached from the teeth as well as from the
`appliances, with the result that all of the appliances previ(cid:173)
`ously connected to the tray are now bonded to the respective
`teeth at their intended, predetermined locations.
`[0009]
`In more detail, one method of indirect bonding of
`orthodontic appliances includes the steps of taking an
`impression of each of the patient's dental arches and then
`making a replica plaster or "stone" model from each impres(cid:173)
`sion. Optionally, a soap solution (such as Model Glow brand
`solution from Whip Mix Corporation) or wax is applied to
`the stone model. A separation solution (such as COE-SEP
`brand tinfoil substitute from GC America, Inc.) is then
`applied to the stone model and allowed to dry. If desired, the
`teeth of the model can be marked with a pencil to assist in
`placing the brackets in ideal positions.
`[0010] Next, the brackets are bonded to the stone models.
`Optionally, the bonding adhesive can be a chemical curing
`adhesive (such as Concise brand adhesive from 3M) or a
`light-curable adhesive (such as Transbond XT brand adhe(cid:173)
`sive or Trans bond LR brand adhesive, from 3M). Optionally,
`the brackets may be adhesive precoated brackets such as
`those described in U.S. Pat. Nos. 5,015,180, 5,172,809,
`5,354,199 and 5,429,299.
`[0011] A transfer tray is then made by placing a matrix
`material over the model as well as over the brackets placed
`on the model. For example, a plastic sheet matrix material
`may be held by a frame and exposed to radiant heat. Once
`the plastic sheet material has softened, it is placed over the
`model and the brackets. Air in the space between the sheet
`material and the model is then evacuated, and the plastic
`sheet material assumes a configuration that precisely
`matches the shape of the replica teeth of the stone model and
`the attached brackets.
`
`0019
`
`Exhibit 1031 page 19 of 29
`DENTAL IMAGING
`
`

`

`US 2007 /0031774 Al
`
`Feb. 8,2007
`
`2
`
`[0012] The plastic material is then allowed to cool and
`harden to form a tray. The tray and the brackets (which are
`embedded in an interior wall of the tray) are then detached
`from the stone model and sides of the tray are trimmed as
`may be desired. Once the patient has returned to the office,
`a quantity of adhesive is placed on the base of the bracket,
`and the tray with the embedded brackets is then placed over
`the matching portions of the patient's dental arch. Since the
`configuration of the interior of the tray closely matches the
`respective portions of the patient's dental arch, each bracket
`is ultimately positioned on the patient's teeth at precisely the
`same location that corresponds to the previous location of
`the same bracket on the stone model.
`
`[0013] Both light-curable adhesives and chemical curing
`adhesives have been used in the past in indirect bonding
`techniques to secure the brackets to the patient's teeth. If a
`light-curable adhesive is used, the tray is preferably trans(cid:173)
`parent or translucent. If a two-component chemical curing
`adhesive is used, the components can be mixed together
`immediately before application of the adhesive to the brack(cid:173)
`ets. Alternatively, one component may be placed on each
`bracket base and the other component may be placed on the
`tooth surface. In either case, placing of the tray with the
`embedded brackets on corresponding portions of the
`patient's dental arch enables the brackets to be bonded to the
`teeth as a group using only a short amount of time that the
`patient is occupying the chair in the operatory. With such a
`technique, individual placement and positioning of each
`bracket in seriatim fashion on the teeth is avoided.
`
`[0014] A variety of transfer trays and materials for transfer
`trays have been proposed in the past. For example, some
`practitioners use a soft sheet material (such as Bioplast tray
`material from Scheu-Dental GmbH or Great Lakes Orth(cid:173)
`odontics, Ltd.) for placement over the stone model and the
`appliances on the model. Either a vacuum or positive
`pressure is applied to respectively pull or push the soft
`material into intimate contact with the model and the appli(cid:173)
`ances on the model. Next, a stiffer sheet material (such as
`Biocryl sheet material, from Scheu-Dental GmbH or Great
`Lakes Orthodontics, Ltd.) is formed over the softer sheet
`material, again using a either a vacuum or positive pressure
`forming technique. The stiffer material provides a backbone
`to the tray, while the softer material initially holds the
`appliances and yet is sufficiently flexible to release from the
`appliances after the appliances have been fixed to the
`patient's teeth.
`
`[0015]
`It has also been proposed in the past to use a
`silicone impression material or a bite registration material
`(such as Memosil 2, from Heraeus-Kulzer GmbH-& Co.
`KG). The silicone material is applied over the appliances
`that are attached to the study model so that the appliances are
`partially encapsulated.
