U.S. patent application number 13/845455 was filed with the patent office on 2013-08-15 for integrated porcelain system for a dental prosthesis.
This patent application is currently assigned to DENTSPLY INTERNATIONAL INC.. The applicant listed for this patent is Slawomir Banasiak, Christopher Chu, Victoriya Shtessel-Nemzer. Invention is credited to Slawomir Banasiak, Christopher Chu, Victoriya Shtessel-Nemzer.
Application Number | 20130209966 13/845455 |
Document ID | / |
Family ID | 40863648 |
Filed Date | 2013-08-15 |
United States Patent
Application |
20130209966 |
Kind Code |
A1 |
Chu; Christopher ; et
al. |
August 15, 2013 |
Integrated Porcelain System for a Dental Prosthesis
Abstract
An integrated dental porcelain system for making dental
prostheses and restorations is provided. The system includes three
universal major components: a) opaque porcelain composition; b)
pressable dentin ingot; and c) veneering porcelain composition that
can be used interchangeably for making restorations. Techniques for
making the prostheses and restorations include porcelain
fused-to-metal (PFM), press-to-metal (PTM), and either pressed
and/or machined all-ceramic methods. The system uses both a
hand-layering of veneering porcelain (PFM technique) and a
hot-pressing process (PTM and all-ceramic technique) to fabricate
the prostheses and restorations.
Inventors: |
Chu; Christopher; (West
Windsor, NJ) ; Banasiak; Slawomir; (Kearny, NJ)
; Shtessel-Nemzer; Victoriya; (Newtown, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Chu; Christopher
Banasiak; Slawomir
Shtessel-Nemzer; Victoriya |
West Windsor
Kearny
Newtown |
NJ
NJ
PA |
US
US
US |
|
|
Assignee: |
DENTSPLY INTERNATIONAL INC.
YORK
PA
|
Family ID: |
40863648 |
Appl. No.: |
13/845455 |
Filed: |
March 18, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12156169 |
May 30, 2008 |
8110035 |
|
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13845455 |
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Current U.S.
Class: |
433/222.1 ;
106/286.4; 427/2.27 |
Current CPC
Class: |
A61C 5/70 20170201; A61C
5/77 20170201; A61C 13/09 20130101; A61C 5/73 20170201; A61K 6/858
20200101; C03C 4/0021 20130101; C03C 8/08 20130101; C09D 1/00
20130101; A61C 13/0006 20130101; C03C 8/06 20130101; A61C 13/0835
20130101; C03C 2204/04 20130101; C03C 8/02 20130101 |
Class at
Publication: |
433/222.1 ;
106/286.4; 427/2.27 |
International
Class: |
A61C 5/10 20060101
A61C005/10; A61C 5/08 20060101 A61C005/08; C09D 1/00 20060101
C09D001/00 |
Claims
1. A dental prosthesis comprising: a metal substructure; an opaque
layer having a composition including the following components:
TABLE-US-00006 Components Concentration Range (Wt. %) SiO.sub.2
42-46% Al.sub.2O.sub.3 8-12% Na.sub.2O 2-5% K.sub.2O 6-9% Li.sub.2O
0-2% CaO 0-2% MgO 0-2% ZrO.sub.2 20-30% SnO.sub.2 1-4%
Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-3% TiO.sub.2 0-2% Sb.sub.2O.sub.3
0-0.1% Fluorescing agent 0-5%
wherein the opaque layer, after firing to a temperature in the
range of 860.degree. to 900.degree. C., forms an opaque coating
over the metal substructure, the opaque coating being thermally
compatible and thermally stable with the metal substructure.
