kerr v. ultradent products

8/13/2019 Kerr v. Ultradent Products

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KERR CORPORATION, a Delawarecorporation,Plaintiff,

V

ULTRADEN T PROD UCTS, INC., aUtah corporation,Defendant.

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SCHEPER KIM HARRIS LLPM A R C S HA RRIS State Bar No. 13664 7)[email protected] AND ER H. COTE State Bar No. 211558)[email protected] W est Fifth Street, 12th FloorLos Angeles CA 90071-2025Telephone: 213 613-4655Facsimile: 213) 613-4656Attorneys for Plaintiff KERR CORPORATION

UNITED STATES DISTRICT COURTCENTRAL DISTRICT OF CALIFORNIA, SOUTHERN DIVISION

CASE NOSA(Vi i )-3(v Cit-- i\bCOMPLAINT FOR DAMAGES ANDINJUNCTIVE RELIEF1 PATENT INFRINGEMENTOF UNITED STATESPATENT NO. 6,692,251UNDER 35 U S C 2712 PATENT INFRINGEMENTOF UNITED STATESPATENT NO. 7,066,733UNDER 35 U S C 2713 PATENT INFRINGEMENTOF UNITED STATESPATENT NO. 7,210,930UNDER 35 U.S.C. 271D E M A N D FOR JURY TRIAL

F I L ECER U.pLSTRIr r

F E 1 8 2 1 4C E N T R A L D i S T R IC T O F C A L I F O R M A

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28COMPLAINT FOR DAM AGES AND INJUNCTIVE RELIEF; DEMAND FOR JURY TRIAL


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Plaintiff Kerr Corporation ( Plaintiff or Kerr ) hereby complains andalleges against Defendant Ultradent Products, Inc. ( Defendant or Ultradent ) asfollows

NATURE OF THE ACTION1 This is an action for patent infringement and arises under the Patent

Laws of the United States, codified in Title 35 of the United States Code.2 On information and belief, Ultradent has infringed and continues to

infringe, under 35 U.S.C. 271(a), and has actively induced others to infringe andcontinues to actively induce others to infringe, under 35 U.S.C. 271(b), Kerr'sUnited States patents, including U.S. Patent Nos. 6,692,251 ( the '251 patent ),7,066,733 ( the '733 patent ), and 7,210,930 ( the '930 patent ) ( Kerr's AssertedPatents ).

THE PARTIES3 Kerr is a corporation organized and existing under the laws of the State

of Delaware, and has its principal place of business at 1717 West Collins Ave.,Orange, CA 92867.

4 Upon information and belief, Ultradent is a corporation organized andexisting under the laws of the State of Utah, and has its principal place of business at505 West 10200 South, South Jordan, UT 84095.

JURISDICTION AND VENUE5 This Court has subject matter jurisdiction under 28 U.S.C. 1331 and

28 U.S.C. 1338(a).6 This Court has personal jurisdiction over Ultradent because, on

information and belief, Ultradent has committed acts of patent infringementthroughout the State of California, and within this judicial district.

7 Venue in this judicial district is appropriate based on 28 U.S.C. 1391(b)-(c), and 1400(b).

COMPLAINT FOR DA MAGES AN D INJUNCTIVE RELIEF; DEMAND FOR JURY TRIAL

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BACKGROUND FACTS8 Kerr designs, develops, manufactures, and sells various products for

use in the dental industry, including, but not limited to dental curing lights.9 Kerr has sought legal protection for its technological innovations,

which has resulted in numerous issued patents, including the patents identified asKerr's Asserted Patents in paragraph 2 above.

10 On February 17, 2004, the United States Patent and Trademark Office( USPTO ) duly and legally issued the '251 patent, entitled Apparatus and Methodfor Curing Materials with Light Radiation. A copy of the '251 patent is attachedhereto as Exhibit A. Kerr is the owner by assignment of all right, title, and interest inand to the '251 patent, and has owned the '251 patent throughout the period ofUltradent's infringing acts complained of herein.

11 On June 27, 2006, the USPTO duly and legally issued the '733 patent,entitled Apparatus and Method for Curing Materials with Light Radiation. A copyof the '733 patent is attached hereto as Exhibit B. Kerr is the owner by assignmentof all right, title, and interest in and to the '733 patent, and has owned the '733patent throughout the period of Ultradent's infringing acts complained of herein.

12 On May 1, 2007, the USPTO duly and legally issued the '930 patent,entitled Apparatus and Method for Curing Materials with Radiation. A copy of the'930 patent is attached hereto as Exhibit C. Kerr is the owner by assignment of allright, title, and interest in and to the '930 patent, and has owned the '930 patentthroughout the period of Ultradent's infringing acts complained of herein.

13 Upon information and belief, Ultradent had knowledge of each ofKerr's Asserted Patents prior to the filing of this Complaint. In addition, Kerr hasmarked certain of its products with the '251 patent number in accordance with 35U.S.C. 287. Moreover, Kerr's service of this Complaint constitutes notice of itsinfringement claims as to each of Kerr's Asserted Patents to Ultradent, under 35U.S.C. 287.

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1 4 On information and belief, Ultradent manufactures and sells variousproducts for use in the dental industry, including, but not limited to dental curinglights. Among the dental curing light products that Ultradent markets and sells, orhas marketed and sold, are its Valo and UltraLume dental curing light products,which use light emitting diodes ( LEDs ) ( Accused Products ).

1 5 On information and belief, Ultradent operates and maintains an internetwebsite, www.ultradent.com , through which Ultradent markets and sells, or hasmarketed and sold, its products, including the Accused Products, to customersworldwide. Ultradent's website includes, or has included, information andinstructions regarding the design and operation of the Accused Products.

COUNT I PATENT INFRINGEMENT(Infringement of '251 patent)

1 6 Kerr realleges and incorporates by reference the allegations ofparagraphs 1-15 above as though fully set forth herein.

1 7 Ultradent has directly infringed and continues to directly infringe the'251 patent by making, using, selling, offering for sale, and/or importing in theUnited States the Accused Products without Kerr's authorization to do so.

1 8 On information and belief, Ultradent's acts of direct infringementalleged above were conducted with knowledge of Kerr's Asserted Patents andtherefore constitute willful patent infringement.

1 9 On information and belief, Ultradent also has indirectly infringed andcontinues to indirectly infringe the '251 patent, by aiding and abetting the acts ofothers that constitute infringement of the '251 patent, without Kerr's authorizationto do so. With knowledge of the '251 patent, Ultradent intends, and has intended, toinduce others to infringe the '251 patent by instructing them to use the AccusedProducts in a manner that Ultradent knows constitutes infringement.

2 0 As a result of Ultradent's actions, Kerr has suffered and continues tosuffer substantial injury, including irreparable injury and monetary damage,

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including but not limited to the loss of sales and profits, which Kerr would havemade but for the acts of infringement by Ultradent. On information and belief, suchinjury and damage incurred by Kerr will continue unless Ultradent is enjoined bythis Court from further acts of infringement.

COUNT II PATENT INFRINGEMENT(Infringement of 733 patent)


2 2 Ultradent has directly infringed and continues to directly infringe the733 patent by making, using, selling, offering for sale, and/or importing in the

United States the Accused Products without Kerr s authorization to do so.2 3 On information and belief, Ultradent s acts of direct infringement

alleged above were conducted with knowledge of Kerr s Asserted Patents andtherefore constitute willful patent infringement.

2 4 On information and belief, Ultradent also has indirectly infringed andcontinues to indirectly infringe the 733 patent, by aiding and abetting the acts ofothers that constitute infringement of the 733 patent, without Kerr s authorizationto do so. With knowledge of the 733 patent, Ultradent intends, and has intended, toinduce others to infringe the 733 patent by instructing them to use the AccusedProducts in a manner that Ultradent knows constitutes infringement.

2 5 As a result of Ultradent s actions, Kerr has suffered and continues tosuffer substantial injury, including irreparable injury and monetary damage,including but not limited to the loss of sales and profits, which Kerr would havemade but for the acts of infringement by Ultradent. On information and belief, suchinjury and damage incurred by Kerr will continue unless Ultradent is enjoined bythis Court from further acts of infringement.

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COUNT III PATENT INFRINGEMENT(Infringement of 930 patent)


2 7 Ultradent has directly infringed and continues to directly infringe the930 patent by making, using, selling, offering for sale, and/or importing in theUnited States the Accused Products without Kerr s authorization to do so.

2 8 On information and belief, Ultradent s acts of direct infringementalleged above were conducted with knowledge of Kerr s Asserted Patents andtherefore constitute willful patent infringement.

2 9 On information and belief, Ultradent also has indirectly infringed andcontinues to indirectly infringe the 930 patent, by aiding and abetting the acts ofothers that constitute infringement of the 930 patent, without Kerr s authorizationto do so. With knowledge of the 930 patent, Ultradent intends, and has intended, toinduce others to infringe the 930 patent by instructing them to use the AccusedProducts in a manner that Ultradent knows constitutes infringement.

3 0 As a result of Ultradent s actions, Kerr has suffered and continues tosuffer substantial injury, including irreparable injury and monetary damage,including but not limited to the loss of sales and profits, which Kerr would havemade but for the acts of infringement by Ultradent. On information and belief, suchinjury and damage incurred by Kerr will continue unless Ultradent is enjoined bythis Court from further acts of infringement.

PRAYER FOR RELIEFWHEREFORE, Kerr prays for the following relief against Ultradent:A That judgment be entered against Ultradent, that Ultradent has

infringed and induced others to infringe each of Kerr s Asserted Patents;B That Ultradent, its agents, sales representatives, servants and

employees, associates, attorneys, parents, successors and assigns, and any and all5COM P L AI NT F OR D A M AGES A ND I NJ UNCTI V E REL IEF ; D EM AND F OR J URY TRI AL


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persons or entities acting at, through, under or in active concert or participation withany or all of them, be preliminarily and permanently enjoined and restrained fromfurther infringement of each of Kerr's Asserted Patents;

C That judgment be entered requiring Ultradent to pay to Kerr monetarydamages sustained by Kerr due to Ultradent's acts of infringement, including lostprofits or reasonable royalty under 35 U.S.C. 284;

D That judgment be entered trebling such monetary damages thatUltradent is required to pay Kerr for willful infringement under 35 U.S.C. 284;

E That this case be adjudged and decreed exceptional under 35 U.S.C. 285, and that Kerr be awarded its reasonable attorney fees;

F That Kerr be awarded its costs and interest on all damages; andG That Kerr be awarded such other and further relief as the Court deems

just and proper.JURY DEMAND

Kerr hereby demands and requests trial by jury of all issues raised that aretriable by jury.

DATED: February 18, 2014 CHEPER KIM HARRIS LLPMARC S. HARRISALEXANDER H. COTE

B y 2644. 6 tAlexander H. CoteAttorneys for Plaintiff KERRCORPORATION

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COMPLAINT FOR DA MAG ES AND INJUNCTIVE RELIEF; DEMAND FOR JURY TRIAL


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ExhibitA


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(12) United States atentLogan et al

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 9 1 1 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1to) Patent No .: S 6,692,251 B 1

(45) Date of Patent: Feb. 17, 2004

(54) APPARATUS AND METHOD FOR CURINGMATERIALS WITH LIGHT RADIATION

75) Inventors: Joseph N. Logan, Trumbull, CT (US);Raymond L. Knox, Bethel, CT (US)

73) Assignee: Kerr Corporation, Orange, CA (US)otice: ubject to any disclaimer, the term of thispatent is extended or adjusted under 35U.S.C. 154(b) by 208 days.

This patent is subject to a terminal dis-claimer.(21) Appl. No.: 09/632,260(22) Filed: ug. 4, 2000

Related U.S. Application Data63) Continuation-in-part of application No. 09/009,205, filed onJan. 20, 1998, now Pat. No. 6,200,134.

(51) Int. C1.7 A61C 3/00(52) U.S. Cl. 433/29; 362/800(58) Field of Search 33/29, 215; 606/1,606/13, 16; 607/80; 362/800(56) eferences Cited

U.S. PATENT DOCUMENTS3,638,013 A /1972 Keller 240/41.153,712,984 A /1973 Lienhard3,733,481 A /1973 Kuyt3,868,513 A /1975 Gonser 250/5043,970,856 A /1976 Mahaffey et al. 250/4934,048,490 A /1977 Troue 240/41.35

(List continued on next page.)FO REIGN PA TENT DO CU MENTS

DE 2 11 233 /1992EP 116405 /1984EP 266 038 0/1991EP 568 666 1/1992

EP 0 320 080 8/1993EP 0 672 435 9/1995(List continued on next page.)