`
`[0016]
`In an article entitled "A New Look at Indirect
`Bonding" by Moskowitz et al. (Journal of Clinical Orth(cid:173)
`odontics, Volume XXX, Number 5, May 1996, pages 277 et
`sec.), a technique for making indirect bonding trays is
`described using Reprosil
`impression material
`(from
`Dentsply International). The impression material is placed
`with a syringe over brackets that have been previously
`placed on a stone model. Next, a sheet of clear thermoplastic
`material is drawn down over the impression material using
`
`a vacuum-forming technique. The resultant transfer tray is
`then removed from the model for subsequent placement on
`the patient's dental arch.
`
`[0017]
`Indirect bonding techniques offer a number of
`advantages over direct bonding techniques. For one thing,
`and as indicated above, it is possible to bond a plurality of
`brackets to a patient's dental arch simultaneously, thereby
`avoiding the need to bond each appliance in individual
`fashion. In addition, the indirect bonding tray helps to locate
`all of the brackets in their proper, intended positions such
`that adjustment of each bracket on the surface of the tooth
`before bonding is avoided. The increased placement accu(cid:173)
`racy of the appliances that is often afforded by indirect
`bonding techniques helps ensure that the patient's teeth are
`moved to their proper, intended positions at the conclusion
`of treatment.
`
`[0018] The state of the art in orthodontics is rapidly
`moving toward digital and computer-aided techniques.
`These techniques include the use of intra and extra-oral
`scanners, three-dimensional (3D) modeling of a tooth struc(cid:173)
`ture, and fabrication of orthodontic devices from digital
`data.
`
`SUMMARY
`
`[0019]
`In general, the invention relates to techniques for
`registering a three-dimensional (3D) coordinate system of a
`physical model of a patient's tooth structure to a 3D coor(cid:173)
`dinate system of a virtual model of the same tooth structure.
`Techniques are described to register the complex geometries
`of the physical and virtual tooth structures by using regis(cid:173)
`tration markers associated with the physical model.
`
`[0020]
`In one example, registration markers are arbitrarily
`placed onto the patient's teeth prior to forming an impres(cid:173)
`sion of the patient's teeth. In another example, registration
`markers are arbitrarily placed onto the impression after the
`impression is formed or onto the casting after the casting is
`formed. Scanning the teeth, impression, or casting with
`markers generates a digital model of the tooth structure
`containing markers. The locations of the registration mark(cid:173)
`ers may then assist registration of the coordinate system of
`the physical model to the coordinate system of the 3D digital
`model for creation of a digital orthodontic prescription for
`the patient.
`
`[0021]
`In one embodiment, a method comprises attaching
`markers to a tooth structure of a patient, forming an impres(cid:173)
`sion of the patient's tooth structure having the attached
`markers, and registering the impression to a digital model of
`the tooth structure based on known locations of the markers.
`
`[0022]
`In another embodiment, an orthodontic marker
`bracket comprises a metallic hemispherical bracket, and a
`bonding pad attached to the metallic hemispherical bracket
`for bonding to a tooth.
`
`[0023]
`In another embodiment, an orthodontic marker
`bracket comprises a light transmitting marker bracket, and a
`bonding pad attached to the light transmitting marker
`bracket for bonding to a tooth.
`
`[0024]
`In another embodiment, a system comprises a tooth
`marker attached to a tooth structure of a patient, an impres(cid:173)
`sion of the tooth structure having the attached markers, a
`
`0020
`
`Exhibit 1031 page 20 of 29
`DENTAL IMAGING
`
`

`

`US 2007 /0031774 Al
`
`Feb. 8,2007
`
`3
`
`computer that registers the impression to a digital model
`based on known locations of the markers.
`
`[0040] FIG. 14 is a top view of an exemplary inverted
`pedestal drilled with holes and tapped with machine threads.
`
`[0025]
`In another embodiment, a method comprises form(cid:173)
`ing a physical model of a patient's tooth structure, attaching
`markers to the physical model, scanning the physical model
`having markers to generate a digital model of the tooth
`structure, and registering the physical model to the digital
`model with known locations of the markers.
`
`[0026] The invention may provide one or more advan(cid:173)
`tages. For example, the techniques may provide for assisted
`( e.g., automatic or semi-automatic) registration of physical
`and virtual models used during indirect bonding tray fabri(cid:173)
`cation. Assisted registration may reduce the labor, cost, and
`probability of error during manufacturing of an orthodontic
`appliance, such as an indirect bonding tray. The details of
`one or more embodiments of the invention are set forth in
`the accompanying drawings and the description below.