2. The dental prosthesis of claim 1 further comprising a porcelain
layer over the opaqued metal substructure, the porcelain layer
having a composition including the following components:
TABLE-US-00007 Oxide Concentration Range (Wt. %) SiO.sub.2 63-66%
Al.sub.2O.sub.3 10-14% Na.sub.2O 3-7% K.sub.2O 9-12% Li.sub.2O 0-2%
CaO 1-4% BaO 0-3% Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2%
wherein the porcelain layer, after pressing at a temperature in the
range of 870.degree. C. to 910.degree. C., forms a dentin body
layer, the dentin body layer being thermally compatible with the
opaqued metal substructure.
3. The dental prosthesis of claim 2, further comprising a shade
stain layer and/or a glaze layer, the shade stain layer and/or the
glaze layer, each having a composition including the following
components: TABLE-US-00008 Oxide Concentration Range (Wt. %)
SiO.sub.2 56-64% Al.sub.2O.sub.3 6-13% Na.sub.2O 7-15% K.sub.2O
7-15% Li.sub.2O 0-5% CaO 0-3% MgO 2-5% SnO.sub.2 0-4%
Tb.sub.4O.sub.7 0-3% CeO.sub.2 0-2% B.sub.2O.sub.3 0-5%
Sb.sub.2O.sub.3 0-0.5% F 0-2.5% TiO.sub.2 0-1%
wherein the stain layer and/or the glaze layer, after firing to a
temperature in the range of 780.degree. to 840.degree. C., form a
shade stain and/or glaze overlayer over the dentin body layer, the
shade stain and/or glaze overlayer being thermally compatible and
thermally stable with the dentin body layer.
4. The dental prosthesis of claim 1 further comprising a veneering
porcelain layer having a composition including the following
components: TABLE-US-00009 Oxide Concentration Range (Wt. %)
SiO.sub.2 62-65% Al.sub.2O.sub.3 8-11% Na.sub.2O 8-11% K.sub.2O
4-7% Li.sub.2O 0-2% CaO 2-5% BaO 0-3% MgO 1-4% SnO.sub.2 0-2%
Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2% Sb.sub.2O.sub.3 0-2%
P.sub.2O.sub.5 0-0.1% TiO.sub.2 0-0.1% F 0-1%
wherein the veneering porcelain layer, after firing at a
temperature in the range of 810.degree. C. to 860.degree. C., forms
a dentin-enamel layer over the opaqued metal substructure, the
dentin-enamel layer being thermally compatible with the opaqued
metal substructure.
5. The dental prosthesis of claim 4, further comprising a glaze
layer having a composition including the following components:
TABLE-US-00010 Oxide Concentration Range (Wt. %) SiO.sub.2 56-64%
Al.sub.2O.sub.3 6-13% Na.sub.2O 7-15% K.sub.2O 7-15% Li.sub.2O 0-5%
CaO 0-3% MgO 2-5% SnO.sub.2 0-4% Tb.sub.4O.sub.7 0-3% CeO.sub.2
0-2% B.sub.2O.sub.3 0-4%
wherein the glaze layer, after firing to a temperature in the range
of 780.degree. to 840.degree. C., forms a glaze overlayer over the
fired dentin-enamel layer, the glaze overlayer being thermally
compatible with the dentin-enamel layer.
6. The dental prosthesis of claim 2, further comprising a veneering
porcelain layer having a composition including the following
components: TABLE-US-00011 Oxide Concentration Range (Wt. %)
SiO.sub.2 62-65% Al.sub.2O.sub.3 8-11% Na.sub.2O 8-11% K.sub.2O
4-7% Li.sub.2O 0-2% CaO 2-5% BaO 0-3% MgO 1-4% SnO.sub.2 0-2%
Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2% Sb.sub.2O.sub.3 0-2%
P.sub.2O.sub.5 0-0.1% TiO.sub.2 0-0.1% F 0-1%
wherein the veneering porcelain layer, after firing at a
temperature in the range of 810.degree. C. to 860.degree. C., forms
an enamel layer over the dentin body layer, the enamel layer being
thermally compatible with the opaqued metal substructure and the
dentin body layer.