OTHER PUBLICATIONSSchlager, Kenneth J. , Ignatius, Ronald W ., An LEDArrayLight Source for Medical Therapy SPIE vol . 1892 M edicalLasers and Systems II (1993) p. 26-35.Tarle, Z. et al., The Effect of the PhotopolymerizationMethod on the Quality of Composite Resin Samples J. ofOral Rehab. 25: 436-442, 1998.Burgess, John 0. et al., An Evaluation of Four LightCuringUnits Comparing Soft and Hard Curing Pract. PeriodontAesthet. Dent. 11(1), 125 -132, 1999.Kanca, III, John and Suh, Byoung I., Pulse Activation:Reducing ResinBased Composite Contraction Stresses atthe Enamel Cavosurface Margins Am. J. of Dentistry,12(3), 107-112, 1999.

(List continued on next page.)Primary ExaminerRalph A. Lewis(74) Attorney Agent or FirmWood Herron Evans,LLP(57) BSTRACTAn instrument and m ethod for curing l ight-curable com -pounds in the m outh of a patient, the instrument comprisinga housing and a plurality of solid state, light-emittingelements on a substrate supported by the housing. Theelements form a collective array on the substrate operablefor collectively emitting light having wavelengths within anarrow band of w avelengths.An optical focusing device is positioned to intercept the lightemitted by the array of elements and includes a non-imagingoptical device which is operable for collimating the lightfrom the array into a beam to be directed onto a com poundfor curing the com pound. A disposable sleeve covers thehousing and array and m ay incorporate the optical focusingdevice . The sleeve is removed and discarded after use toeliminate the need to au toclave the instrument.

42 Claims, 3 Drawing Sheets

US006692251B11 2 ) United States Patent 1 6 ) P a t e n t N 6 8 U S 6 , 6 9 2 , 2 5 1 B1

Logan e t a l . 4 5 ) D a t e o f P a t e n t : * F e b . 1 7 , 2 0 0 4

( 5 4 ) APPARATUSAND METHOD FOR CURING EP 0 3 2 0 0 8 0 8 / 1 9 9 3MATERIALS WITH LIGHT RADIATION EP 0 6 7 2 4 3 5 9 / 1 9 9 5

7 5 ) I n v e n t o r s : J o s e p h N . L o g a n , T r u m b u l l , CT ( U S ) ; L l s t C o n ? r m e d o n n e x t p a g e )Raymond L . K n o x , B e t h e l , CT ( U S ) OTHER PUBLICATIONS

7 3 ) A s s i g n e e ; Kerr C o r p o r a t i o n , O r a n g e , CA U s ) S c h l a g e r , K e n n e t h J , I g n a t i u s , R o n a l d W . , An LEDArrayL i g h t S o u r c e f o r M e d i c a l T h e r a p y , S P I E v o l . 1 8 9 2 M e d i c a l* ) N o t i c e : S u b j e c t t o a n y d i s c l a i m e r , t h e t e r m o f t h i s L a s e r s a n d S y s t e m s H ( 1 9 9 3 ) P - 2 6 3 5

p a t e n t i s e x t e n d e d o r a d j u s t e d u n d e r 3 5 T a r l e , Z . e t a l . , T h e E ? r e c t o f t h e P h o t o p o l y m e r i z a t i o nU _ S , C , 1 5 4 ( b ) b y 2 0 8 d a y s , Method o n t h e Q u a l i t y o f C o m p o s i t e R e s i n S a m p l e s , J . o f

O r a l R e h a b . 2 5 : 4 3 6 4 4 2 , 1 9 9 8 .B u r g e s s , J o h n O . e t a l . , A n E v a l u a t i o n o f F o u r L i g h t C u r i n gU n i t s C o m p a r i n g S o f t a n d Hard C u r i n g , P r a c t . P e r i o d o n tA e s t h e t . D e n t . 1 1 1 ) , 1 2 5 1 3 2 , 1 9 9 9 .K a n c a , I I I , J o h n a n d S u b , Byoung 1 . , P u l s e A c t i v a t i o n :

2 1 ) A p p l ' NO 0 9 / 6 3 2 2 6 0 R e d u c i n g R e s i n B a s e d C o m p o s i t e C o n t r a c t i o n S t r e s s e s a t2 2 ) F i l e d ; Aug , 2 0 0 0 t h e E n a m e l C a v o s u r f a c e M a r g i n s , Am. J . o f D e n t i s t r y ,1 2 3 ) , 1 0 7 1 1 2 , 1 9 9 9 .

T h i s p a t e n t i s s u b j e c t t o a t e r m i n a l d i sc l a i m e r .

R e l a t e d U . S . A p p l l c a t l o n Data L i s t C o n t i n u e d o n n e x t p a g e )6 3 ) g o n t i z r b u a l t i g o g n i n p a r t p o f a I I i I p l i c 6 z 1 t 2 i g r 6 I I I ; 4 0 9 / 0 0 9 , 2 0 5 , ? l e d o n P r i m a r y E x a m i n e r _ R a 1 p h A _ L e w i s

a n now a t 0 ' 74 Attorne A ent, or FirmWood, Herron Evans,gLLP(51) I n t . cl? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A61C 3/00

( 5 2 ) U.S.Cl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 3 / 2 9 ; 362/800 ( 5 7 ) ABSTRACT( 5 8 ) F i e l d Of Search . . . . . . . . . . . . . . . . . . . . . . . 4 3 3 / 2 9 , 2 1 5 ; 6 0 6 / 1 , An i n s t r u m e n t a n d method f o r c u r i n g l i g h t - c u r a b l e com

p o u n d s i n t h e mouth o f a p a t i e n t , t h e i n s t r u m e n t c o m p r i s i n g. a h o u s i n g and a p l u r a l i t y o f s o l i d s t a t e , l i g h t - e m i t t i n g

( 5 6 ) R e f e r e n c e s C l t e d e l e m e n t s o n a s u b s t r a t e s u p p o r t e d by t h e h o u s i n g . TheUS ATENT DOCUMENTS e l e m e n t s form a c o l l e c t i v e a r r a y on t h e s u b s t r a t e o p e r a b l ef o r c o l l e c t i v e l y e m i t t i n g l i g h t h a v i n g W a v e l e n g t h s W i t h i n anarroW band o f W a v e l e n g t h s .

6 0 6 / 1 3 , 1 6 ; 6 0 7 / 8 0 ; 3 6 2 / 8 0 0

3,638,013 A 1/1972 Keller . . . . . . . . . . . . . . . . . . . . . 240/41153 , 7 1 2 , 9 8 4 A 1 / 1 9 7 3 L i e n h a r d3 , 7 3 3 , 4 8 1 A 5 / 1 9 7 3 K u y t3 8 6 8 5 1 3 A 2 / 1 9 7 5 G o n s e r _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 2 5 0 / 5 0 4 An p t i c a l f o c u s i n g d e v i c e i s p o s i t i o n e d t o i n t e r c e p t t h e l i g h t3 , 9 7 0 , 8 5 6 A 7 / 1 9 7 6 Mahaffey e t a 1 _ _ _ _ _ _ _ _ 250/493 emitted b y t h e a r r a y of elements and includes a non-imaging4 , 0 4 8 , 4 9 0 A 9 / 1 9 7 7 T r o u e . . . . . . . . . . . . . . . . . . . . . . 2 4 0 / 4 1 3 5 o p t i c a l d e v i c e which i s o p e r a b l e f o r c o l l i m a t i n g t h e l i g h t

from t h e a r r a y i n t o a beam t o be d i r e c t e d o n t o a compoundL i s t C o n t i n u e d o n n e x t p a g e ) f o r c u r i n g t h e c o m p o u n d . A i s p o s a b l e s l e e v e c o v e r s t h eFOREIGN PATENT DOCUMENTS h o u s i n g a n d a r r a y a n d may i n c o r p o r a t e t h e o p t i c a l f o c u s i n g

d e v i c e . The s l e e v e i s removed and d i s c a r d e d a f t e r u s e t oDE 4 2 1 1 2 3 3 1 / 1 9 9 2 e l i m i n a t e t h e need t o a u t o c l a v e t h e i n s t r u m e n t .EP 0116405 8 / 1 9 8 4EP 0 266 038 1 0 / 1 9 9 1EP 0 5 6 8 6 6 6 1 1 / 1 9 9 2 4 2 C l a i m s , 3 Drawing S h e e t s


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US 6 692 251 B1Page 2

U.S. PATENT DOCUMENTS EP 879582 1/1998EP 880 945 2/19984,114,274 A /1978 Jones EP 884 025 2/19984,114,946 A /1978 Hoffmeister et al. EP 885 025 2/19984,184,196 A /1980 Moret et al. 433/29 EP 998 880 /20004,185,891 A /1980 Kaestner 350/167 EP 031 326 /20004,233,649 A /1980 Scheer et al. EP 090 607 /20014,186,748 A /1980 Schlager 128/736 EP 090 608 /20014,209,907 A /1980 Tsukada et al. EP 093 765 /20014,230,453 A 0/1980 Reimers 433/29 EP 112 721 /20014,280,273 A /1981 Vincent EP 138 276 0/20014,298,806 A 1/1981 Herold 250/504 EP 138 349 0/20014,337,759 A /1982 Popovich et al. 126/438 EP 830 851 /20024,385,344 A /1983 Gonser 362/32 EP 830 852 /20024,391,588 A /1983 Matsui EP 228 738 /20024,398,885 A /1983 Loge et al. 433/126 EP 740 567 1/20024,450,139 A /1984 Bussiere et al. 422/186.3 GB 212 010 A /19894,610,630 A /1986 Betush JP -30275 /19944,666,406 A /1987 Kanca III 433/229 JP -141001 /19964,729,076 A /1988 Masami et al. 362/235 JP -10238 /19974,810,194 A /1989 Snedden 433/91 JP -194786 /19974,826,431 A /1989 Fujimura et al. 433/29 JP 10033573 /19984,846,546 A /1989 Cuda 350/96.24 W O O 83/01311 /19834,888,489 A 2/1989 Bryan 250/504 W O 084/04463 1/19844,935,665 A /1990 Murata 313/500 W O 092/02275 /19924,936,808 A /1990 Lee 445/24 W O O 93/09847 /19934,963,798 A 0/1990 McDermott 315/312 W O 093/21842 1/19934,999,310 A /1991 Kim 437/51 W O 095/19810 /19955,003,434 A /1991 Gonser et al. 362/32 W O 095/26217 0/19955,029,957 A /1991 Hood 350/96.2 W O 097/37722 0/19975,115,761 A /1992 Hood 118/641 W O 097/46279 2/19975,147,204 A /1992 Patten et al. 433/229 W O 097/46280 2/19975,150,016 A /1992 Sawase et al. 315/294 W O 098/03131 /19985,161,879 A 1/1992 McDermott 362/206 W O 098/04317 /19985,162,696 A 1/1992 Goodrich 313/511 W O 099/11324 /19995,201,655 A /1993 Friedman 433/29 W O O 99/20346 /19995,233,283 A /1993 Kennedy 320/13 W O O 00/01464 /20005,242,602 A /1993 Richardson et al. 210/745 W O O 00/02491 /20005,265,792 A 1/1993 Harrah et al. 228/6.2 W O O 00/13608 /20005,278,629 A /1994 Schlager et al. 356/313 W O O 00/15296 /20005,283,425 A /1994 Imamura 250/208.1 W O O 0041726 /20005,290,169 A /1994 Friedman et al. 433/29 W O O 00/41767 /20005,312,249 A /1994 Kennedy W O O 00/41768 /20005,316,473 A /1994 Hare 433/29 W O O 00/43067 /20005,373,114 A 2/1994 Kondo et al. 174/268 W O O 00/43068 /20005,420,768 A /1995 Kennedy 362/119 W O O 00/45733 /20005,471,129 A 1/1995 Mann 320/21 W O O 00/67660 1/20005,521,392 A /1996 Kennedy et al. 250/492.1 W O O 00/676048 1/20005,535,230 A /1996 Abe 372/43 W O O 01/03770 /20015,617,492 A /1997 Beach et al. 385/33 W O O 00/14012 /20015,634,711 A /1997 Kennedy et al. 362/119 W O O 01/24724 /20015,660,461 A /1997 Ignatius et al. 362/241 W O O 01/54770 /20015,664,042 A /1997 Kennedy 385/136 W O O 01/60280 /20015,698,866 A 2/1997 Doiron et al. 257/99 W O O 01/64129 /20015,707,139 A /1998 Haitz 362/231 W O O 01/68035 /20015,711,665 A /1998 Adam et al. 433/9 W O O 01/69691 /20015,747,363 A /1998 Wei et al. 438/5 W O O 02/06723 /20026,008,264 A 2/1999 Ostler et al. 522/4 W O O 02/09610 /20026,102,696 A /2000 Osterwalder et al. 433/29 W O O 02/32505 /20026,200,134 B1 * /2001 Kovac et al. 433/29 W O O 02/33312 /20026 331 111 B1 2/2001 Cao W O O 02/49721 /20026,379,149 B1 /2002 Franetzki6,419,483 B1 /2002 Adam et al. OTHER PU BLICATIONS6,439,888 B1 /2002 Boutoussov et al.6,468,077 B1 0/2002 Melikechi et al.

