Appl. No.: 17/553,590
`Reply to Office Action of May 15, 2023
`
`Attorney Docket No.: 22773-826.309
`
`LISTING OF THE CLAIMS
`
`(Canceled)
`
`(Previously Presented) A method of making a multilayer dental aligner for repositioning
`
`1.
`
`2.
`
`a patient’s teeth from a first arrangement toward a second arrangement, the method comprising:
`
`providing a multilayer sheet comprising:
`
`a first layer;
`
`a second layer; and
`
`a third layer; and
`
`wherein the first layer consists of a first polymer having:
`
`a flexural modulus greater than 150,000 psi;
`
`an elongation at break of greater than 70%; and
`
`a light transmission between 400 nm and 800 nm of greater than about
`
`75%; and
`
`wherein the second layer consists of a second polymer different than the first
`
`polymer, wherein the second polymeris a thermoplastic polyurethane elastomer having:
`
`a hardness from 60A to 85D;
`
`an elongation at break of greater than 200%; and
`
`a light transmission between 400 nm and 800 nm of greater than about
`
`75%;
`
`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.
`
`(Previously Presented) The method of claim 2, wherein the first polymer is a co-
`
`polyester.
`
`Page 2 of 7
`
`
`Reply to Office Action of May 15, 2023
`
`Attorney Docket No.: 22773-826.309
`
`LISTING OF THE CLAIMS
`
`(Canceled)
`
`(Previously Presented) A method of making a multilayer dental aligner for repositioning
`
`1.
`
`2.
`
`a patient’s teeth from a first arrangement toward a second arrangement, the method comprising:
`
`providing a multilayer sheet comprising:
`
`a first layer;
`
`a second layer; and
`
`a third layer; and
`
`wherein the first layer consists of a first polymer having:
`
`a flexural modulus greater than 150,000 psi;
`
`an elongation at break of greater than 70%; and
`
`a light transmission between 400 nm and 800 nm of greater than about
`
`75%; and
`
`wherein the second layer consists of a second polymer different than the first
`
`polymer, wherein the second polymeris a thermoplastic polyurethane elastomer having:
`
`a hardness from 60A to 85D;
`
`an elongation at break of greater than 200%; and
`
`a light transmission between 400 nm and 800 nm of greater than about
`
`75%;
`
`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.
`
`(Previously Presented) The method of claim 2, wherein the first polymer is a co-
`
`polyester.
`
`Page 2 of 7
`
`
`
`Appl. No.: 17/553,590
`Reply to Office Action of May 15, 2023
`
`Attorney Docket No.: 22773-826.309
`
`4.
`
`(Previously Presented) The method of claim 3, wherein the first polymer has a tensile
`
`strength yield of 4000 psi to 6500 psi.
`
`5.
`
`(Previously Presented) The method of claim 3, wherein the first polymer has an
`
`elongation at yield of greater than 4%.
`
`6.
`
`(Previously Presented) The method of claim 3, wherein the first polymer has a tensile
`
`modulus of greater than 150,000psi.
`
`7-9.
`
`(Canceled)
`
`10.
`
`(Previously Presented) The method of claim 2, wherein the thermoplastic polyurethane
`
`elastomerhas an ultimate tensile strength of greater than 5000 psi.
`
`11.
`
`(Previously Presented) The method of claim 2, wherein the first polymer has an elastic
`
`modulus greater than the thermoplastic polyurethane elastomer.
`
`12.
`
`(Previously Presented) The method of claim 2, wherein the first polymer is a co-
`
`polyester; and wherein the third layer comprises a third polymer, wherein the third polymeris a
`
`sameor different co-polyester as the first layer.
`
`13.
`
`(Previously Presented) The method of claim 2, wherein the first polymer is a co-
`
`polyester; and wherein the third layer comprises a third polymer, wherein the third polymeris a
`
`sameor different thermoplastic polyurethane elastomeras the secondlayer.