7. The dental prosthesis of claim 6, further comprising a glaze
layer over the fired enamel layer, the glaze layer having a
composition including the following components: TABLE-US-00012
Oxide Concentration Range (Wt. %) SiO.sub.2 56-64% Al.sub.2O.sub.3
6-13% Na.sub.2O 7-15% K.sub.2O 7-15% Li.sub.2O 0-5% CaO 0-3% MgO
2-5% SnO.sub.2 0-4% Tb.sub.4O.sub.7 0-3% CeO.sub.2 0-2%
B.sub.2O.sub.3 0-4%
wherein the glaze layer, after firing to a temperature in the range
of 780.degree. to 840.degree. C., forms a glaze overlayer over the
pressed enameled dentin body layer, the glaze overlayer being
thermally compatible with the enameled dentin body layer.
8. A dental prosthesis comprising: an all-ceramic core, and a
porcelain layer having a composition including the following
components; TABLE-US-00013 Oxide Concentration Range (Wt. %)
SiO.sub.2 63-66% Al.sub.2O.sub.3 10-14% Na.sub.2O 3-7% K.sub.2O
9-12% Li.sub.2O 0-2% CaO 1-4% BaO 0-3% Tb.sub.4O.sub.7 0-2%
CeO.sub.2 0-2%
wherein the porcelain layer, after pressing at a temperature in the
range of 870.degree. C. to 910.degree. C., forms a dentin body
layer, forms a dentin body layer, the dentin body layer being
thermally compatible with the ceramic core.
9. The dental prosthesis claim 8, further comprising a veneering
porcelain layer having a composition including the following
components TABLE-US-00014 Oxide Concentration Range (Wt. %)
SiO.sub.2 62-65% Al.sub.2O.sub.3 8-11% Na.sub.2O 8-11% K.sub.2O
4-7% Li.sub.2O 0-2% CaO 2-5% BaO 0-3% MgO 1-4% SnO.sub.2 0-2%
Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2% Sb.sub.2O.sub.3 0-2%
P.sub.2O.sub.5 0-0.1% TiO.sub.2 0-0.1%
wherein the veneering porcelain layer, after firing at a
temperature in the range of 810.degree. C. to 860.degree. C., forms
an enamel layer over the dentin body layer, the enamel layer being
thermally compatible with the dentin body layer.
10. The dental prosthesis claim 9, further comprising a glaze layer
over the fired enamel layer, the glaze layer having a composition
including the following components: TABLE-US-00015 Oxide
Concentration Range (Wt. %) SiO.sub.2 56-64% Al.sub.2O.sub.3 6-13%
Na.sub.2O 7-15% K.sub.2O 7-15% Li.sub.2O 0-5% CaO 0-3% MgO 2-5%
SnO.sub.2 0-4% Tb.sub.4O.sub.7 0-3% CeO.sub.2 0-2% B.sub.2O.sub.3
0-4%
wherein the glaze layer, after firing to a temperature in the range
of about 780.degree. to 840.degree. C., forms a glaze overlayer
over the dentin body layer, the glaze overlayer being thermally
compatible with the dentin body layer.
11. A method for making a dental prosthesis comprising the step of:
providing a metal substructure; applying an opaque composition over
the metal substructure, the opaque composition including the
following components: TABLE-US-00016 Component Concentration Range
(Wt. %) SiO.sub.2 42-46% Al.sub.2O.sub.3 8-12% Na.sub.2O 2-5%
K.sub.2O 6-9% Li.sub.2O 0-2% CaO 0-2% MgO 0-2% ZrO.sub.2 20-30%
SnO.sub.2 1-4% Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-3% TiO.sub.2 0-2%
Sb.sub.2O.sub.3 0-0.1% Fluorescing agent 0-5%
and firing to a temperature in the range of 860.degree. to
900.degree. C. to form an opaqued metal substructure.
12. The method of claim 11, wherein the opaque composition is in
powder or paste form prior to being fired.
13. The method of claim 11, wherein the opaque composition is
applied to the metal substructure by spraying, slurry dipping, or
electro-depositing.