Swift Jr., Edward J. et al., Ed., Contemporary PhotocuringIssues Part II J. Esthetic Dentistry, 12 1), 50-57,2000.FOREIGN PATENT DOCUMENTS Mayes, Joe H., Curing Lights: An Overview Unknown p.

US 6 , 6 9 2 , 2 5 1 B1P a g e 2

US. PATENT DOCUMENTS EP 0 879582 1 1 / 1 9 9 8EP 0 880 945 1 2 / 1 9 9 84 , 1 1 4 , 2 7 4 A 9 / 1 9 7 8 J o n e s E 1 2 0 884 025 1 2 / 1 9 9 84 , 1 1 4 , 9 4 6 A 9 / 1 9 7 8 H o f f m e i s t e r e t a l . E 1 2 0 885 025 1 2 / 1 9 9 84,184,196 A 1/1980 Moret e t a l . . . . . . . . . . . . . . . . . . . 433/29 E 1 ) 0 9 9 8 880 5/20004,185,891 A 1/1980 Kaestner . . . . . . . . . . . . . . . . . . . . . 350/167 E 1 2 1 031 326 8/20004 , 2 3 3 , 6 4 9 A 1 / 1 9 8 0 S c h e e r e t a l . E 1 2 1 090 607 4 / 2 0 0 14,186,748 A 2/1980 Schlager . . . . . . . . . . . . . . . . . . . . . 128/736 E 1 2 1 090 608 4/20014 , 2 0 9 , 9 0 7 A 7 / 1 9 8 0 Tsukada e t a l . E 1 2 1 093 765 4 / 2 0 0 14,230,453 A 10/1980 Reimers . . . . . . . . . . . . . . . . . . . . . . 433/29 E 1 2 1 112 721 7/20014 , 2 8 0 , 2 7 3 A * 7 / 1 9 8 1 V i n c e n t E 1 2 1 138 276 1 0 / 2 0 0 14,298,806 A 11/1981 Herold . . . . . . . . . . . . . . . . . . . . . . . 250/504 E 1 ) 1 138 349 10/20014 , 3 3 7 , 7 5 9 A 7 / 1982 Popovich e t a l . . . 1 2 6 / 4 3 8 E 1 2 0 830 851 5 / 2 0 0 24,385,344 A 5/1983 Gonser . . . . . . . . . . . . . . . . . . . . . . . . 362/32 E 1 2 0 830 85 2 5/20024 , 3 9 1 , 5 8 8 A 7 / 1 9 8 3 M a t s u i E 1 2 1 228 738 8 / 2 0 0 24,398,885 A 8/1983 Loge e t a l . . . . . . . . . . . . . . . . . . 433/126 E 1 2 0 740 567 11/20024,450,139 A 5/1984 Bussiere e t a l . . . . . . . . . . 422/186.3 GB 2 212 010 A 7/19894 , 6 1 0 , 6 3 0 A 9 / 1 9 8 6 B e t u s h J 1 2 6 - 3 0 2 7 5 2 / 1 9 9 44,666,406 A 5/1987 Kanca, III . . . . . . . . . . . . . . . . . . 433/229 J 1 2 8_141001 6/19964 , 7 2 9 , 0 7 6 A 3/1988 M a s a mi e t a l . . . 362/235 J 1 2 9 4 0 2 3 8 1/19974,810,194 A 3/1989 Snedden . . . . . . . 433/91 J 1 2 8494786 2/19974 , 8 2 6 , 4 3 1 A 5 / 1 9 8 9 F u j i m u r a e t a l . 4 3 3 / 2 9 J 1 2 4 1 0 0 3 3 5 7 3 2 / 1 9 9 84,846,546 A 7/1989 Cuda . . . . . . . . . . . . 350/9624 W0 WO 3/01311 4/19834 , 8 8 8 , 4 8 9 A 1 2 / 1 9 8 9 B r y a n 2 5 0 / 5 0 4 W0 WO84/04463 1 1 / 1 9 8 44 , 9 3 5 , 6 6 5 A 6/1990 Murata . . 313/500 W0 WO92/02275 2/19924,936,808 A 6/1990 Lee . . . . . . . . . . . . . . 445/24 W0 WO 3/09847 5/19934 , 9 6 3 , 7 9 8 A 10/1990 McDermott . . 315/312 W0 WO93/218 4 2 1 1 / 1 9 9 34,999,310 A 3/1991 Kim . . . . . . . . . . . . . 437/51 W0 WO95/19810 7/19955 , 0 0 3 , 4 3 4 A 3 / 1 9 9 1 G o n s e r e t a l . 3 6 2 / 3 2 W0 WO95/26217 1 0 / 1 9 9 55 , 0 2 9 , 9 5 7 A 7 / 1 9 9 1 Hood 3 5 0 / 9 6 . 2 W0 WO97/37722 1 0 / 1 9 9 75,115,761 A 5 / 1 9 9 2 Hood . . . . . . . . . . 118/6 41 W0 WO97/46279 12/19975,147,204 A 9/1992 P a t t e n e t a l . . . . . 433/229 W0 WO97/46280 12/19975 , 1 5 0 , 0 1 6 A 9/1992 Sawase e t a l . . . 315/294 W0 WO98/03131 1/19985 , 1 6 1 , 8 7 9 A 1 1 / 1 9 9 2 McDermott . . 3 6 2 / 2 0 6 W0 logs/04317 2 / 1 9 9 85,162,696 A 11/1992 Goodrich . . . . . . . . . . . . . . . . . . . . 313/511 W0 WO99/11324 3/19995,201,655 A 4/1993 Friedman . . . . . . . . . . . . . . . . . . . . . 433/29 W0 WO 9/20346 4/19995,233,283 A 8/1993 Kennedy . . . . . . . . . 320/13 W0 WO 0/01464 1/20005,242,602 A 9/1993 Richardson e t a l . . . . . . . . . 210/745 W0 WO 0/02491 1/20005,265,792 A 11/1993 Harrah e t a l . . . . . . . . . . . . . . . . . 228/6.2 W0 WO 0/13608 3/20005 , 2 7 8 , 6 2 9 A 1 / 1 9 9 4 S c h l a g e r e t a l . . . 356/313 W0 WO 0/15296 3 / 2 0 0 05,283,425 A 2/1994 I m am u r a . . . . . . . . . . . . . . . . . 2 5 0 /2 0 81 W0 W0 0 4 1726 7/20005,290,169 A 3/1994 Friedman e t a l . . . . . . . . . . . . . . 433/29 W0 WO 0/41767 7/20005 , 3 1 2 , 2 4 9 A 5 / 1 9 9 4 Kennedy W0 WO 0 / 4 1 7 6 8 7 / 2 0 0 05,316,473 A 5/1994 Hare . . . . . . . . . . . . . . . . . . . . . . . . . . . 433/29 W0 WO 0/43067 7/20005,373,114 A 12/1994 Kondo e t a l . . . . . . . . . . . . . . . . 174/268 W0 WO 0/43068 7/20005 , 4 2 0 , 7 6 8 A 5 / 1 9 9 5 Kennedy . . 3 6 2 / 1 1 9 W0 WO 0 / 4 5 7 3 3 8 / 2 0 0 05,471,129 A 11/1995 Mann . . . . . . . . . . . . . . . . . . . . . . . . . . 320/21 W0 WO 0/67660 11/20005,521,392 A 5/1996 Kennedy e t a l . . . . . . . . . . 250/492.1 W0 W0 0/676048 11/20005,535,230 A 7/1996 Abe . . . . . . . . . . . . . 372/43 W0 WO 1/03770 1/20015,617,492 A 4/1997 Beach e t a l . . . . . . . . . . . . . . . . . . . 385/33 W0 WO 0/14012 3/20015,634,711 A 6/1997 Kennedy e t a l . . . . . . . . . . . . . 362/119 W0 WO 1/24724 4/20015,660,461 A 8/1997 I g n a t i u s e t a l . . . . . 362/241 W0 WO 1/54770 8/20015,664,042 A 9/1997 Kennedy . . . . . . . . . . . . . . . . . . . . 385/136 W0 WO 1/60280 8/20015,698,866 A 12/1997 Doiron e t a l . . . . . . . . . . . . . . . . . 257/99 W0 WO 1/64129 9/20015 , 7 0 7 , 1 3 9 A 1 / 1 9 9 8 H a i t Z . . 362/231 W0 WO 1/68035 9 / 2 0 0 15,711,665 A 1/1998 Adarn e t a l . . . . . . . . . . . . . . . . . . . . 433/9 W0 WO 1/69691 9/20015,747,363 A 5/1998 Wei e t a l . . . . . . . . . . . . . . . . . . . . . . . 438/5 W0 WO 2/06723 1/20026 , 0 0 8 , 2 6 4 A 12/1999 O s t l e r e t a l . . . 522/4 W0 WO 2/09610 2/20026,102,696 A * 8/2000 Osterwalder e t a l . . . . . . . . . . 433/29 W0 WO 2/32505 4/20026,200,134 B1 * 3/2001 K o v a c e t a l . . . . . . . . . . . . . . . . . . 433/29 W0 WO 2/33312 4/20026 , 3 3 1 , 1 1 1 B1 1 2 / 2 0 0 1 Cao W0 WO 2 / 4 9 7 2 1 6 / 2 0 0 26 , 3 7 9 , 1 4 9 B1 4 / 2 0 0 2 F r a n e t Z k i6 , 4 1 9 , 4 8 3 B1 7 / 2 0 0 2 Adarn e t a l . OTHER PUBLICATIONS6 , 4 3 9 , 8 8 8 B1 8 / 2 0 0 2 Boutoussov e t a l .6 , 4 6 8 , 0 7 7 B1 1 0 / 2 0 0 2 M e l i k e c h i e t a l .

