Granted Patent B2

US 12,661,252 · App. 16/719,043 · Granted Jun 23, 2026

Inventors: W. Keith Thornton (Dallas, TX); Alastair Edwin McAuley (Dallas, TX)

Assignee: AirWay Technologies, LLC

A61F5/566A61M16/0057A61M16/0488A61M16/0605A61M16/0666A61M16/0683B29B13/02B29B13/08B29C65/562B29K2667/00B29L2031/753

Abstract

Claims (43)

1 . An oral appliance comprising:

a lower frame comprising a lower occlusal surface, the lower frame further comprising a material that maintains its shape at temperatures at or below 100 degrees Celsius;

a lower thermoplastic moldable tray coupled to the lower frame such that the lower thermoplastic moldable tray is positioned between the lower frame and a mandibular arch of a user when the lower frame is positioned in a mouth of the user, wherein the lower thermoplastic moldable tray comprises irradiated, cross-linked thermoplastic polymer not customized to any user's teeth, and wherein the irradiated, cross-linked thermoplastic polymer softens to be moldable to a shape of a portion of the user's mandibular arch when the thermoplastic polymer is heated to 40 to 80 degrees Celsius;

an upper frame separate from the lower frame, wherein the upper frame comprises an upper occlusal surface;

an upper thermoplastic moldable tray separate from the lower thermoplastic moldable tray, wherein the upper thermoplastic moldable tray is coupled to the upper frame such that the upper thermoplastic moldable tray is positioned between the upper frame and a maxillary arch of the user when the upper frame is positioned in the mouth; and

a device coupled to the upper frame along a midline of the upper frame, wherein the device is arranged to engage the lower frame and to adjust a forward position of the upper frame relative to the lower frame.

2 . The oral appliance of claim 1 , wherein the lower frame further comprises a flange extending perpendicular from at least a portion of the lower occlusal surface of the lower frame, wherein the flange extends perpendicular from a labial edge of the lower occlusal surface, such that the flange is configured to be positioned proximate a labial surface of at least some teeth of the mandibular arch.

3 . The oral appliance of claim 2 , wherein the flange further comprises:

a first distal portion configured to be positioned proximate at least one of a left bicuspid and a left molar of the mandibular arch; and

a second distal portion configured to be positioned proximate at least one of a right bicuspid and a right molar of the mandibular arch.

4 . The oral appliance of claim 3 , wherein the flange is non-contiguous, such that:

the first distal portion of the flange is separated from a mesial portion of the flange; and

the second distal portion of the flange is separated from the mesial portion of the flange.

5 . The oral appliance of claim 1 , wherein the lower frame comprises a material that provides rigidity while allowing flexion.

6 . The oral appliance of claim 1 , wherein the lower frame comprises a material selected from the group consisting of polycarbonate, nylon, acrylonitrile butadiene styrene (ABS), and polyethylene.

7 . The oral appliance of claim 1 , the lower thermoplastic moldable tray comprises a channel configured to engage at least some teeth of the mandibular arch of the user.

8 . The oral appliance of claim 1 , wherein the lower thermoplastic moldable tray extends beyond a labial edge of the lower frame.

9 . An oral appliance comprising:

a lower frame comprising a lower occlusal surface;

a lower thermoplastic moldable tray coupled to the lower frame such that the lower thermoplastic moldable tray is positioned between the lower frame and a mandibular arch of a user when the lower frame is positioned in a mouth of the user, wherein the lower thermoplastic moldable tray comprises irradiated, cross-linked thermoplastic polymer not customized to any user's teeth, and wherein the irradiated, cross-linked thermoplastic polymer softens to be moldable to a shape of a portion of the user's mandibular arch when the thermoplastic polymer is heated to 40 to 80 degrees Celsius;

an upper frame separate from the lower frame, wherein the upper frame comprises an upper occlusal surface;

an upper thermoplastic moldable tray separate from the lower thermoplastic moldable tray, wherein the upper thermoplastic moldable tray is coupled to the upper frame such that the upper thermoplastic moldable tray is positioned between the upper frame and a maxillary arch of the user when the upper frame is positioned in the mouth;

and

a device coupled to the upper frame along a midline of the upper frame, wherein the device is arranged to engage the lower frame and to adjust a forward position of the upper frame relative to the lower frame.

10 . The oral appliance of claim 9 , wherein the upper occlusal surface is configured to be positioned proximate the maxillary arch of the user.

11 . The oral appliance of claim 9 , wherein the lower frame comprises a material that provides rigidity while allowing flexion.

12 . The oral appliance of claim 9 , wherein the lower frame comprises a material that maintains its shape at temperatures at or below 100 degrees Celsius.

13 . The oral appliance of claim 9 , wherein the lower thermoplastic moldable tray defines a smooth channel along the lower occlusal surface.

14 . The oral appliance of claim 9 , wherein the lower thermoplastic moldable tray couples to the lower frame such that the lower frame does not extend beyond the lower thermoplastic moldable tray in a buccal direction.

15 . The oral appliance of claim 9 , wherein the lower thermoplastic moldable tray extends beyond a labial edge of the lower frame.

16 . The oral appliance of claim 9 , wherein the lower tray comprises polycaprolactone.

17 . An oral appliance comprising:

a lower frame comprising a material that maintains its shape at temperatures at or below 100 degrees Celsius, the lower frame further comprising:

a lower occlusal surface; and

a flange extending perpendicular from the lower occlusal surface;

a lower thermoplastic moldable tray coupled to the lower frame such that the lower thermoplastic moldable tray is positioned between the lower frame and a mandibular arch of a user when the lower frame is positioned in a mouth of the user, wherein the lower thermoplastic moldable tray comprises irradiated, cross-linked thermoplastic polymer not customized to any user's teeth, and wherein the irradiated, cross-linked thermoplastic polymer softens to be moldable to a shape of a portion of the user's mandibular arch when the thermoplastic polymer is heated to 40 to 80 degrees Celsius;

an upper frame separate from the lower frame, wherein the upper frame comprises an upper occlusal surface;

an upper thermoplastic moldable tray separate from the lower thermoplastic moldable tray, wherein the upper thermoplastic moldable tray is coupled to the upper frame such that the upper thermoplastic moldable tray is positioned between the upper frame and a maxillary arch of the user when the upper frame is positioned in the mouth;

and

a device coupled to the upper frame along a midline of the upper frame, wherein the device is arranged to engage the lower frame and to adjust a forward position of the upper frame relative to the lower frame.

18 . The oral appliance of claim 17 , wherein the lower frame comprises a material that provides rigidity while allowing flexion.

19 . The oral appliance of claim 17 , wherein the lower frame comprises a material selected from the group consisting of polycarbonate, nylon, acrylonitrile butadiene styrene (ABS), and polyethylene.

20 . The oral appliance of claim 17 , wherein the lower thermoplastic moldable tray extends beyond a labial edge of the frame.

Assignments (1)

Continuity (5)

References Cited (400)