14. The method of claim 11, further comprising the steps of:
applying a porcelain composition over the opaqued substructure, the
porcelain composition including the following components:
TABLE-US-00017 Oxide Concentration Range (Wt. %) SiO.sub.2 63-66%
Al.sub.2O.sub.3 10-14% Na.sub.2O 3-7% K.sub.2O 9-12% Li.sub.2O 0-2%
CaO 1-4% BaO 0-3% Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2%
and firing to a temperature in the range of 870.degree. C. to
910.degree. C. to form a dentin body layer over the opaque
substructure, the dentin body layer being thermally compatible with
the opaqued substructure.
15. The method of claim 14, further comprising the steps of:
applying a shade stain composition and/or a glaze composition, each
including the following components: TABLE-US-00018 Oxide
Concentration Range (Wt. %) SiO.sub.2 56-64% Al.sub.2O.sub.3 6-13%
Na.sub.2O 7-15% K.sub.2O 7-15% Li.sub.2O 0-5% CaO 0-3% MgO 2-5%
SnO.sub.2 0-4% Tb.sub.4O.sub.7 0-3% CeO.sub.2 0-2% B.sub.2O.sub.3
0-5% Sb.sub.2O.sub.3 0-0.5% F 0-2.5% TiO.sub.2 0-1%
and firing at a temperature in the range of 780.degree. to
840.degree. C. to form a shade stain and/or glaze layer over the
dentin body layer, the shade stain and/or glaze layer being
thermally compatible and thermally stable with the dentin body
layer.
16. The method of claim 11, further comprising the steps of:
applying a veneering porcelain composition including the following
components: TABLE-US-00019 Oxide Concentration Range (Wt. %)
SiO.sub.2 62-65% Al.sub.2O.sub.3 8-11% Na.sub.2O 8-11% K.sub.2O
4-7% Li.sub.2O 0-2% CaO 2-5% BaO 0-3% MgO 1-4% SnO.sub.2 0-2%
Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2% Sb.sub.2O.sub.3 0-2%
P.sub.2O.sub.5 0-0.1% TiO.sub.2 0-0.1% F 0-1%
and firing at a temperature in the range of 810.degree. C. to
860.degree. C. to form a dentin-enamel layer over the opaqued
substructure, the dentin-enamel layer being thermally compatible
with the opaqued substructure.
17. The method of claim 16, wherein the later applied dentin-enamel
layer is applied by a hot pressing technique or hand build-up
technique.
18. The method of claim 16, further comprising the steps of:
applying a glaze composition including the following components:
TABLE-US-00020 Oxide Concentration Range (Wt. %) SiO.sub.2 56-64%
Al.sub.2O.sub.3 6-13% Na.sub.2O 7-15% K.sub.2O 7-15% Li.sub.2O 0-5%
CaO 0-3% MgO 2-5% SnO.sub.2 0-4% Tb.sub.4O.sub.7 0-3% CeO.sub.2
0-2% B.sub.2O.sub.3 0-5% Sb.sub.2O.sub.3 0-0.5% F 0-2.5% TiO.sub.2
0-1%
and firing to a temperature in the range of 780.degree. to
840.degree. C. to form a glaze overlayer over the fired
dentin-enamel layer, the glaze overlayer being thermally compatible
with the dentin-enamel layer.
19. The method of claim 14, further comprising the steps of:
applying a veneering porcelain composition including the following
components: TABLE-US-00021 Oxide Concentration Range (Wt. %)
SiO.sub.2 62-65% Al.sub.2O.sub.3 8-11% Na.sub.2O 8-11% K.sub.2O
4-7% Li.sub.2O 0-2% CaO 2-5% BaO 0-3% MgO 1-4% SnO.sub.2 0-2%
Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2% Sb.sub.2O.sub.3 0-2%
P.sub.2O.sub.5 0-0.1% TiO.sub.2 0-0.1% F 0-1%
and firing at a temperature in the range of 810.degree. C. to
860.degree. C. to form an enamel layer over the dentin body layer,
the enamel layer being thermally compatible with the opaqued metal
substructure and the dentin body layer.
