fig1 shows a comparison 19 of the construction of the dental guard with other prior art manufacturing processes . the diagrams that are located and referenced throughout this section to help you gain a broader understanding of how the dental custom dental guard differs from boil and bite mouth guard manufacturing companies . many companies start with 4 mm material 21 which does not suck into the interproximal contacts very well which in turn can cause a loose fit . other companies will typically use a use a second layer that is 2 mm or 3 mm thick material 22 which creates bulky mouth guard on the palate of the athlete . at this point , prior art mouth guards put graphics on top of the already approximately 8 mm thick material of material which reduces down to approximately 4 - 5 mm of thickness . the prior art makes every dental guard in essentially the exact same way and using the exact same material no matter what size mouth of the user . with custom dental guards , after a dental impression has been obtained a thin clear layer of material is used as a base material 31 of between 1 mm and 2 mm . a second layer 32 is combined to the first layer . the second layer is custom hand layering for thickness control and adding hard layer of protection maintaining 100 % bondable surface between layers with no added delaminating risk . within this layer air pockets or cushions can be included for shock dispersion when applicable or desired . the second layer 32 is then heat treated until it is completely smooth and uniform . a wire 36 is placed over the hard acrylic and the wire is formed to the guard . third layer 33 is either 2 mm or 3 mm material . this sub assembly of layers has not yet been added to the palate area . the thickness of the material that is used is based on the width of the palatal area of each unique user . the fourth or last layer 34 is clear either 2 mm or 1 . 5 mm depending on the patient &# 39 ; s mouth . the improvements are not only with the graphic quality , but also with the manufacturing process . fig2 shows a flow chart of the manufacturing process used to create the reformable dental guard . first the design mold is placed in the thermoforming unit 80 . an eva sheet is placed on top of the ring 81 . the heating mechanism is initiated to heat the eva material 82 . once the eva material sags to approximately 1 ″ 83 the thermoforming cylinder is lowered 84 to the ring to seal and pressurize the chamber between 70 to 90 psi . when the cooling process is complete , the eva material is formed on the mold 85 . when cool down process is complete , raise the cylinder and remove eva sheet from mold 86 . excess material that forms on the outside of the design mold is cut and trimmed off of the mold 87 . a hard adrylic layer 32 is added . the arched sine wire 36 is the placed onto the mouth guard where a hard acrylic layer 35 is added to the guard to bond and retain the arched sine wire . the acrylic layer also increases the structural strength of the mouth guard over the front anterior teeth . the material is placed back on the mold and the mold is placed back into the thermoforming unit 89 . a second eva sheet is placed on top of the ring 90 . the heating process is initiate with the heating mechanism to heat the second sheet of eva material 91 . once the material sags to touch mold 92 , initiate the thermoforming cylinder to lower towards the ring 93 to seal and pressurize the chamber between 70 - 90 psi . when cool down process is complete 94 , raise the cylinder and remove the 2 layers of formed eva sheet from the mold 95 . any desired graphics or artwork is applied to the mouth guard surface where it is the desired location 88 . for some complex graphics additional layers of eva may be required between different graphic images . cut and trim the excess material that formed outside of the design mold 96 . polish the edges so that there are no excess and the edges are rounded and curved . cutting , trimming , and polishing skillsets are learned in the custom mouth guard arena . because of the construction of the reusable mouth guard , if the fit is not correct , the mouth guard can be re - boiled and the material will essentially re - flow and allow a person , or a subsequent person to boil and bite the mouth guard to achieve a custom fit mouth guard . the re - heating and bite operation can be repeated numerous times with little or no degradation or compromise in the custom fit . to form the reformable dental guard in the mouth of a user reformable dental guard is heated in water between 180 and 212 degrees fahrenheit and then placed into a mouth on upper teeth of a person whereupon the person closes said mouth and forces said upper teeth into the reformable dental guard for create an initial impression into the reformable dental guard . if the user wants to re - form the dental guard or another user want to use the same dental guard the reformable dental guard is again re - boiled where the dental guard will reflow into its original condition where it can conform into the mouth of the user . fig3 shows a pictorial view of what occurs when a jaw is struck , and fig4 shows a partial cross section of the dental guard in a user . in normal resting mode the mandible 43 is cushioned by the connective tissue 42 to the condyle 41 at the end of the jaw in the socket 40 . when an unprotected athlete receives an impact 18 to the lower jaw or chin . the impact is translated 17 through the jaw or mandible 43 and can cause an impact that can hit the brain thereby causing a concussion . the concussion is the result of the mandible 53 being pushed so hard that the connective tissue 52 is squeezed into the condyle 51 and into the socket 50 . from fig3 the mandible 63 is cushioned by the reformable dental guard 60 that cushions the athletes 16 teeth 61 to