S w i f t J r . , E d w a r d J . e t a l . , E d . , C o n t e m p o r a r y P h o t o c u r i n gI s s u e s , P a r t I I , J . E s t h e t i c D e n t i s t r y , 1 2 1 ) , 5 0 5 7 , 2 0 0 0 .M a y e s , J o e H . , C u r i n g L i g h t s : An O v e r v i e w , U n k n o w n , p .FOREIGN PATENT DOCUMENTS


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Uno, Shigeru and Asmussen, Erik, Marginal Adaptation ofa Restorative Resin Polymerized at Reduced Rate, Scand J.Dent. Res. 1991; 99: 440-4.DavidsonKaban, Saliha S. et al., The Effect of Curing LightVariations on Bulk Curing and WalltoWall Quality of TwoTypes and Various Shades of Resin Composites, Dent. Mater.13: 344-352, Nov. 1997.Mehl, A. et al., Physical Properties and Gap Formation ofLightCured Composites With and Without SoftstartPoly-merization , J. of Dentistry, 25, 321-330, 1997.Koran, Peter and Kurschner, Ralf, Effect of Sequentialversus Continuous Irradiation of a LightCured Resin Com-posite on Shsrinkage, Viscosity, Adhesion, and Degree ofPolymerization, Am. J. of Dentistry, 11, No. 1, 17-22, 1998.Feltzer, A. J. et al., Influence of Light Intensity on Polymer-ization Shrinkage and Integrity of RestorationCavity Inter-face, Eur. J. Oral Sciences, 103: 322-326, 1995.Kato, Hiromasa, Relationship Between the Velocity of Poly-merization and Adaptation to Dentin Cavity Cavity Wall of

LightCured Composite, Dental Materials J. 6 1): 32-37,1987.Sakaguchi, Ronald L. and Berge, Hong Xu, Reduced LightEnergy Density Decreases PostGel Contraction WhileMaintaining Degree of Conversion in Composites, J ofDentistry, 26, 695-700, 1998.Eibofner et al., Lighting Fixture for a Medical or DentalHandpiece, U52001/0007739, U.S. Patent Application Pub-lication, published Jul. 12, 2001.Gemunder et al., Photo Curing Light System Having Modu-lated Light Intensity Control, U52002/0014864, U.S. PatentApplication Publication, published Feb. 7, 2002.Hooker et al., Optical Wave guide Concentrator and Illumi-nating Device, U52002/0051367, U.S. Patent ApplicationPublication, published May 2, 2002.* cited by examiner

US 6 , 6 9 2 , 2 5 1 B1P a g e 3

U n o , S h i g e r u a n d A s r n u s s e n , E r i k , M a r g i n a l A d a p t a t i o n o fa R e s t o r a t i v e R e s i n Polymerized a t Reduced R a t e , Scand .D e n t . R e s . 1 9 9 1 ; 9 9 : 4 4 0 4 .D a v i d s o n K a b a n , S a l i h a S . e t a l . , T h e E ? r e c t o f C u r i n g L i g h tV a r i a t i o n s o n B u l k C u r i n g and W a l l t o W a l l Q u a l i t y o f TwoT y p e s a n d V a r i o u s S h a d e s o f R e s i n C o m p o s i t e s , D e n t . M a t e r .1 3 : 3 4 4 3 5 2 , N o v . 1 9 9 7 .M e h l , A . e t a l . , P h y s i c a l P r o p e r t i e s a n d Gap F o r m a t i o n o fL i g h t C u r e d C o m p o s i t e s W i t h a n d W i t h o u t S o f t s t a r t P o l ym e r i z a t i o n , J . o f D e n t i s t r y , 2 5 , 3 2 1 3 3 0 , 1 9 9 7 .K o r a n , P e t e r a n d K u r s c h n e r , R a l f , E ? r e c t o f S e q u e n t i a lv e r s u s Continuous I r r a d i a t i o n o f a LightCured Resin Comp o s i t e o n S h s r i n k a g e , V i s c o s i t y , A d h e s i o n , a n d D e g r e e o fP o l y m e r i z a t i o n , Am. . o f D e n t i s t r y , 1 1 , N o . 1 , 1 7 2 2 , 1 9 9 8 .F e l t Z e r , A . J . e t a l . , I n ? u e n c e o f L i g h t I n t e n s i t y o n P o l y m e ri z a t i o n S h r i n k a g e a n d I n t e g r i t y o f R e s t o r a t i o n C a v i t y I n t e rf a c e , E u r . J . O r a l S c i e n c e s , 1 0 3: 3 2 2 3 2 6 , 1 9 9 5 .K a t o , H i r o r n a s a , R e l a t i o n s h i p B e t w e e n t h e V e l o c i t y o f P o l ym e r i z a t i o n a n d A d a p t a t i o n t o D e n t i n C a v i t y C a v i t y W a l l o f

L i g h t C u r e d C o m p o si t e , D e n t a l M a t e r i a l s J . 6 1 ) : 3 2 3 7 ,1 9 8 7 .S a k a g u c h i , R o n a l d L . a n d B e r g e , Hong X u , R e d u c e d L i g h tE n e r g y D e n s i t y D e c r e a s e s P o s t G e l C o n t r a c t i o n W h i l eM a i n t a i n i n g D e g r e e o f C o n v e r s i o n i n C o m p o s i t e s , J . o fD e n t i s t r y , 2 6 , 6 9 5 7 0 0 , 1 9 9 8 .E i b o f n e r e t a l . , L i g h t i n g F i x t u r e f o r a Medical o r DentalH a n d p i e c e , U S 2 0 0 1 / O 0 0 7 7 3 9 , US. P a t e n t A p p l i c a t i o n P u bl i c a t i o n , p u b l i s h e d J u l . 1 2 , 2 0 0 1 .G e r n u n d e r e t a l . , P h o t o C u r i n g L i g h t S y s t e m H a v i n g Modul a t e d L i g h t I n t e n s i t y C o n t r o l , U S 2 0 0 2 / O 0 1 4 8 6 4 , US. P a t e n tA p p l i c a t i o n P u b l i c a t i o n , p u b l i s h e d F e b . 7 , 2 0 0 2 .H o o k e r e t a l . , O p t i c a l W a v e g u i d e C o n c e n t r a t o r a n d I l u m in a t i n g D e v i c e , U S 2 0 0 2 / 0 0 5 1 3 6 7 , US. P a t e n t A p p l i c a t i o nP u b l i c a t i o n , p u b l i s h e d May 2 , 2 0 0 2 .* c i t e d by e X a r n i n e r


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US 6,692,251 B1

Curable adhesive compound s and bonding or filling com -pounds are widely used for structurally connecting objectsurfaces together or for filling gaps, openings and cavities inan object surface. Such curable compo unds are generallymanipulated and positioned on the object surface in asemi-solid state and are then hardened or cured in positionto a mo re solid and permanent state. The curing or hardeningof applicable compou nds is generally a chem ical processwhich is promoted and driven by one or more curingcond itions or factors. For example, the curing process m aybe driven by exposure of the semi-solid compound andcom ponents thereof to air or by exposure of such a com-pound an d its components to an energy source, such as a heatsource.Other curable adhesive and filling compound s are cured

by exposure to radiated energy such as visible and non-visible light energy. Such compo unds, referred to as light-curable compoun ds, are manipulated in a sem i-solid forminto an area or o nto a work surface. Light radiation, pref-erably in the form of a light beam at a specific wavelengthor band of wavelengths, is then directed onto the compou nd.The com pound includes l ight-sensitive chemical compo -nents therein which, when e xposed to the light at the specificwavelength, promote the curing or hardening of the com -pound in the desired position on the work surface to bond,fill , or co at the surface.As an example, l ight-curable f i ll ing and adhesive com-pounds are widely used in dental procedures. Dentists uselight-curable dental compounds for coating and sealing tooth

surfaces, filling caries and o ther cavities in the tooth surface,and securing crowns and various other den tal structures to atooth surface. Conventionally, dental compounds are curedby exposure to light in the blue range of the spectrum. Oncecured, the dental compo und reduces further tooth decay,bonds the dental structure, and/or provides additional struc-ture to a tooth. Therefore, it is important that the compoundsare com pletely cured. 55More specifically, for curing light-curable dentalcom pounds, visible blue light, and particularly a blue lightbeam from a han d-held curing light device, is directed ontoa tooth surface containing the desired comp ound layer. Theblue light penetrates into the com pound layer on the tooth 6surface for complete curing. The duration of the exposure toblue light for proper curing of the comp ound layer is dictatedby the type of compound and the thickness of the compoun dlayer, as well as the power level an d charac teristics of the

2

25

3

35

45

5

APPARATUS AND METHOD FOR C URINGMATERIALS WITH LIGHT RADIATIONRELATED APPLICATIONS

This app lication is a continuation-in-part of U.S. Ser. No.09/009,205, entitled Apparatus and Method for CuringMaterials with Radiation and filed on Jan. 20, 1998 nowU.S. Pat. No. 6,200,134 Bl, which ap plication is incorp o-rated herein by reference in its entirety.FIELD OF THE INVENTION

This app lication is related to the curing of m aterials withradiation and, mo re specifically, to curing dental coating andfilling com poun ds with light.BACKGRO UND OF THE INVENTION

2cavities will require a greater amount of radiated powerdirected onto the tooth surface for prope r curing.

While l ight-curable com pounds have shown very benefi-cial results in the den tal field, existing technique s and den tal5 curing light dev ices utilized to deliver the light to the tooth

surface have various drawbacks. For example, existingdental curing devices requ ire specific filtering m echanisms.Filtering must be do ne for severa l reasons. First, it is knownthat certain wavelengths of blue light are harm ful to human1 tissue. While attempts are mad e to direct the light beam o nlyon to the tooth surface, a certain amount of oral tissueexposure to the light is inevitable. Therefore, harmful wave-lengths m ust be filtered. Additionally, light-curable com -pounds are usually sensitive to light having a somewhat15 specific wavelength, such as a specific blue light wavelengthwith currently available dental compounds. Therefore adental curing light filtering device is tune d to em it light atthe proper wavelengths for both patient safety and propercuring.

Many existing conventional dental curing lights use broadspectrum lamp elements, such as halogen b ulbs. As a result,dental curing lights must utilize special and complicatedfiltering devices or filters which receive the b road spectrumlight from the lamp element, and then filter the light toprovide on ly the light at the desirable wav elengths. Avail-able lamp elements deliver a wide spectrum of radiation,including visible light, UV light, and infra-red light.Therefore, prior art curing techniques and light devices havegenerally been very inefficient, because a large amount ofthe radiated light power is lost simply due to filtering of asignificant part of the light spectrum. For example, the inputpower to a conventional halogen bulb may typically bearound 80 W atts, whereas the output power from the dentallight device of light at the desired blue wavelength, forexamp le 400-500 nanom eters, is typically less than o ne-half(0.5) Watt.Additionally, the efficiency of the prior art dental curinglights is further degraded by pow er losses due to the angle

4 of incidence o f the radiated light upon the filtering element.For exam ple, many prior art curing lights utilize reflectivefilters which reflect only the light at the desirablewavelengths, such as b lue light, onto the tooth surface anddental compound. Light at the undesirable wavelengths ispassed through the filter to a light absorbing componentwhere it is dissipated. If the angle of incide nce of the lightfrom the halog en bulb va ries significantly from the desiredangle of incidence for the filtering element surface (e.g.,45), then a reduced am ount of the desirable light is reflectedonto the tooth surface. This further decreases the am ount ofdesirable light power which is av ailable for curing the dentalcompou nd. Conversely, a higher amount of l ight at unde-sirable wavelengths may also be reflected onto the toothsurface, rather than being transmitted through the filteringelemen t to be dissipated.

Still another draw back with prior art curing lights is thatthey generate significant amounts of heat and thereforerequire complicated cooling systems to operate within theproper temperature range. The significant amount of lightenergy at the undesirable wavelengths, which is generatedby the halogen b ulb, must be filtered or otherwise captured.The cap tured or filtered energy is then dissipated in the formof heat. Therefore, power absorbing and heat dissipatingelements are required within conventional curing light

US 6 , 6 9 2 , 2 5 1 B11

APPARATUSAND METHOD FOR CURINGMATERIALS WITH LIGHT RADIATION

RELATED APPLICATIONST h i s a p p l i c a t i o n i s a c o n t i n u a t i o n - i n - p a r t o f US. S e r . N o .

0 9 / 0 0 9 , 2 0 5 , e n t i t l e d A p p a r a t u s a n d M e t h o d f o r C u r i n gM a t e r i a l s With R a d i a t i o n and ? l e d on J a n . 2 0 , 1998 nowUS. P a t . N o . 6 , 2 0 0 , 1 3 4 B 1 , W h i c h a p p l i c a t i o n i s i n c o r p or a t e d h e r e i n b y r e f e r e n c e i n i t s e n t i r e t y .