20. The porcelain composition of claim 19, wherein the later
applied dentin-enamel layer is applied by a hand build-up
technique.
21. The method of claim 19, further comprising the steps of:
applying a glaze composition including the following components:
TABLE-US-00022 Oxide Concentration Range (Wt. %) SiO.sub.2 56-64%
Al.sub.2O.sub.3 6-13% Na.sub.2O 7-15% K.sub.2O 7-15% Li.sub.2O 0-5%
CaO 0-3% MgO 2-5% SnO.sub.2 0-4% Tb.sub.4O.sub.7 0-3% CeO.sub.2
0-2% B.sub.2O.sub.3 0-5% Sb.sub.2O.sub.3 0-0.5% F 0-2.5% TiO.sub.2
0-1%
and firing to a temperature in the range of 780.degree. to
840.degree. C. to form a glaze layer over the fired enamel layer,
the glaze overlayer being thermally compatible with the fired
enamel layer.
22. A method for making a dental prosthesis comprising the step of:
providing an all ceramic core; applying a porcelain composition
over the ceramic core, the porcelain composition including the
following components: TABLE-US-00023 Oxide Concentration Range (Wt.
%) SiO.sub.2 63-66% Al.sub.2O.sub.3 10-14% Na.sub.2O 3-7% K.sub.2O
9-12% Li.sub.2O 0-2% CaO 1-4% BaO 0-3% Tb.sub.4O.sub.7 0-2%
CeO.sub.2 0-2%
and firing at a temperature in the range of 870.degree. C. to
910.degree. C. to form a dentin body layer over the ceramic core,
the dentin body layer being thermally compatible with the ceramic
core.
23. The method of claim 22, further comprising the steps of:
applying a porcelain composition including the following
components: TABLE-US-00024 Oxide Concentration Range (Wt. %)
SiO.sub.2 62-65% Al.sub.2O.sub.3 8-11% Na.sub.2O 8-11% K.sub.2O
4-7% Li.sub.2O 0-2% CaO 2-5% BaO 0-3% MgO 1-4% SnO.sub.2 0-2%
Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2% Sb.sub.2O.sub.3 0-2%
P.sub.2O.sub.5 0-0.1% TiO.sub.2 0-0.1% F 0-1%
and firing at a temperature in the range of 810.degree. C. to
860.degree. C. to form an enamel layer over the dentin body layer,
the enamel layer being thermally compatible with the dentin body
layer.
24. The method of claim 23, further comprising the steps of:
applying a glaze composition including the following components:
TABLE-US-00025 Oxide Concentration Range (Wt. %) SiO.sub.2 56-64%
Al.sub.2O.sub.3 6-13% Na.sub.2O 7-15% K.sub.2O 7-15% Li.sub.2O 0-5%
CaO 0-3% MgO 2-5% SnO.sub.2 0-4% Tb.sub.4O.sub.7 0-3% CeO.sub.2
0-2% B.sub.2O.sub.3 0-5% Sb.sub.2O.sub.3 0-0.5% F 0-2.5% TiO.sub.2
0-1%
and firing to a temperature in the range of 780.degree. to
840.degree. C. to form a glaze layer over the fired enamel layer,
the glaze layer being thermally compatible with the fired enamel
layer.
Description
CLAIM OF PRIORITY
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/343,905, filed on Jan. 5, 2012, which is a
continuation of U.S. patent application Ser. No. 12/156,169, filed
on May 30, 2008, now U.S. Pat. No. 8,110,035, which are herein
incorporated by reference for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to materials for making
dental prostheses and restorations such as inlays, onlays, veneers,
crowns, and bridges. Particularly, the materials include one
universal opaque, one universal pressable ingot, and one universal
veneering porcelain that can be used interchangeably to manufacture
a prosthesis or restoration using different techniques. This
includes porcelain-fused-to-metal (PFM), press-to-metal (PTM), and
pressed or computer-aided-manufacturing (CAM) machined all-ceramic
techniques.