`Other features, objects, and advantages of the invention will
`be apparent from the description and drawings, and from the
`claims.
`
`BRIEF DESCRIPTION OF DRAWINGS
`
`[0027] FIG. 1 is a block diagram illustrating an exemplary
`computer environment 2 in which a clinic and a manufac(cid:173)
`turing facility communicate information throughout an indi(cid:173)
`rect bonding tray manufacturing process.
`
`[0028] FIG. 2 is a block diagram illustrating an exemplary
`process at a clinic.
`
`[0029] FIGS. 3A and 3B are block diagrams illustrating an
`exemplary process at an indirect bonding device manufac(cid:173)
`turing facility.
`
`[0030] FIG. 4 is a perspective view of an exemplary
`pedestal of known geometry.
`
`[0031] FIGS. SA and 5B are perspective views of a digital
`model of a casting attached to a pedestal.
`
`[0032] FIG. 6 is a perspective view of an exemplary
`fixture of a robotic device.
`
`[0033] FIG. 7 is a perspective view of an exemplary
`pedestal with attached model mated to an exemplary fixture
`of a robotic device.
`
`[0034] FIG. 8 is a side elevation view of an exemplary
`casting assembly.
`
`[0035] FIG. 9 is a block diagram of an exemplary process
`according to one embodiment of the invention.
`
`[0036] FIGS. lOA and 10B are an occlusal and distal view
`respectively of an exemplary impression tray with three
`hemispherical dimples.
`
`[0037] FIGS. llA and 11B are a top and rear elevation
`view respectively of an exemplary main pedestal with three
`pillars.
`
`[0038] FIGS. 12A and 12B are a top and rear elevation
`view respectively of an exemplary impression tray attached
`to an exemplary main pedestal.
`
`[0039] FIG. 13 is a rear elevation view of an exemplary
`enclosing wall resting on a main pedestal with attached
`impressions.
`
`[0041] FIG. 15 is a rear elevation view of an exemplary
`inverted pedestal fitted and properly aligned with screws
`strategically located and threaded into the casting material,
`upon a main pedestal, with an enclosing wall.
`
`[0042] FIG. 16 is an inverted rear elevation view of an
`exemplary inverted pedestal with screws securing the posi(cid:173)
`tion of the solid casting.
`
`[0043] FIG. 17 is block diagram illustrating an exemplary
`process at a clinic, distinguishable from FIGS. 3A and 3B by
`the placement of marker brackets at the clinic.
`
`[0044] FIG. 18 is a perspective view of an exemplary
`metallic hemispherical bracket.
`
`[0045] FIG. 19 is a perspective view of an exemplary
`marker tool for attaching marker brackets to a patient's
`tooth.
`
`[0046] FIG. 20 is a cross section of an exemplary hemi(cid:173)
`spherical cup in bell housing of a marker tool.
`
`[0047] FIG. 21 is a perspective view of an exemplary
`surfaced 3D digital model with a marker bracket.
`
`[0048] FIG. 22 is a perspective view of an exemplary CNC
`machined plate with a surface profile machined into it.
`
`[0049] FIG. 23 is a side view of a casting set into the
`machined surface of an exemplary plate.
`
`[0050] FIG. 24 is a perspective view of a casting set into
`the machined surface of an exemplary plate.
`
`DETAILED DESCRIPTION
`
`[0051] FIG. 1 is a block diagram illustrating an exemplary
`computer environment 2 in which a clinic and a manufac(cid:173)
`turing facility communicate information throughout an indi(cid:173)
`rect bonding
`tray manufacturing process. Although
`described with respect to manufacturing of indirect bonding
`trays, the techniques may be applied to other computer(cid:173)
`implemented processes for assisting orthodontic diagnosis
`and treatment.
`
`Initially, manufacturing facility 12 produces a den(cid:173)
`[0052]
`tal impression tray 10 for receiving dental impressions of a
`dental arch or other tooth structure of patient 6. Manufac(cid:173)
`turing facility 12 ships dental impression tray 10 to clinic 8.
`The dental impression tray 10 is loaded with a quantity of
`impression material just prior to taking the impression at
`clinic 8, or alternatively is preloaded with quantity of
`impression material by the manufacturer before shipment to
`the clinic. Impression tray 10 is adapted to extend along the
`entire dental arch, although as an alternative it is possible to
`use an impression tray that extends along a fewer number of
`teeth such as a dental quadrant.
`
`[0053] An orthodontic practitioner of clinic 8 utilizes
`dental impression tray 10 to capture an impression of the
`dental arch of patient 6. Clinic 8 stores digital information
`in a patient record within a database to associate the patient
`record with the particular dental impression tray 10. Clinic
`8 may, for example, update a local database having a
`plurality of patient records. Alternatively, clinic 8 may
`remotely update a central database within manufacturing
`facility 12 via network 14.