FIE LD OF THE INVENTIONT h i s a p p l i c a t i o n i s r e l a t e d t o t h e c u r i n g o f m a t e r i a l s W i t h

r a d i a t i o n a n d , more s p e c i ? c a l l y , t o c u r i n g de n t a l c o a t i n g a n d? l l i n g c o m p o u n d s w i t h l i g h t .BACKGROUND OF THE INVENTION

C u r a b l e a d h e s i v e compounds a n d b o n d i n g o r ? l l i n g c o r np o u n d s a r e W i d e l y u s e d f o r s t r u c t u r a l l y c o n n e c t i n g o b j e c ts u r f a c e s t o g e t h e r o r f o r ? l l i n g g a p s , o p e n i n g s a n d c a v i t i e s i na n o b j e c t s u r f a c e . Such c u r a b l e compounds a r e g e n e r a l l ym a n i p u l a t e d a n d p o s i t i o n e d o n t h e o b j e c t s u r f a c e i n as e r n i - s o l i d s t a t e and a r e t h e n hardened o r c u r e d i n p o s i t i o nt o a more s o l i d and permanent t a t e . The c u r i n g o r hardeningo f a p p l i c a b l e compounds i s g e n e r a l l y a c h e m i c a l p r o c e s sWhich i s promoted and d r i v e n b y o n e o r more c u r i n gc o n d i t i o n s o r f a c t o r s . F o r e x a m p l e , t h e c u r i n g p r o c e s s mayb e d r i v e n b y e x p o s u r e o f t h e s e r n i - s o l i d compound a n dcomponents t h e r e o f t o a i r o r b y exposure o f such a c o r npound and t s components o a n energy s o u r c e , such a s a h e a tsource.

O t h e r c u r a b l e a d h e s i v e a n d ? l l i n g compounds a r e c u r e db y exposure t o r a d i a t e d e n e r g y , such a s v i s i b l e and nonv i s i b l e l i g h t e n e r g y . Such c o r n p o u n d s , r e f e r r e d t o a s l i g h tc u r a b l e compounds, a r e m a n i p u l a t e d i n a s e r n i - s o l i d formi n t o an a r e a o r o n t o a W o r k s u r f a c e . L i g h t r a d i a t i o n , p r e fe r a b l y i n t h e f o r m o f a l i g h t beam a t a s p e c i ? c W a v e l e n g t ho r band o f W a v e l e n g t h s , i s t h e n d i r e c t e d o n t o t h e compound.T h e compound i n c l u d e s l i g h t - s e n s i t i v e c h e r n i c a l compon e n t s t h e r e i n W h i c h , When e x p o s e d t o t h e l i g h t a t t h e s p e c i ? cW a v e l e n g t h , p r o m o t e t h e c u r i n g o r h a r d e n i n g o f t h e c o r npound i n t h e d e s i r e d p o s i t i o n on t h e W o rk s u r f a c e t o b o n d ,? l l , o r c o a t t h e s u r f a c e .

As a n e x a m p l e , l i g h t - c u r a b l e ? l l i n g a n d a d h e s i v e c o r npounds a r e W i d e l y u s e d i n d e n t a l p r o c e d u r e s . D e n t i s t s u s el i g h t - c u r a b l e d e n t a l c o m p o u n d s f o r c o a t i n g a n d s e a l i n g t o o t hs u r f a c e s , ? l l i n g c a r i e s a n d o t h e r c a v i t i e s i n t h e t o o t h s u r f a c e ,and s e c u r i n g croWns and v a r i o u s o t h e r d e n t a l s t r u c t u r e s t o at o o t h s u r f a c e . C o n v e n t i o n a l l y , d e n t a l compounds a r e c u r e dby e x p o s u r e t o l i g h t i n t h e b l u e r a n g e o f t h e s p e c t r u m . Oncec u r e d , t h e d e n t a l c o r n p o u n d r e d u c e s f u r t h e r t o o t h d e c a y ,b o n d s t h e d e n t a l s t r u c t u r e , a n d / o r p r o v i d e s a d d i t i o n a l s t r u ct u r e t o a t o o t h . T h e r e f o r e , i t i s i m p o r t a n t t h a t t h e compoundsa r e c o m p l e t e l y c u r e d .

More s p e c i ? c a l l y , f o r c u r i n g l i g h t - c u r a b l e d e n t a lc o r n p o u n d s , v i s i b l e b l u e l i g h t , a n d p a r t i c u l a r l y a b l u e l i g h tbeam f r o m a h a n d - h e l d c u r i n g l i g h t d e v i c e , i s d i r e c t e d o n t oa t o o t h s u r f a c e c o n t a i n i n g t h e d e s i r e d compound a y e r . Theb l u e l i g h t p e n e t r a t e s i n t o t h e compound l a y e r o n t h e t o o t hs u r f a c e f o r c o m p l e t e c u r i n g . The d u r a t i o n o f t h e e x p o s u r e t ob l u e l i g h t f o r p r o p e r c u r i n g o f t h e compound a y e r i s d i c t a t e db y t h e t y p e o f compound a n d t h e t h i c k n e s s o f t h e compoundl a y e r , a s W e l l a s t h e poWer l e v e l and c h a r a c t e r i s t i c s o f t h e

10

1 5

20

25

30

35

40

45

50

55

60

2c a v i t i e s W i l l r e q u i r e a g r e a t e r amount o f r a d i a t e d poWerd i r e c t e d o n t o t h e t o o t h s u r f a c e f o r p r o p e r c u r i n g .

W h i l e l i g h t - c u r a b l e compounds h a v e shoWn v e r y b e n e ?c i a l r e s u l t s i n t h e d e n t a l ? e l d , e x i s t i n g t e c h n i q u e s a n d d e n t a lc u r i n g l i g h t d e v i c e s u t i l i Z e d t o d e l i v e r t h e l i g h t t o t h e t o o t hs u r f a c e h a v e v a r i o u s d r a W b a c k s . F o r e x a m p l e , e x i s t i n gd e n t a l c u r i n g d e v i c e s r e q u i r e s p e c i ? c ? l t e r i n g m e c h a n i s m s .F i l t e r i n g must b e done f o r s e v e r a l r e a s o n s . F i r s t , i t i s knoWnt h a t c e r t a i n W a v e l e n g t h s o f b l u e l i g h t a r e h a r m f u l t o humant i s s u e . While a t t e m p t s a r e made o d i r e c t t h e l i g h t beam o n l yon t o t h e t o o t h s u r f a c e , a c e r t a i n amount o f o r a l t i s s u ee x p o s u r e t o t h e l i g h t i s i n e v i t a b l e . T h e r e f o r e , h a r r n f u l Wavel e n g t h s r n u s t b e ? l t e r e d . A d d i t i o n a l l y , l i g h t - c u r a b l e c o r np o u n d s a r e u s u a l l y s e n s i t i v e t o l i g h t h a v i n g a somewhats p e c i ? c W a v e l e n g t h , s u c h a s a s p e c i ? c b l u e l i g h t W a v e l e n g t hW i t h c u r r e n t l y a v a i l a b l e d e n t a l c o r n p o u n d s . T h e r e f o r e , ad e n t a l c u r i n g l i g h t ? l t e r i n g d e v i c e i s t u n e d t o e m i t l i g h t a tt h e p r o p e r W a v e l e n g t h s f o r b o t h p a t i e n t s a f e t y a n d p r o p e rc u r i n g .

Many x i s t i n g c o n v e n t i o n a l d e n t a l c u r i n g l i g h t s u s e b r o a ds p e c t r u m l a r n p e l e m e n t s , s u c h a s h a l o g e n b u l b s . As r e s u l t ,d e n t a l c u r i n g l i g h t s r n u s t u t i l i Z e s p e c i a l a n d c o m p l i c a t e d? l t e r i n g d e v i c e s o r ? l t e r s Which r e c e i v e t h e b r o a d s p e c t r u ml i g h t f r o m t h e l a m p e l e m e n t , a n d t h e n ? l t e r t h e l i g h t t op r o v i d e o n l y t h e l i g h t a t t h e d e s i r a b l e W a v e l e n g t h s . A v a i la b l e l a r n p e l e r n e n t s d e l i v e r a w i d e s p e c t r u m o f r a d i a t i o n ,i n c l u d i n g v i s i b l e l i g h t , UV i g h t , a n d i n f r a - r e d l i g h t .T h e r e f o r e , p r i o r a r t c u r i n g t e c h n i q u e s a n d l i g h t d e v i c e s h a v eg e n e r a l l y b e e n v e r y i n e f ? c i e n t , b e c a u s e a l a r g e amount o ft h e r a d i a t e d l i g h t poWer i s l o s t s i m p l y d u e t o ? l t e r i n g o f as i g n i ? c a n t p a r t o f t h e l i g h t s p e c t r u m . F o r e x a m p l e , t h e i n p u tpoWer t o a c o n v e n t i o n a l h a l o g e n b u l b r n a y t y p i c a l l y b ea r o u n d 8 0 W a t t s , W h e r e a s t h e o u t p u t power f r o m t h e d e n t a ll i g h t d e v i c e o f l i g h t a t t h e d e s i r e d b l u e W a v e l e n g t h , f o re x a m p l e 4 0 0 5 0 0 n a n o r n e t e r s , i s t y p i c a l l y l e s s t h a n o n e - h a l f0 . 5 ) W a t t .

A d d i t i o n a l l y , t h e e f f i c i e n c y o f t h e p r i o r a r t d e n t a l c u r i n gl i g h t s i s f u r t h e r d e g r a d e d b y p o W e r l o s s e s d u e t o t h e a n g l eo f i n c i d e n c e o f t h e r a d i a t e d l i g h t upon t h e ? l t e r i n g e l e r n e n t .F o r e x a m p l e , many p r i o r a r t c u r i n g l i g h t s u t i l i Z e r e ? e c t i v e? l t e r s Which r e ? e c t o n l y t h e l i g h t a t t h e d e s i r a b l eW a v e l e n g t h s , s u c h a s b l u e l i g h t , o n t o t h e t o o t h s u r f a c e a n dd e n t a l c o r n p o u n d . L i g h t a t t h e u n d e s i r a b l e W a v e l e n g t h s i sp a s s e d t h r o u g h t h e ? l t e r t o a l i g h t a b s o r b i n g c o r n p o n e n tW h e r e i t i s d i s s i p a t e d . I f t h e a n g l e o f i n c i d e n c e o f t h e l i g h tf r o m t h e h a l o g e n b u l b v a r i e s s i g n i ? c a n t l y f r o m t h e d e s i r e da n g l e o f i n c i d e n c e f o r t h e ? l t e r i n g e l e m e n t s u r f a c e e . g . ,4 5 ) , t h e n a r e d u c e d amount o f t h e d e s i r a b l e l i g h t i s r e ? e c t e do n t o t h e t o o t h s u r f a c e . T h i s f u r t h e r d e c r e a s e s t h e amount o fd e s i r a b l e l i g h t poWer W h i c h i s a v a i l a b l e f o r c u r i n g t h e d e n t a lc o r n p o u n d . C o n v e r s e l y , a h i g h e r a m o u n t o f l i g h t a t u n d es i r a b l e W a v e l e n g t h s may a l s o b e r e ? e c t e d o n t o t h e t o o t hs u r f a c e , r a t h e r t h a n b e i n g t r a n s m i t t e d t h r o u g h t h e ? l t e r i n ge l e m e n t t o b e d i s s i p a t e d .

S t i l l a n o t h e r d r a W b a c k W i t h p r i o r a r t c u r i n g l i g h t s i s t h a tt h e y g e n e r a t e s i g n i ? c a n t a m o u n t s o f h e a t a n d t h e r e f o r er e q u i r e c o r n p l i c a t e d c o o l i n g s y s t e m s t o o p e r a t e W i t h i n t h ep r o p e r t e m p e r a t u r e r a n g e . T h e s i g n i ? c a n t a m o u n t o f l i g h te n e r g y a t t h e u n d e s i r a b l e W a v e l e n g t h s , W h i c h i s g e n e r a t e dby t h e h a l o g e n b u l b , m u s t b e ? l t e r e d o r o t h e r W i s e c a p t u r e d .The c a p t u r e d o r ? l t e r e d e n e r g y i s t h e n d i s s i p a t e d i n t h e formo f h e a t . T h e r e f o r e , p o W e r a b s o r b i n g a n d h e a t d i s s i p a t i n ge l e m e n t s a r e r e q u i r e d W i t h i n c o n v e n t i o n a l c u r i n g l i g h t


16/57

US 6,692,251 B1unused light energy in the form of heat. The high poweroutput required for the halogen bulb to produce the desiredlight power level for curing, creates a significantly highthermal load on the shields. The shields must then be cooled.Generally, fan elem ents are used in the dental light device toprovide conv ective cooling to the shields. The add itionalcooling elements increase the size of the light device andcom plicate its design. As will be appreciated, it is desirableto keep the light device as small and maneuverable aspossible, since it is hand-held and used in a patient's mouth.Add itionally, a therm al load is also placed on the reflec-tive filter element, which m ust then also be cooled, such asby heat sinks and fans. The absorption devices and heatdissipating systems not only com plicate the operation anddesign of the light device, but also m ake it more expensiveto produce, and more subject to operational failure.Anothe r drawback of prior art dental curing light devicesis the limited operational life of the lamp element, such asa halogen bulb. The bulbs frequently burn out and m ust bereplaced. Furthermore, the heat generated inside the lightdevice which is usually enclosed shortens the effectiveoperational lifespan of the bulb.Attempts have been m ade in the prior art to address someof these drawbacks. For example, Japanese Patent Applica-tions No. 6-30275, 6-285508, 7-163863, and 8-194786; U.S.Pat. Nos. 5,420,768 and 5,634,711; and U.K. patent appli-cation No. GB 2,329,756, all disclose various devices usingpackaged, conventional light-emitting diodes or LED s, toprovide a curing light source w ith light in the desirable bluerange. While specific blue light is provided by the L EDswithout significant filtering, various of these devices requirecom plicated internal designs for focusing of the curing light,or require specific electronic control of the LEDs.Furthermore, large num bers of conventional LEDs are n ec-essary. As illustrated in the Figures of those applications, thesolid state LED elem ents are spread out over a circuit boardor other support structure and require a somewhat largehousing to contain all of the conventional LEDs necessaryfor generating the intensity of light which is required forpractical curing uses. Therefore, it has been difficult toprovide a suitable curing light using conventional LEDs,which w ill generate sufficient curing power in a small andcomplete design.