[0004] 2. Brief Description of the Related Art
[0005] There are various methods known in the dental arts for
making dental prostheses and restorations. By the term,
"prosthesis" or "restoration" as used herein, it is meant any
product that replaces or restores lost tooth structure, teeth, or
oral tissue including, but not limited to, implant stents, bite
registrations, crown and bridges, fillings, baseplates, splints,
denture liners, custom trays, artificial teeth, repairs for natural
teeth, veneers, denture repairs, denture relines, retainers,
orthodontic components, provisional dental devices, inlays, onlays,
orthodontic appliances, temporary dentures, temporary partial
dentures, maxillofacial prostheses, obturators, and occular
prostheses, and the like.
[0006] Conventional dental prostheses may include a metal coping or
substructure to provide additional mechanical strength and
durability to the prosthesis. In practice, the metal copings are
covered with glass or ceramic-based materials that mimic the color
and form of natural teeth. The metal copings support the glass or
ceramic-based veneering layer and provide enhanced structural
strength and toughness to the restoration.
[0007] A traditional method for making a dental prosthesis is known
as "porcelain-fused-to-metal" (PFM). Typically, the process of
making a PFM restoration involves applying three layers of
porcelain onto a metal framework. Initially, an opaque porcelain
composition, in either powder or paste form, is applied over a
metal framework to form an opaque layer that masks the metal.
Subsequently, a dentin body layer is built up using dentin
porcelain powder and then a third layer simulating the incisal
portion of a natural tooth is built up using enamel porcelain
powder. In PFM restorations, the layering of the wet porcelain
compositions is traditionally done by hand. The porcelain
compositions are fired at high temperatures to form hard and
durable dentin and incisal layers having the appearance of natural
teeth. Other porcelain materials, such as opaceous dentin, dentin
modifier, and stain porcelain, margin, and final margin porcelains
can be added to enhance the esthetics of the final dental
restoration. The PFM restorations can be finished by applying a
thin layer of glaze porcelain to provide a glossy surface
finish.
[0008] One drawback with PFM restorations is that the dark-colored
margin may be exposed at the gum line and the restoration may not
have the most pleasing esthetics. To improve esthetics,
"all-ceramic" systems have been developed. These all-ceramic
systems use a ceramic core in place of the metal framework. The
ceramic core is coated with at least one porcelain layer. In one
technique, an all-ceramic prosthesis having a core is fabricated
using a hot-pressing technique. (For example, the Empress.TM.
prosthetic system (Ivoclar Vivadent AG, Liechtenstein) was
developed.) An alternative way of fabricating all-ceramic cores is
to use a computer-aided-manufacturing (CAM) method and machine
directly on a ceramic block as described in the Cerec.TM. system
(Sirona Dental Systems GmbH, Germany). While all-ceramic prostheses
may offer improved esthetics over PFM restorations, the all-ceramic
prostheses tend to be more brittle. Traditionally, all-ceramic
prostheses have been limited generally to anterior up to pre-molar
applications. Although in recent years, using high strength alumina
and zirconia as the core has allowed all-ceramic restorations to be
used in posterior and bridge applications.
[0009] Another method that has grown in popularity over the last
several years is known as the "press-to-metal" (PTM) process. The
PTM process involves placing a metal coping or substructure in a
mold. The coping is then coated with an opaque porcelain
composition which may be in powder or paste form. The opaque
coating is followed by wax-up and spruing to form the prosthesis
form. The form is then invested in a ceramic investment material,
and the wax is burned out. This forms the prosthesis mold. A
porcelain layer is fused to the opaque surface by hot-pressing an
ingot porcelain material onto the coping contained in the mold at
fusing temperatures. The hot-pressed porcelain flows into the
burn-out cavity to form the dentin layer. The prosthesis is then
divested of the molding material and finished. The result is a
strong and tough dental prosthesis having a metal substructure that
is veneered with porcelain. The prosthesis has generally good
esthetics with integrated transparency that matches the appearance
of natural dentition.