increase the frictional forces between the teeth to reduce movement of the mandible 63 . fig5 shows a bottom view of another embodiment of the reformable dental guard 60 on the upper pallet . from fig4 the dental guard is formed from the anterior teeth ( incisors and canines ) 70 to the posterior teeth ( molars and bicuspids ) 71 . optional air cushions 75 are shown placed between adjacent incisors and canines . in this embodiment seven air cushions are shown , but more or less air cushions 75 are contemplated . locating the air cushions 75 between the teeth is generally placed because extra space exists between the teeth without increasing the thickness of the dental guard . placement of the cushion ( s ) 75 is generally not made between posterior teeth 71 because impacts to this area of the mouth are less common . the wire 36 is shown wrapping from the front teeth with the wire 36 terminating 39 at the posterior teeth 71 . fig6 shows a cross sectional view of the dental guard from fig5 . a thin clear layer of material is used as a base material 31 . a second layer 32 is combined to the first layer . the second layer is custom hand layering for thickness control and adding hard layer of protection maintaining 100 % bondable surface between layers with no added delaminating risk . within this layer air pockets or cushions 75 can be included for shock dispersion when applicable or desired . the second layer 32 is then heat treated until it is completely smooth and uniform . third layer 33 is either 2 mm or 3 mm material . the eva layer 37 is also shown in this figure . this sub assembly of layers has not yet been added to the palate area . the thickness of the material that is used is based on the width of the palatal area of each unique user . the fourth or last layer 34 is clear either 2 mm or 1 . 5 mm depending on the patient &# 39 ; s mouth . controlling the thickness of the dental guard is critical to providing comfort and protection . there has been limited published articles on testing that has been performed on mouth guards after a mouth guard has been manufactured . even the surface area being tested only gives the best representation of the type of impact and simulation as an estimate to the protection . fig7 a , fig7 b and fig7 c show the shape and position of the hard acrylic 38 and the reinforcing wire 39 in the reusable mouth guard . the dental guard is formed from the anterior teeth ( incisors and canines ) 70 to the posterior teeth ( molars and bicuspids ) 71 . optional air cushions 75 are shown placed between adjacent incisors and canines . the reinforcing wire 36 is formed in as a spline or sine wave . the wire 36 is shown wrapping from the front teeth with the wire 36 terminating 39 at the posterior teeth 71 . the reinforcing wire 36 maintains the shape and distribute impact forces . the reinforcing wire is completely embedded and encapsulated within the dental guard . additional location of the hard acrylic can be placed along the length of the wire and at the ends of the wire depending upon the nature of the sport , user teeth grinding and other factors . the reinforcing wire 39 is spline or sine shaped to protect the distal tips of the anterior teeth ( incisors and canines ) 70 and arches to the posterior teeth ( molars and bicuspids ) 71 to provide additional protection to the teeth and provide structural shape to the dental guard . at the sides of the dental guard the reinforcing wire arches near the gum line to increase the vertical displacement of the wire to improve retention of the reinforcing wire within the dental guard to reduce a potential of the wire from being “ stripped ” from the dental guard . it is also contemplated that the reinforcing wire can be knurled or otherwise surface treated to increase retention of the reinforcing wire 39 within the dental guard . fig8 a shows an inside perspective view of the mold used to make the reformable dental guard , and fig8 b shows a bottom perspective view of the reformable dental guard . the bottom 100 of the mold is where the mold sits flat within the thermoforming unit . the sheets of eva material are placed on the top surface of the mold as might be seen in fig7 a . from this top perspective view 7 a the mold has a raised outer ridge 103 that forms the general profile where teeth would exist in the mouth of the athlete . a lowered area 104 in the front of the mold provides some clearance between the front teeth . a clearance area 105 in the center of the mold provides clearance for the tongue of the athlete . a ridge 101 and 102 forms the trim area for the gums of an athlete . the vertical wall 106 provides a clearance for the teeth of an athlete . thus , specific embodiments of a cushioned reformable dental guard have been disclosed . it should be apparent , however , to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein . the inventive subject matter , therefore , is not to be restricted except in the spirit of the appended claims .
improvements in cushioned custom dental guard to be constructed with eva instead of polyshok . the molding process ensures that the mouth guard provides even fit on all of the teeth . the custom fit is performed by taking an impression of the upper teeth and gums of the user . the dental guard can then be constructed to ensure a proper custom fit . each layer provides a different function to provide an ideal cushion , as well as integration of artwork that is visible through the front of the dental guard . the dental guard may include air cells or chambers . the air cells provide a cushion by compressing the air cells to absorb an impact and spread the force of the impact over a greater area . a reinforcing wire maintains the shape and distribute impact forces . the reinforcing wire is completely embedded and encapsulated within the dental guard .