Hyperelastic shape setting devices and fabrication methods
AssigneeOrmco Corporation
InventorAlfred Johnson
Life of this patent
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Abstract
Shape-setting methods for fabricating devices made of single crystal shape memory alloys. In particular the methods described may be used to fabricate dental arches of single-crystal shape memory alloys. The methods include drawing a single crystal of a shape memory alloy from a melt of the alloy. This is followed by heating, forming, and quenching the crystal sufficiently rapid to limit the formation of alloy precipitates to an amount which retains hyperelastic composition and properties of the crystal.
Claims31
A method of shape-setting a wire of single-crystal shape memory alloy into an arched wire shape so that it is comprised of a single-crystal shape memory alloy, the method comprising the steps of:
- heating the wire to a first temperature sufficient for annealing the alloy;
- forcing the wire into an arched shape while the wire is held at the first temperature, wherein the heating and forcing steps are performed in less than 10 seconds;
- and
- rapidly cooling the alloy to room temperature sufficiently quickly to cause the alloy to form a single-crystal.
A method of shape-setting a wire of single-crystal alloy into a dental arch so that it is comprised of a single-crystal shape memory alloy, the method comprising the steps of:
- heating the wire to an annealing temperature sufficient for annealing the alloy;
- forcing the heated wire into a dental arch shape by forcing the wire against a mandrel, wherein the steps of heating and forcing the wire against the mandrel are performed in less than 10 seconds;
- and
- rapidly cooling the wire by quenching to a cooling temperature sufficiently quickly to cause the alloy to remain a single-crystal in the dental arch shape.
A method of shape-setting an alloy into a dental arch so that it is comprised of a single-crystal CuAlNi shape memory alloy, the method comprising the steps of:
- heating a wire of CuAlNi alloy to a first temperature sufficient to place the Cu, Al and Ni in solution;
- rapidly quenching the alloy to a second temperature to prevent precipitation of the Cu, Al and Ni so that the alloy remains as a single-crystal of CuAlNi;
- constraining the alloy into a dental arch shape;
- heating the alloy to a third temperature for a first time period, wherein the third temperature and first time period are sufficient to cause the alloy to lose its strength;
- and
- cooling the alloy to a fourth temperature for a second time period, wherein the fourth temperature and second time period are sufficient to cause the alloy to remain a single-crystal in the shape.
A dental arch comprising a hyperelastic, single-crystal shape memory material, the dental arch having an elongate, curved length that is configured to fit within a human mouth.
An apparatus for forming a wire of shape memory alloy into a dental arch while preserving the single-crystal nature of the wire, the apparatus comprising:
- a power source for heating the wire to above an annealing temperature of the shape memory alloy;
- a holder for holding the ends of the wire so that the wire may be heated by the power source;
- a mandrel for shaping the wire;
- a driver for driving the mandrel against the heated wire held by the holder;
- and
- a quenching sub-assembly for rapidly quenching the wire connected to the mandrel to room temperature within less than about 1 second.
An apparatus for forming a wire of shape memory alloy into a dental arch while preserving the single-crystal nature of the wire, the apparatus comprising:
- a voltage source for heating the wire to above an annealing temperature of the shape memory alloy;
- a pair of conductive holders for holding the ends of the wire in electrical communication with the voltage source so that the wire can be heated by the power source;
- a curved mandrel for shaping the wire;
- a plunger above the mandrel for driving the mandrel against the heated wire held by the holder;
- and
- a quenching sub-assembly comprising a bath positioned below the mandrel and plunger and configured to receive the mandrel and wire to rapidly quench the wire to room temperature within less than about 1 second.
Dependencies are inferred from the claim text.