[0010] Conventional methods for making PFM, PTM, and all-ceramic
restorations are described in the patent literature. For example,
Kosmos, U.S. Pat. No. 4,741,699 discloses making a porcelain dental
restoration having fluorescence that matches the fluorescence of
natural teeth. The restoration includes a metal supporting
substrate, a body layer, and incisal layer. An aqueous slurry of an
opaque porcelain is applied and fired to the metal substrate. A
body layer and incisal layer are formed from porcelain powder
mixtures containing fluorescent pigment. The powder mixtures
comprise a base porcelain, stained porcelain, and fluorescing agent
and are applied by hand to build-up the restoration.
[0011] Komma et al., U.S. Pat. No. 5,281,563 describes methods for
making metal and ceramic dentures. The ceramic powder is applied to
the metallic framework as an aqueous slurry and fired at elevated
temperatures to produce the prosthesis. Komma notes that it is
important that the firing temperature (processing temperature) of
the ceramic body be at least 100.degree. C. below the solidus
temperature of the material in the metallic framework and the
coefficient of thermal expansion of the ceramic body be only very
slightly less than that of the metallic material, so that no cracks
are produced in the lining layer during firing and cooling
down.
[0012] Brodkin et al., U.S. Pat. No. 6,428,614 is directed to an
opaque porcelain material for making both all-ceramic and
porcelain-fused-to-metal (PFM) restorations. The opaque porcelain
exhibits a coefficient of thermal expansion (CTE) substantially
equal to or slightly above the CTE of the metal to which the
porcelain is being applied. The porcelain material is fabricated
from a mixture of two frit compositions. The porcelain material has
a composition of 48 to 65% SiO.sub.2; 10 to 15% Al.sub.2O.sub.3;
0.5 to 2% CaO; 1.5 to 3% Li.sub.2O; 15 to 17% K.sub.2O; 4 to about
6% Na.sub.2O; and 0.4 to 1% F.
[0013] Chu and Banasiak, US Patent Application Publication No. US
2007/0196788 discloses a dental prosthesis having a metal coping
that is coated with an opaque coating. A single porcelain layer
having an integrated tooth-like translucency is coated over the
opaque coating. The porcelain layer is formed of a dentin fit and
enamel fit that is sintered into an ingot shape. The weight percent
of dentin fit is in the range of 70 to 85% and the weight percent
of enamel frit is in the range of 15 to 30%. The resulting
restoration has strong substructure that is veneered with porcelain
having an integrated transparency.
[0014] One major problem with conventional PFM, PTM, and
all-ceramic systems available in the marketplace today is that the
components of each system are tailored to their own applications.
The materials cannot be used interchangeably across the systems due
to the thermal incompatibility among the components and/or metal
substructure. Hence, systems with various components need to be
purchased separately for making different types of restorations.
This may cause over-inventory problems and confusion over mixing
use of the components in dental laboratories.
[0015] It is an object of the present invention to provide an
integrated porcelain system having components that can be used
interchangeably among porcelain-fused-to metal (PFM),
press-to-metal (PTM), and pressed or computer-aided-manufacturing
(CAM) machined all-ceramic restorations It is another object of the
invention to provide a universal opaque porcelain composition that
can be used for making PFM and PTM prostheses. Yet another object
of the invention is to provide universal pressable ingots that can
be used for making dentin body layers over opaqued metal framework
in PTM prostheses and all-ceramic cores. It is still another object
of the invention to provide a universal veneering porcelain
composition that can be used for making dentin-enamel layers and
enamel layers. These and other objects, features, and advantages of
the present invention are evident from the following description
and illustrated embodiments.