`
`14.
`
`(Previously Presented) The method of claim 13, wherein the first layer is disposed
`
`between the second layer and the third layer.
`
`15.
`
`(Previously Presented) The method of claim 2, wherein the first layer is disposed between
`
`the secondlayer andthethird layer.
`
`16.
`
`(Previously Presented) A method of making a multilayer dental aligner for repositioning
`
`a patient’s teeth fromafirst arrangement toward a second arrangement, the method comprising:
`
`providing a multilayer sheet comprising:
`
`Page 3 of 7
`
`
`
`Appl. No.: 17/553,590
`Reply to Office Action of May 15, 2023
`
`Attorney Docket No.: 22773-826.309
`
`a first layer;
`
`a second layer; and
`
`a third layer; and
`
`wherein the first layer consists of a co-polyester; and
`
`wherein the second layer consists of a thermoplastic polyurethane elastomer, the
`
`thermoplastic polyurethane elastomer having:
`
`a hardness from 60A to 85D;
`
`an elongation at break of greater than 200%; and
`
`a light transmission between 400 nm and 800 nm of greater than about
`
`75%;
`
`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
`
`towards the second arrangement; and
`
`trimming excess material from the thermoformed multilayer sheet to form the dental
`
`aligner.
`
`17.
`
`(Previously Presented) The method of claim 16, wherein the third layer comprises a co-
`
`polyester.
`
`18.
`
`(Previously Presented) The method of claim 16, wherein the third layer is disposed
`
`adjacentto the first layer.
`
`19.
`
`(Previously Presented) The method of claim 18, wherein the third layer is co-extruded
`
`with or laminatedto the first layer.
`
`20.
`
`(Previously Presented) The method of claim 16, wherein the multilayer sheet further
`
`comprises a fourth layer comprising a thermoplastic polyurethane elastomer.
`
`21.
`
`(Previously Presented) The method of claim 20, wherein the first layer and the third layer
`
`are disposed between the second layer and the fourth layer.
`
`Page 4 of 7
`
`
`
`Appl. No.: 17/553,590
`Reply to Office Action of May 15, 2023
`
`Attorney Docket No.: 22773-826.309
`
`22.
`
`(Previously Presented) The method of claim 20, wherein the third layer comprises a
`
`thermoplastic polyurethane elastomer.
`
`23.
`
`(Previously Presented) The method of claim 22, wherein the first layer is disposed
`
`between the second layer and the third layer.
`
`24.
`
`(Previously Presented) The method of claim 16, wherein the co-polyester ofthe first layer
`
`has a flexural modulus greater than 150,000 psi.
`
`25.
`
`(Previously Presented) The method of claim 16, wherein the co-polyester ofthe first layer
`
`has an elongation at break of greater than 70%.
`
`26.
`
`(Previously Presented) The method of claim 16, wherein the co-polyester ofthe first layer
`
`has an elongation at yield of greater than 4%.
`
`27.
`
`(Previously Presented) The method of claim 16, wherein the co-polyester ofthe first layer
`
`has a tensile strength yield of 4000 psi to 6500 psi.
`
`28.
`
`(Previously Presented) The method of claim 16, wherein the co-polyester ofthe first layer
`
`has having a tensile modulus of greater than 150,000 psi.
`
`29.
`
`(Previously Presented) The method of claim 16, wherein the co-polyester ofthe first layer
`
`has a light transmission between 400 nm and 800 nm of greater than about 75%.
`
`30.
`
`(Previously Presented) The method of claim 16, wherein the thermoplastic polyurethane
`
`elastomerof the second layer has a compression set of greater than 40% after 24 hours at 70° C.
`
`31-32. (Canceled)
`
`33.
`
`(Previously Presented) The method of claim 16, wherein the co-polyester has an elastic
`
`modulus greater than the thermoplastic polyurethane elastomer.
`
`Page 5 of 7
`
`
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