Using traditional packaged LEDs, as disclosed in theabove-cited art, has specifically presented difficulties asso-ciated with generating sufficient curing power within areasonably sized device which may be adequately cooled.Further complications with such devices have resulted fromattempts to concentrate the light from the large grouping oftraditional LEDs into a small area and at a sufficient powerdensity so as to be useful for curing. Such difficulties inproviding a suitable curing light device utilizing the existingtraditional packaged LED technology is highlighted by thelack of a w ell-received and w idely-utilized dental curinglight on the market which utilizes such technology.Alternatively the devices and technology disclosed inU.S. patent application Ser. N o. 09/009,205, noted above,have prov ided a curing device w ith solid state, light-emittingcomponents w hich generate sufficient curing pow er densi-ties in a reasonably-sized device that may be properlycooled. Further efforts by the inventors of the presentapplication are continuing to improve the existing technol-ogy disclosed in that earlier application and to provide thedesirable curing po wer density, size and therm al character-

4work surface, such as a tooth surface, once the light has beengenerated by the element or bulb. The light is generatedwithin the main housing of the curing light and must betransmitted to an output end o f the housing. Existing dental

5 curing lights utilize elongated light guides to deliver lightfrom the light generating elements inside the housing to thetooth.

Light guides are usually comprised of a large num ber ofoptical fibers fused together into an elongated guide. The10 air/glass interfaces between the generating elemen ts and theinput end of the light guide and the output end of the lightguide and the inside of the mouth are inefficient and m ayproduce approximately a 10 loss in power per interface.Furthermore, prior art devices may utilize a converging lens15 to focus light into the input end of the light guide. Thisprovides another lossy interface encountered by the light.Such inefficiencies further increase the cure time that isnecessary, and/or create the need for higher power andassociated heat) to provide the necessary curing light inten-2 0 sityAnother concern with dental curing lights is that suchl ights are m edical/dental instrume nts, and a portion of theinstrument is introduced into a cav ity of the bo dy, i .e. themouth. Since the same curing light will be utilized with25 different patients, cross-contamination between patents mustbe avoided . Accordingly, sterilization of the curing light, ora portion thereof, has been necessary with conventionaldevices. Sterilization, often referred to as autoclaving,requires additional equipmen t which must be purchased and3 maintained by the dentist or other physician. Sterilizationalso introduces an extra step in between curing procedures.Furthermore, the high heat required for sterilization m ay,over time, damage components of the curing light.Accordingly, conventional curing lights m ust be designed to35 withstand sterilization and the high temperatures associatedtherewith of to otherw ise address the sterilization issue.

According ly, it is an objective of the present invention toprovide a sim ple, durable curing light device for hardening4 or curing light-curable compounds. Particularly, it is anobjective to provide such a curing light device for curingdental compounds used for dental fillings and coatings.

It is another objective to provide a curing light utilizingsolid state light elements.45 t is another objective to provide a curing light which hasa compact and simple design and which is capable ofproviding a light power density that is useful for practical

curing applications.It is still another objective of the present inven tion to cure5 compounds with curing lights utilizing less power andhaving greater efficiency to reduce the amount of heatenergy generated by the device and thus reduce the heatenergy wh ich must be dissipated. Furthermore, it is desirableto provide more efficient cooling of the light-generating55 devices.

It is still another objective of the invention to eliminate thenecessity of reflective filters and o ther filter elements withina light device for curing light-curable compou nds.6 t is still another objective to address the need for sterilitywithin a curing light.

It is still a further objective to provid e a blue light devicewhich operates within a small space and is easily m anipu-lated within the mo uth of a dental patient.

US 6 , 6 9 2 , 2 5 1 B13

u n u s e d l i g h t e n e r g y i n t h e f o r m o f h e a t . The h i g h powero u t p u t r e q u i r e d f o r t h e h a l o g e n b u l b t o p r o d u c e t h e d e s i r e dl i g h t p o W e r l e v e l f o r c u r i n g , c r e a t e s a s i g n i ? c a n t l y h i g ht h e r m a l l o a d on h e s h i e l d s . The s h i e l d s must t h e n be c o o l e d .G e n e r a l l y , f a n e l e m e n t s a r e u s e d i n t h e d e n t a l l i g h t d e v i c e t op r o v i d e c o n v e c t i v e c o o l i n g t o t h e s h i e l d s . The a d d i t i o n a lc o o l i n g e l e m e n t s i n c r e a s e t h e s i Z e o f t h e l i g h t d e v i c e a n dc o m p l i c a t e i t s d e s i g n . As i l l b e a p p r e c i a t e d , i t i s d e s i r a b l et o keep t h e l i g h t d e v i c e a s s m a l l and maneuverable a sp o s s i b l e , s i n c e i t i s h a n d - h e l d a n d u s e d i n a p a t i e n t s m o u t h .

A d d i t i o n a l l y , a t h e r m a l l o a d i s a l s o p l a c e d on t h e r e ? e ct i v e ? l t e r e l e m e n t , Which must t h e n a l s o b e c o o l e d , s u c h a sby h e a t s i n k s a n d f a n s . The a b s o r pt i o n d e v i c e s a n d h e a td i s s i p a t i n g s y s t e m s n o t o n l y c o m p l i c a t e t h e o p e r a t i o n a n dd e s i g n o f t h e l i g h t d e v i c e , b u t a l s o make t m o r e e x p e n s i v et o p r o d u c e , a n d more s u b j e c t t o o p e r a t i o n a l f a i l u r e .

A n o t h e r d r a W b a c k o f p r i o r a r t d e n t a l c u r i n g l i g h t d e v i c e si s t h e l i m i t e d o p e r a t i o n a l l i f e o f t h e l a m p e l e m e n t , s u c h a sa h a l o g e n b u l b . The b u l b s f r e q u e n t l y b u r n o u t a n d must b er e p l a c e d . F u r t h e r m o r e , t h e h e a t g e n e r a t e d i n s i d e t h e l i g h td e v i c e , W h i c h i s u s u a l l y e n c l o s e d , s h o r t e n s t h e e f f e c t i v eo p e r a t i o n a l l i f e s p a n o f t h e b u l b .

A t t e m p t s h a v e been made i n t h e p r i o r a r t t o a d d r e s s someo f t h e s e d r a W b a c k s . F o r e x a m p l e , J a p a n e s e P a t e n t A p p l i c at i o n s N o . 6 - 3 0 2 7 5 , 6 - 2 8 5 5 0 8 , 7 - 1 6 3 8 63 , a n d 8 - 1 9 4 7 8 6 ; US.P a t . N o s . 5 , 4 2 0 , 7 6 8 a n d 5 , 6 3 4 , 7 1 1 ; a n d U K . p a t e n t a p p l ic a t i o n N o . GB , 3 2 9 , 7 5 6 , a l l d i s c l o s e v a r i o u s d e v i c e s u s i n gp a c k a g e d , c o n v e n t i o n a l l i g h t - e m i t t i n g d i o d e s o r LEDs, t op r o v i d e a c u r i n g l i g h t s o u r c e W i t h l i g h t i n t h e d e s i r a b l e b l u er a n g e . W h i l e s p e c i ? c b l u e l i g h t i s p r o v i d e d b y t h e LEDsW i t h o u t s i g n i ? c a n t ? l t e r i n g , v a r i o u s o f t h e s e d e v i c e s r e q u i r ec o m p l i c a t e d i n t e r n a l d e s i g n s f o r f o c u s i n g o f t h e c u r i n g l i g h t ,o r r e q u i r e s p e c i ? c e l e c t r o n i c c o n t r o l o f t h e LEDs.F u r t h e r m o r e , l a r g e numbers o f c o n v e n t i o n a l L E D s a r e n e ce s s a r y . As l l u s t r a t e d i n t h e F i g u r e s o f t h o s e a p p l i c a t i o n s , t h es o l i d s t a t e LED elements a r e spread out over a c i r c u i t boardo r o t h e r s u p p o r t s t r u c t u r e a n d r e q u i r e a someWhat l a r g eh o u s i n g t o c o n t a i n a l l o f t h e c o n v e n t i o n a l L E D s n e c e s s a r yf o r g e n e r a t i n g t h e i n t e n s i t y o f l i g h t W h i c h i s r e q u i r e d f o rp r a c t i c a l c u r i n g u s e s . T h e r e f o r e , i t h a s b e e n d i f ? c u l t t op r o v i d e a s u i t a b l e c u r i n g l i g h t u s i n g c o n v e n t i o n a l L E D s ,Which W i l l g e n e r a t e s u f ? c i e n t c u r i n g poWer i n a s m a l l a n dc o m p l e t e d e s i g n .

U s i n g t r a d i t i o n a l p a c k a g e d LEDs, a s d i s c l o s e d i n t h ea b o v e - c i t e d a r t , h a s s p e c i ? c a l l y p r e s e n t e d d i f f i c u l t i e s a s s oc i a t e d W i t h g e n e r a t i n g s u f ? c i e n t c u r i n g poWer W i t h i n ar e a s o n a b l y s i Z e d d e v i c e W h i c h may b e a d e q u a t e l y c o o l e d .F u r t h e r c o m p l i c a t i o n s W i t h s u c h d e v i c e s h a v e r e s u l t e d f r o ma t t e m p t s t o c o n c e n t r a t e t h e l i g h t f r o m t h e l a r g e g r o u p i n g o ft r a d i t i o n a l LEDs n t o a small a r e a and a t a s u f f i c i e n t poWerd e n s i t y s o a s t o b e u s e f u l f o r c u r i n g . Such d i f ? c u l t i e s i np r o v i d i n g a s u i t a b l e c u r i n g l i g h t d e v i c e u t i l i Z i n g t h e e x i s t i n gt r a d i t i o n a l p a c k a g e d LED t e c h n o l o g y i s h i g h l i g h t e d b y t h el a c k o f a W e l l - r e c e i v e d a n d W i d e l y - u t i l i z e d d e n t a l c u r i n gl i g h t on t h e m a r k e t Which u t i l i Z e s s u c h t e c h n o l o g y .A l t e r n a t i v e l y , t h e d e v i c e s a n d t e c h n o l o g y d i s c l o s e d i nUS. p a t e n t a p p l i c a t i o n S e r . N o . 0 9 / 00 9 , 2 0 5 , n o t e d a b o v e ,h a v e p r o v i d e d a c u r i n g d e v i c e W i t h s o l i d s t a t e , l i g h t - e m i t t i n gc o m p o n e n t s W h i c h g e n e r a t e s u f f i c i e n t c u r i n g p o W e r d e n s it i e s i n a r e a s o n a b l y - s i Z e d d e v i c e t h a t may b e p r o p e r l yc o o l e d . F u r t h e r e f f o r t s b y t h e i n v e n t o r s o f t h e p r e s e n ta p p l i c a t i o n a r e c o n t i n u i n g t o i m p r o v e t h e e x i s t i n g t e c h n o logy d i s c l o s e d i n t h a t e a r l i e r a p p l i c a t i o n a n d t o p r o v i d e t h ed e s i r a b l e c u r i n g poWer d e n s i t y , s i Z e a n d t h e r m a l c h a r a c t e r

10

1 5

20

25

30

35

40

45

50

55

60

4W o r k s u r f a c e , s u c h a s a t o o t h s u r f a c e , once t h e l i g h t h a s beeng e n e r a t e d b y t h e e l e m e n t o r b u l b . T h e l i g h t i s g e n e r a t e dW i t h i n t h e m a i n h o u s i n g o f t h e c u r i n g l i g h t , a n d m u s t b et r a n s m i t t e d t o a n o u t p u t e n d o f t h e h o u s i n g . E x i s t i n g d e n t a lc u r i n g l i g h t s u t i l i Z e e l o n g a t e d l i g h t g u i d e s t o d e l i v e r l i g h tf r o m t h e l i g h t g e n e r a t i n g e l e m e n t s i n s i d e t h e h o u s i n g t o t h et o o t h .

