Appl. No.: 17/553,590
`Reply to Office Action of August 17, 2023
`
`Attorney Docket No.: 22773-826.309
`
`AMENDMENTS TO THE CLAIMS
`
`This listing of claims will replace all prior versions, and listings of claims in the
`
`application:
`
`Listing of Claims:
`
`1.
`
`2.
`
`(Canceled)
`
`(Currently Amended) A method of making a multilayer dental aligner for repositioning a
`
`patient’s teeth from a first arrangement toward a second arrangement, the method comprising:
`
`providing a multilayer sheet comprising:
`
`a first soft polymerlayer;
`
`a first hard polymerlayer:
`
`a second soft polymerlayer; and
`
`a second hard polymerlayer; and
`
`a third hard polymerlayer:
`
`wherein each of the first hard polymer layer, the second hard polymer layer, and
`
`the third hard polymerlayer consists of a co-polyesterfirstpehymer having:
`
`a flexural modulus greater than 150,000 psi; [[and]]
`
`a tensile strength yield of 4000 psi to 6500 psi;
`
`an elongation at yield of greater than 4%; and
`
`an elongation at break of greater than 70%;
`
`wherein each of the first soft polymer layer and the second soft polymer layer
`
`
`
`a hardness from 60A to 85D; and
`
`an elongation at break of greater than 200%;
`
`wherein each of the first soft polymer layer and the second soft polymer layer
`
`have a thickness of about 25 um to about 100 um: and
`
`Page 2 of 12
`
`
`Reply to Office Action of August 17, 2023
`
`Attorney Docket No.: 22773-826.309
`
`AMENDMENTS TO THE CLAIMS
`
`This listing of claims will replace all prior versions, and listings of claims in the
`
`application:
`
`Listing of Claims:
`
`1.
`
`2.
`
`(Canceled)
`
`(Currently Amended) A method of making a multilayer dental aligner for repositioning a
`
`patient’s teeth from a first arrangement toward a second arrangement, the method comprising:
`
`providing a multilayer sheet comprising:
`
`a first soft polymerlayer;
`
`a first hard polymerlayer:
`
`a second soft polymerlayer; and
`
`a second hard polymerlayer; and
`
`a third hard polymerlayer:
`
`wherein each of the first hard polymer layer, the second hard polymer layer, and
`
`the third hard polymerlayer consists of a co-polyesterfirstpehymer having:
`
`a flexural modulus greater than 150,000 psi; [[and]]
`
`a tensile strength yield of 4000 psi to 6500 psi;
`
`an elongation at yield of greater than 4%; and
`
`an elongation at break of greater than 70%;
`
`wherein each of the first soft polymer layer and the second soft polymer layer
`
`
`
`a hardness from 60A to 85D; and
`
`an elongation at break of greater than 200%;
`
`wherein each of the first soft polymer layer and the second soft polymer layer
`
`have a thickness of about 25 um to about 100 um: and
`
`Page 2 of 12
`
`
`
`Appl. No.: 17/553,590
`Reply to Office Action of August 17, 2023
`
`Attorney Docket No.: 22773-826.309
`
`wherein the multilayer sheet has a thickness of about 600 um to about 1000 um:
`
`wherein the first hard polymer layer is disposed between the first soft polymer
`
`layer and the second soft polymerlayer:
`
`providing a mold;
`
`thermoforming the multilayer sheet over the mold to form a plurality of tooth-receiving
`
`cavities configured to receive and reposition the patient’s teeth from the first arrangement toward
`
`the second arrangement; and
`
`trimming excess material from the thermoformed multilayer sheet to form the dental
`
`aligner.
`
`3-5.
`
`(Canceled)
`
`6.
`
`(Currently Amended) The method of claim 2 ¢latm3, wherein the co-polyester first
`
`polymer has a tensile modulus of greater than 150,000 psi.
`
`7-9.
`
`(Canceled)
`
`10.
`
`(Currently Amended) The method of claim 2, wherein the elastomer thermeplastic
`
`poburethane-elastomer has an ultimate tensile strength of greater than 5000psi.
`
`11.
`
`(Currently Amended) The method of claim 2, wherein the co-polyester first-pebymer has
`
`an elastic modulus greater than the elastomer thermeplastic_pebyurethane-clastomer.
`
`12.
`
`(Canceled)
`
`
`
`asame-ordifferent thermoplastic polyurethane elastomer astheseeondteyer.
`
`14-18. (Canceled)
`
`19.
`
`(Currently Amended) The method of claim 2 elat+m+8, wherein the thirdtayer the first
`
`soft polymerlayer is co-extruded with or laminated to the first hard polymerlayer.
`
`Page 3 of 12
`
`
`
`Appl. No.: 17/553,590
`Reply to Office Action of August 17, 2023
`
`Attorney Docket No.: 22773-826.309
`
`20-28. (Canceled)
`
`
`
`29. (Currently Amended) The method of claim 2 elaima—6, wherein the co-polyesterefthe
`
`firstlayer has a light transmission between 400 nm and 800 nm ofgreater than about 75%.
`
`30.
`
`(Currently Amended) The method of claim 2 ¢laim—46, wherein the elastomer
`
`
`
`thermoplastic_pelypurethane-elastomerofthe-secondtayerhas a compression set of greater than
`
`40% after 24 hours at 70° C,
`
`31-33. (Canceled)
`
`34.
`
`(Currently Amended) The method of claim 2 ¢laim—t, wherein the first-pelymer co-
`
`polyester has a light transmission between 400 nm and 800 nm of greater than about 75%, and
`
`wherein the thermeplastie_pelyurethane—elastemer elastomer has a light transmission between
`
`400 nm and 800 nm ofgreater than about 75%.
`
`35.
`
`(Currently Amended) The method of claim 2 elatta—+6, wherein thermeplastte
`
`pobyurethaneelastomer the elastomer has a light transmission between 400 nm and 800 nm of
`
`greater than about 75%.
`
`36.
`
`(New) The method of claim 2, wherein the first hard polymer layer, the second hard
`
`polymerlayer, and the third hard polymer layer have a thickness of about 400 um to about 1100
`
`um.
`
`37.
`
`(New) The method of claim 2, wherein the first hard polymer layer, the second hard
`
`polymerlayer, and the third hard polymer layer have a thickness of about 500 um to about 900
`
`um.
`
`38.
`
`(New) The method of claim 2, wherein the first hard polymer layer, the second hard
`
`polymerlayer, and the third hard polymer layer have a thickness of about 550 um to about 750
`
`um.
`
`Page 4 of 12
`
`
`
`Appl. No.: 17/553,590
`Reply to Office Action of August 17, 2023
`
`Attorney Docket No.: 22773-826.309
`
`39.
`
`(New) The method of claim 2, wherein one ofthe first soft polymer layer and the second
`
`soft polymer layer are configured to contact the patient’s teeth to reposition the patient’s teeth
`
`from the first arrangement toward the second arrangement.
`
`AO.
`
`(New) The method of claim 2, wherein the first soft polymer layer and the second soft
`
`polymerlayer serve as exterior layers of the multilayer dental aligner.
`
`41.
`
`(New) The methodof claim 2, wherein the elastomeris a co-polyester elastomer.
`
`42.
`
`(New) The method of claim 2, wherein the elastomer is a thermoplastic co-polyester
`
`elastomer.
`
`Page 5 of 12
`
`
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