`
`0021
`
`Exhibit 1031 page 21 of 29
`DENTAL IMAGING
`
`

`

`US 2007 /0031774 Al
`
`Feb. 8,2007
`
`4
`
`In either case, clinic 8 then returns dental impres(cid:173)
`[0054]
`sion tray 10 to manufacturing facility 12. Manufacturing
`facility 12 utilizes dental impression tray 10 to construct an
`indirect bonding tray 16 for use in physically placing
`brackets on the teeth of patient 6.
`
`[0055] Construction of indirect bonding tray 16 involves a
`multi-step process conducted at manufacturing facility 12.
`First, manufacturing facility 12 creates a casting from dental
`impression tray 10. The term "casting" is used generally
`herein to refer to any type of physical model made from
`dental impression tray 10, for example, a replica made from
`plaster of Paris or from a polymeric material such as an
`epoxy that transmits actinic radiation. Suitable epoxy and
`other polymeric materials are described in published U.S.
`patent application 20040219473, which is incorporated by
`reference herein. The term "casting" is also used generally
`herein to refer to a physical model of predicted tooth
`positions, such as a stereolithographic model used in the
`fabrication of tooth positioning trays. Examples of tooth
`positioning trays include those sold by Align Technology of
`Santa Clara, Calif. and those described in U.S. Pat. Nos.
`6,309,215 and 6,705,863, both of which are incorporated by
`reference herein. Optionally, in instances where a digital
`model of the entire arch is not needed, the casting may
`include a fewer number of teeth than the number of teeth
`represented in the impression.
`
`[0056]
`In certain embodiments, the casting contains or is
`affixed to one or more registration components having
`known physical characteristics. The registration components
`may have been placed into the impression tray at clinic 8 and
`transferred to the casting or may have been attached to or
`embedded within the casting at manufacturing facility 12.
`
`[0057] Next, manufacturing facility 12 scans the casting or
`the impression with one or more registration components to
`generate a three-dimensional (3D) digital model of the tooth
`structure. Multiple castings or impressions may be scanned
`simultaneously to reduce the number of scans. For example,
`scanning a casting of a patient's upper jaw along with a
`casting of the patient's lower jaw and bite impression
`enables registration of the models relative to each other (for
`setting the bite) along with registration of the castings to the
`virtual models all in a single scan. The registration compo(cid:173)
`nents enable manufacturing facility 12 to utilize the digital
`model for receiving prescription data and bracket placement
`data from clinic 8 in order to automatically place brackets
`onto the casting per the clinic's specifications. Manufactur(cid:173)
`ing facility 12 then forms indirect bonding tray 16 from the
`casting with the affixed brackets. Lastly, manufacturing
`facility 12 forwards indirect bonding tray 16 to clinic 8 for
`use in a conventional indirect bonding procedure to place the
`brackets on the teeth of patient 6.
`
`[0058] Manufacturing facility 12 may produce indirect
`bonding tray 16 by placing a matrix material in the form of
`a plastic sheet over the casting and the brackets and exposing
`the matrix material to radiant heat. Air in the space between
`the sheet material and the casting is then forced out by a
`pressure differential between the inner and outer surfaces of
`the sheet material (i.e. either by vacuum forming or positive
`pressure forming), and the plastic sheet material assumes a
`configuration that precisely matches the shape of the replica
`teeth of the casting and the attached brackets. Suitable
`indirect bonding trays and methods for making indirect
`
`bonding trays are described, for example, in copending and
`commonly assigned U.S. patent application Ser. No. 10/428,
`301 entitled "Method and Apparatus for Indirect Bonding of
`Orthodontic Appliances", filed May 2, 2003 to Cleary et al.,
`Ser. No. 10/428,255 entitled "Orthodontic Appliances Hav(cid:173)
`ing a Contoured Bonding Surface", filed May 2, 2003 to
`Cleary et al., and Ser. No. 10/678,841 entitled "Method and
`Apparatus for Bonding Orthodontic Appliances to Teeth",
`filed Oct. 3, 2003 to Cleary et al., all of which are entirely
`incorporated herein by reference.
`
`[0059] As further described, techniques may be used to
`assist (e.g., automatically or semi-automatically) registra(cid:173)
`tion of a physical model to a corresponding digital model for
`automated appliance manufacturing, such as manufacturing
`of an indirect bonding device from the casting. For example,
`the techniques involve attaching or embedding one or more
`registration components of know