L i g h t g u i d e s a r e u s u a l l y c o m p r i s e d o f a l a r g e number o fo p t i c a l ? b e r s f u s e d t o g e t h e r i n t o a n e l o n g a t e d g u i d e . T h ea i r / g l a s s i n t e r f a c e s b e t W e e n t h e g e n e r a t i n g e l e m e n t s a n d t h ei n p u t e n d o f t h e l i g h t g u i d e a n d t h e o u t p u t e n d o f t h e l i g h tg u i d e a n d t h e i n s i d e o f t h e mouth a r e i n e f ? c i e n t a n d mayp r o d u c e a p p r o x i m a t e l y a 10% l o s s i n poWer p e r i n t e r f a c e .F u r t h e r m o r e , p r i o r a r t d e v i c e s may t i l i Z e a c o n v e r g i n g l e n st o f o c u s l i g h t i n t o t h e i n p u t e n d o f t h e l i g h t g u i d e . T h i sp r o v i d e s a n o t h e r l o s s y i n t e r f a c e e n c o u n t e r e d b y t h e l i g h t .Such i n e f ? c i e n c i e s f u r t h e r i n c r e a s e t h e c u r e t i m e t h a t i sn e c e s s a r y , a n d / o r c r e a t e t h e n e e d f o r h i g h e r poWer ( a n da s s o c i a t e d h e a t ) t o p r o v i d e t h e n e c e s s a r y c u r i n g l i g h t i n t e ns i t y .

A n o t h e r c o n c e r n W i t h d e n t a l c u r i n g l i g h t s i s t h a t s u c hl i g h t s a r e m e d i c a l / d e n t a l i n s t r u m e n t s , a n d a p o r t i o n o f t h ei n s t r u m e n t i s i n t r o d u c e d i n t o a c a v i t y o f t h e b o d y , i . e . t h em o u t h . S i n c e t h e same c u r i n g l i g h t W i l l b e u t i l i Z e d W i t hd i f f e r e n t p a t i e n t s , c r o s s - c o n t a m i n a t i o n b e t W e e n p a t e n t s m u s tb e a v o i d e d . A c c o r d i n g l y , s t e r i l i Z a t i o n o f t h e c u r i n g l i g h t , o ra p o r t i o n t h e r e o f , h a s b e e n n e c e s s a r y W i t h c o n v e n t i o n a ld e v i c e s . S t e r i l i Z a t i o n , o f t e n r e f e r r e d t o a s a u t o c l a v i n g ,r e q u i r e s a d d i t i o n a l e q u i p m e n t W h i c h m u s t b e p u r c h a s e d a n dm a i n t a i n e d by t h e d e n t i s t o r o t h e r p h y s i c i a n . S t e r i l i Z a t i o na l s o i n t r o d u c e s a n e x t r a s t e p i n b e t W e e n c u r i n g p r o c e d u r e s .F u r t h e r m o r e , t h e h i g h h e a t r e q u i r e d f o r s t e r i l i Z a t i o n m a y ,o v e r t i m e , d a m a g e c o m p o n e n t s o f t h e c u r i n g l i g h t .A c c o r d i n g l y , c o n v e n t i o n a l c u r i n g l i g h t s m u s t b e d e s i g n e d t oW i t h s t a n d s t e r i l i Z a t i o n a n d t h e h i g h t e m p e r a t u r e s a s s o c i a t e dt h e r e W i t h o f t o o t h e r W i s e a d d r e s s t h e s t e r i l i Z a t i o n i s s u e .

A c c o r d i n g l y , i t i s a n o b j e c t i v e o f t h e p r e s e n t i n v e n t i o n t op r o v i d e a s i m p l e d u r a b l e c u r i n g l i g h t d e v i c e f o r h a r d e n i n go r c u r i n g l i g h t - c u r a b l e c o m p o u n d s . P a r t i c u l a r l y , i t i s a no b j e c t i v e t o p r o v i d e s u c h a c u r i n g l i g h t d e v i c e f o r c u r i n gd e n t a l c o m p o u n d s u s e d f o r d e n t a l ? l l i n g s a n d c o a t i n g s .

I t i s a n o t h e r o b j e c t i v e t o p r o v i d e a c u r i n g l i g h t u t i l i Z i n gs o l i d s t a t e l i g h t e l e m e n t s .

I t i s a n o t h e r o b j e c t i v e t o p r o v i d e a c u r i n g l i g h t W h i c h h a sa c o m p a c t a n d s i m p l e d e s i g n a n d W h i c h i s c a p a b l e o fp r o v i d i n g a l i g h t p o W e r d e n s i t y t h a t i s u s e f u l f o r p r a c t i c a lc u r i n g a p p l i c a t i o n s .I t i s s t i l l a n o t h e r o b j e c t i v e o f t h e p r e s e n t i n v e n t i o n t o c u r ec o m p o u n d s W i t h c u r i n g l i g h t s u t i l i Z i n g l e s s p o W e r a n dh a v i n g g r e a t e r e f ? c i e n c y t o r e d u c e t h e a m o u n t o f h e a te n e r g y g e n e r a t e d by t h e d e v i c e a n d t h u s r e d u c e t h e h e a te n e r g y W h i c h m u s t b e d i s s i p a t e d . F u r t h e r m o r e , i t i s d e s i r a b l et o p r o v i d e more e f ? c i e n t c o o l i n g o f t h e l i g h t - g e n e r a t i n gd e v i c e s .

I t i s s t i l l a n o t h e r o b j e c t i v e o f t h e i n v e n t i o n t o e l i m i n a t e t h en e c e s s i t y o f r e ? e c t i v e ? l t e r s a n d o t h e r ? l t e r e l e m e n t s W i t h i na l i g h t d e v i c e f o r c u r i n g l i g h t - c u r a b l e c o m p o u n d s .

I t i s s t i l l a n o t h e r o b j e c t i v e t o a d d r e s s t h e n e e d f o r s t e r i l i t yW i t h i n a c u r i n g l i g h t .

I t i s s t i l l a f u r t h e r o b j e c t i v e t o p r o v i d e a b l u e l i g h t d e v i c eWhich o p e r a t e s W i t h i n a s m a l l s p a c e a n d i s e a s i l y manipul a t e d W i t h i n t h e mouth o f a d e n t a l p a t i e n t .


17/57

US 6 692 251 B15

SUMMA RY OF THE INVENTIONAn instrument and method for curing light-curablecomp ounds such as dental comp ounds in the mouth of apatient comprises a housing which supports a plurality ofsolid state light-emitting elements. The elements are pref-erably light-emitting dies formed of a semiconductor mate-rial. The elements are mounted on a substrate supported bythe housing to form a collective array w hich is operable forcollectively emitting light having a wavelength within a

narrow band of wavelengths. In one embodiment of theinvention the narrow band of wavelengths includes that ofthe blue wavelength. However other wavelengths mightalso be utilized dependin g upon the light sensitivity of thecurable compound utilized.One suitable housing for the invention includes a gun-shaped housing which has a handle portion and a barrelportion. The handle portion is held by an op erator and thebarrel portion is directed toward a work surface such as atooth. A portable power supply m ay be utilized within thehousing such that the instrument is a hand-held instrumentwhich is completely portable. In one embodiment of theinvention the array of light-emitting elements is positionedon the distal end of the barrel portion of the housing whichis placed within the mo uth of a patient so that the light isdelivered directly to a work surface such as a tooth. In analternative embodiment the array of elements may be posi-tioned in the housing such that the generated light must betransmitted to the distal end such as by an optical fiber lightguide.

In accordance W ith one aspect of the present invention anoptical focusing device is positioned to intercept the lightemitted by the array of elements. The optical focusingdevice is a non-imaging optical device which is operab le forcollimating the light from the array into a beam to bedirected on to a compoun d for curing the compound. Thenon-imaging device efficiently collimates and transmits thelight from the array to a work surface without inefficienciesassociated w ith imaging lenses in the prior art. A reflectiveelement may b e positioned between the array and the opticalfocusing device for further efficiently directing light fromthe array into the optical focusing device to be collimatedand delivered to a w ork surface.

In accordance with another aspect of the presentinvention the array of dies is arranged on a substrate in adensity which is operable for em itting a pow er density oflight in the range of 200-1400 mW/cm . Such a densityprovides a desirable curing power to the w ork surface for asuitable cure. For cooling such an array and the substrate onwhich the elements are mounted the present inventionutilizes conductive cooling wherein a heat tube containing aheat-conductive liquid is thermally coupled to the substratefor conductively transferring heat generated by the array ofelements away from the substrate. In one embodiment of theinvention the heat sink is thermally coupled to the substrateand the heat tube is then thermally coupled to the heat sink.In that way heat is conductively transferred away from thesubstrate and elements. A heat exchang er is coupled to theother end of the heat tube for convectively transferring heatto the air such as with the utilization of a fan.

In another aspect of the present invention a sleeve isutilized over a portion of the housing during the curingprocess. After each curing process the sleeve may beremoved and discarded or autoclaved thus eliminating the

6use. In one embodimen t of the invention the non-imagingoptical device such as a non-imaging lens and a reflectiveelement are coupled to an end of the sleeve. W hen the sleeveis positioned over a portion of the housing the reflective5 element and lens are aligned coaxially w ith the array colli-

mating light from the array. In a disposable embodiment ofthe sleeve both the non-imaging lens and reflective elementare disposable and are discarded with the sleeve after eachuse.1 he array which comp rises a plurality of dies positionedon a flat substrate generally emits light within a range of0-180. W hen the array is located at the distal end of thehousing the non-imaging lens and reflective element arecapable of capturing the light within the 180 range and15 effectively and efficiently collimating the light into a beamdirected to the work surface. When the array is positionedfurther within the housing away from the distal end of thehousing and away from the work surface the non-imaginglens is operable for collimating light within the 180 range2 into a beam which does not diverge significantly from anacceptance angle of an optical fiber light guide. In that waylight is efficiently directed through the light guide and

housing to the distal end of the housing whereupon it isemitted onto a work surface such as a tooth. Preferably the25 array is mounted onto the distal end of the housing fordirectly delivering light to the work surface. In that way anoptical fiber light guide which has multiple lossy air/glassinterfaces may be eliminated for efficient transmission oflight.3 One em bodiment of the invention utilizes a single non-imaging optical focusing device for the array of elem ents.Alternatively the elements might range in sub-groups on thearray and multiple non-imaging optical devices may beutilized.35

BRIEF DESCRIPTION OF THE DRAW INGSThe accompanying drawings which are incorporated inand constitute a part of this specification illustrate embo di-

4 ments of the invention and together with a general descrip-tion of the invention given below serve to explain theprinciples of the invention.FIG. 1 is a side view in partial cross-section of oneembodiment of a curing light device in accordance with the

45 principles of the invention.FIG . 2 is a side view in partial cross-section of a portionof the embodim ent of the invention illustrated in FIG . 1.FIG. 2A is a side view in partial cross-section of aportion of another embodiment of the invention.FIG. 2B is a plane view of an array of dies in accordancewith an em bodiment of the present invention.FIG . 3 is a side view in partial cross-section of a portionof another embodiment of the invention.

55 IG. 4 is a side view in partial cross-section of a portionof another embodim ent of the present invention.DETAILED DESCRIPTION OF THEINVENTION

6 IG. 1 illustrates one embodiment of a curing light deviceor curing light for curing light-curable compounds such asdental compounds in accordance with the aspects of thepresent invention. In FIG . 1 device 10 includes a housing 12which is to be manipulated for curing. Housing 12 is

5

US 6 , 6 9 2 , 2 5 1 B15

SUMMARY OF THE INVENTIONAn i n s t r u m e n t a n d method f o r c u r i n g l i g h t - c u r a b l e

compounds, s u c h a s d e n t a l compounds i n t h e mouth o f ap a t i e n t , c o m p r i s e s a h o u s i n g W h i c h s u p p o r t s a p l u r a l i t y o fs o l i d s t a t e , l i g h t - e m i t t i n g e l e m e n t s . The e l e m e n t s a r e p r e fe r a b l y l i g h t - e m i t t i n g d i e s formed o f a s e m i c o n d u c t o r m a t er i a l . The e l e m e n t s a r e mounted on a s u b s t r a t e s u p p o r t e d b yt h e h o u s i n g t o form a c o l l e c t i v e a r r a y Which i s o p e r a b l e f o rc o l l e c t i v e l y e m i t t i n g l i g h t h a v i n g a W a v e l e n g t h W i t h i n anarroW band o f W a v e l e n g t h s . I n one embodiment o f t h ei n v e n t i o n , t h e n a r r o W band o f W a v e l e n g t h s i n c l u d e s t h a t o ft h e b l u e W a v e l e n g t h . H o W e v e r , o t h e r W a v e l e n g t h s m i g h ta l s o b e u t i l i Z e d , d e p e n d i n g u p o n t h e l i g h t s e n s i t i v i t y o f t h ec u r a b l e compound u t i l i Z e d .

One s u i t a b l e h o u s i n g f o r t h e i n v e n t i o n i n c l u d e s a guns h a p e d h o u s i n g Which h a s a h a n d l e p o r t i o n a n d a b a r r e lp o r t i o n . T h e h a n d l e p o r t i o n i s h e l d b y a n o p e r a t o r a n d t h eb a r r e l p o r t i o n i s d i r e c t e d toWard a W o r k s u r f a c e , such a s at o o t h . A o r t a b l e poWer s u p p l y may b e u t i l i Z e d W i t h i n t h eh o u s i n g s u c h t h a t t h e i n s t r u m e n t i s a h a n d - h e l d i n s t r u m e n tWhich i s c o m p l e t e l y p o r t a b l e . I n o n e embodiment o f t h ei n v e n t i o n , t h e a r r a y o f l i g h t - e m i t t i n g e l e m e n t s i s p o s i t i o n e don t h e d i s t a l e n d o f t h e b a r r e l p o r t i o n o f t h e h o u s i n g Whichi s p l a c e d W i t h i n t h e mouth o f a p a t i e n t s o t h a t t h e l i g h t i sd e l i v e r e d d i r e c t l y t o a W o r k s u r f a c e , such a s a t o o t h . I n ana l t e r n a t i v e e m b o d i m e n t , t h e a r r a y o f e l e m e n t s may b e p o s it i o n e d i n t h e h o u s i n g s u c h t h a t t h e g e n e r a t e d l i g h t m u s t b et r a n s m i t t e d t o t h e d i s t a l e n d , s u c h a s by a n o p t i c a l ? b e r l i g h tg u i d e .

I n a c c o r d a n c e With o n e a s p e c t o f t h e p r e s e n t i n v e n t i o n , a no p t i c a l f o c u s i n g d e v i c e i s p o s i t i o n e d t o i n t e r c e p t t h e l i g h te m i t t e d b y t h e a r r a y o f e l e m e n t s . T h e o p t i c a l f o c u s i n gd e v i c e i s a n o n - i m a g i n g o p t i c a l d e v i c e W h i c h i s o p e r a b l e f o rc o l l i m a t i n g t h e l i g h t from t h e a r r a y i n t o a beam t o b ed i r e c t e d on t o a compound f o r c u r i n g t h e compound. Then o n - i m a g i n g d e v i c e e f ?c i e n t l y c o l l i m a t e s a n d t r a n s m i t s t h el i g h t from t h e a r r a y t o a W o r k s u r f a c e W i t h o u t i n e f ? c i e n c i e sa s s o c i a t e d W i t h i m a g i n g l e n s e s i n t h e p r i o r a r t . A e ? e c t i v ee l e m e n t may b e p o s i t i o n e d b e t W e e n t h e a r r a y a n d t h e o p t i c a lf o c u s i n g d e v i c e f o r f u r t h e r e f f i c i e n t l y d i r e c t i n g l i g h t f r o mt h e a r r a y i n t o t h e o p t i c a l f o c u s i n g d e v i c e t o b e c o l l i m a t e dand d e l i v e r e d t o a W o r k s u r f a c e .

I n a c c o r d a n c e W i t h a n o t h e r a s p e c t o f t h e p r e s e n ti n v e n t i o n , t h e a r r a y o f d i e s i s a r r a n g e d on a s u b s t r a t e i n ad e n s i t y W h i c h i s o p e r a b l e f o r e m i t t i n g a p o W e r d e n s i t y o fl i g h t i n t h e r a n g e o f 2001400 mW/cm2. Such a d e n s i t yp r o v i d e s a d e s i r a b l e c u r i n g poWer t o t h e W o r k s u r f a c e f o r as u i t a b l e c u r e . For c o o l i n g such an a r r a y and t h e s u b s t r a t e onWhich t h e e l e m e n t s a r e m o u n t e d , t h e p r e s e n t i n v e n t i o nu t i l i Z e s c o n d u c t i v e c o o l i n g W h e r e i n a h e a t t u b e c o n t a i n i n g ah e a t - c o n d u c t i v e l i q u i d i s t h e r m a l l y c o u p l e d t o t h e s u b s t r a t ef o r c o n d u c t i v e l y t r a n s f e r r i n g h e a t g e n e r a t e d b y t h e a r r a y o fe l e m e n t s aWay from t h e s u b s t r a t e . I n one embodiment o f t h ei n v e n t i o n , t h e h e a t s i n k i s t h e r m a l l y c o u p l e d t o t h e s u b s t r a t ea n d t h e h e a t t u b e i s t h e n t h e r m a l l y c o u p l e d t o t h e h e a t s i n k .I n t h a t W a y , h e a t i s c o n d u c t i v e l y t r a n s f e r r e d aWay f r o m t h es u b s t r a t e a n d e l e m e n t s . A e a t e x c h a n g e r i s c o u p l e d t o t h eo t h e r e n d o f t h e h e a t t u b e f o r c o n v e c t i v e l y t r a n s f e r r i n g h e a tt o t h e a i r , such a s With t h e u t i l i Z a t i o n o f a f a n .

I n a n o t h e r a s p e c t o f t h e p r e s e n t i n v e n t i o n , a s l e e v e i su t i l i Z e d o v e r a p o r t i o n o f t h e h o u s i n g d u r i n g t h e c u r i n gp r o c e s s . A f t e r e a c h c u r i n g p r o c e s s , t h e s l e e v e may b eremoved a n d d i s c a r d e d o r a u t o c l a v e d , t h u s e l i m i n a t i n g t h e

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6u s e . I n one embodiment o f t h e i n v e n t i o n , t h e non-imagingo p t i c a l d e v i c e , s u c h a s a n o n - i m a g i n g l e n s , a n d a r e ? e c t i v eelement a r e coupled t o a n end o f t h e s l e e v e . When h e s l e e v ei s p o s i t i o n e d o v e r a p o r t i o n o f t h e h o u s i n g , t h e r e ? e c t i v ee l e m e n t a n d l e n s a r e a l i g n e d c o a X i a l l y W i t h t h e a r r a y c o l l im a t i n g l i g h t f r o m t h e a r r a y . I n a d i s p o s a b l e embodiment o ft h e s l e e v e , b o t h t h e n o n - i m a g i n g l e n s a n d r e ? e c t i v e e l e m e n ta r e d i s p o s a b l e and a r e d i s c a r d e d W i t h t h e s l e e v e a f t e r e a c hu se.

The a r r a y , W h i c h c o m p r i s e s a p l u r a l i t y o f d i e s p o s i t i o n e don a ? a t s u b s t r a t e , g e n e r a l l y e m i t s l i g h t W i t h i n a r a n g e o f0 1 8 0 . When h e a r r a y i s l o c a t e d a t t h e d i s t a l end o f t h eh o u s i n g , t h e n o n - i m a g i n g l e n s a n d r e ? e c t i v e e l e m e n t a r ec a p a b l e o f c a p t u r i n g t h e l i g h t W i t h i n t h e 1 8 0 r a n g e a n de f f e c t i v e l y a n d e f f i c i e n t l y c o l l i m a t i n g t h e l i g h t i n t o a beamd i r e c t e d t o t h e W o rk s u r f a c e . W h en t h e a r r a y i s p o s i t i o n e df u r t h e r W i t h i n t h e h o u s i n g , aWay f r o m t h e d i s t a l e n d o f t h eh o u s i n g , a n d aWay f r o m t h e Work s u r f a c e , t h e n o n - i m a g i n gl e n s i s o p e r a b l e f o r c o l l i m a t i n g l i g h t W i t h i n t h e 1 8 0 r a n g ei n t o a beam Which d o e s n o t d i v e r g e s i g n i ? c a n t l y from a na c c e p t a n c e a n g l e o f a n o p t i c a l ? b e r l i g h t g u i d e . I n t h a t W a y ,l i g h t i s e f ? c i e n t l y d i r e c t e d t h r o u g h t h e l i g h t g u i d e a n dh o u s i n g t o t h e d i s t a l e n d o f t h e h o u s i n g W h e r e u p o n i t i se m i t t e d o n t o a W o r k s u r f a c e , such a s a t o o t h . P r e f e r a b l y , t h ea r r a y i s mounted o n t o t h e d i s t a l end o f t h e h o u s i n g f o rd i r e c t l y d e l i v e r i n g l i g h t t o t h e W o rk s u r f a c e . I n t h a t W a y , a no p t i c a l ? b e r l i g h t g u i d e , W h i c h h a s m u l t i p l e l o s s y a i r / g l a s si n t e r f a c e s , may b e e l i m i n a t e d f o r e f f i c i e n t t r a n s m i s s i o n o fl i g h t .

One embodiment o f t h e i n v e n t i o n u t i l i Z e s a s i n g l e noni m a g i n g o p t i c a l f o c u s i n g d e v i c e f o r t h e a r r a y o f e l e m e n t s .A l t e r n a t i v e l y , t h e e l e m e n t s m i g h t r a n g e i n s u b - g r o u p s o n t h ea r r a y a n d m u l t i p l e , n o n - i m a g i n g o p t i c a l d e v i c e s may b eu t i l i Z e d .

BRIEF DESCRIPTION OF THE DRAWINGST h e a c c o m p a n y i n g d r a W i n g s , W h i c h a r e i n c o r p o r a t e d i n

a n d c o n s t i t u t e a p a r t o f t h i s s p e c i ? c a t i o n , i l l u s t r a t e embodim e n t s o f t h e i n v e n t i o n a n d , t o g e t h e r W i t h a g e n e r a l d e s c r i pt i o n o f t h e i n v e n t i o n g i v e n b e l o W , s e r v e t o e X p l a i n t h ep r i n c i p l e s o f t h e i n v e n t i o n .

FIG. 1 i s a s i d e vieW i n p a r t i a l c r o s s - s e c t i o n o f oneembodiment o f a c u r i n g l i g h t d e v i c e i n a c c o r d a n c e W i t h t h ep r i n c i p l e s o f t h e i n v e n t i o n .

F I G . 2 i s a s i d e v i e W , i n p a r t i a l c r o s s - s e c t i o n , o f a p o r t i o no f t h e embodiment o f t h e i n v e n t i o n i l l u s t r a t e d i n F I G . 1 .

F I G . 2A s a s i d e v i e W , i n p a r t i a l c r o s s - s e c t i o n , o f ap o r t i o n o f a n o t h e r embodiment o f t h e i n v e n t i o n .

FIG. 2 B i s a p l a n e vieW o f a n a r r a y o f d i e s i n a c c o r d a n c eW i t h a n embodiment o f t h e p r e s e n t i n v e n t i o n .

F I G . 3 i s a s i d e v i e W , i n p a r t i a l c r o s s - s e c t i o n , o f a p o r t i o no f a n o

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