SUMMARY OF THE INVENTION
[0016] The present invention provides an integrated dental
porcelain system for making dental prostheses and restorations. The
system includes three universal major components: a) opaque
porcelain composition; b) pressable dentin ingot; and c) veneering
porcelain composition that can be used interchangeably for making
porcelain fused-to-metal (PFM), press-to-metal (PTM), and either
pressed and/or machined all-ceramic restorations. The system uses
both a hand-layering of veneering porcelain (PFM) and a
hot-pressing process (PTM & all-ceramic) to fabricate a
prosthesis or restoration for the patient.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The novel features that are characteristic of the present
invention are set forth in the appended claims. However, the
preferred embodiments of the invention, together with further
objects and attendant advantages, are best understood by reference
to the following detailed description in connection with the
accompanying drawings in which:
[0018] FIG. 1 is a cross-sectional schematic view of a PFM crown on
a die model fabricated with components in accordance with the
invention;
[0019] FIG. 2 is a cross-sectional schematic view of a full-contour
PTM crown on a die model fabricated with components in accordance
with the invention;
[0020] FIG. 3 is a cross-sectional schematic view of an incisal
cutback PTM crown on a die model fabricated with components in
accordance with the invention;
[0021] FIG. 4 is a cross-sectional schematic view of a
full-contour, pressed all-ceramic crown on a die model fabricated
with components in accordance with the invention;
[0022] FIG. 5 is a cross-sectional schematic view of an incisal
cutback, pressed all-ceramic crown on a die model fabricated with
components in accordance with the invention;
[0023] FIG. 6 is a cross-sectional schematic view of a
full-contour, CAM-machined all-ceramic crown on a die model
fabricated with components in accordance with the invention;
and
[0024] FIG. 7 is a cross-sectional schematic view of an incisal
build-up, CAM-machined all-ceramic crown on a die model fabricated
with components in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The present invention relates to materials, methods, and
kits for making dental prostheses. The materials of this invention
which may be supplied as components of a kit, can be used to
provide porcelain/metal restorations, using either hand layering of
veneering porcelain (PFM) or a pressing process (PTM) to apply a
finished surface, along with all-ceramic restorations.
[0026] The materials for making the dental prostheses in accordance
with this invention include principally: (1) universal opaquing
porcelains, in either powder or paste form, for masking the surface
of metal framework that would otherwise be visible through the
porcelain veneer. This is used for making both PFM and PTM
restorations; (2) universal pressable ingots for pressing dentin
body over opaqued metal framework to make PTM restorations or for
pressing a stand-alone all-ceramic core; and (3) universal
dentin/enamel porcelain for building incisal layer in making either
PFM, PTM, and/or all-ceramic (either pressed or machined)
restorations. These materials can be supplied in a kit to a dental
laboratory for making the dental prostheses.
[0027] In addition, the kit may include a shade stain porcelain
paired with a glaze porcelain for shading and finishing either
full-contour PTM and/or all-ceramic restorations. The applied shade
stain and glaze porcelain compositions are fired in a single step.
Also, the same glaze porcelain can be used for finishing PFM,
incisal cutback PTM, and all-ceramic restorations in accordance
with this invention. Further, the kit may include other porcelain
materials such as opaceous dentin, dentin modifier, correction,
margin, and final margin porcelain for finishing the prosthesis, as
necessary. The different components of the kit are discussed in
further detail below.
Universal Opaque Porcelain
[0028] The universal opaque porcelain composition is used for
coating the metal substructure of the prosthesis. The opaque
coating masks the metal substructure and prevents the dark-colored
surface and edges of the substructure from being visible. This
coating step results in an "opaqued" metal substructure. The opaque
porcelain can be applied over the metal substructure in powder or
paste form. The opaque porcelain can be applied by spraying, slurry
dip, electro-depositing, or other methods known to those skilled in
the art. Then, the composition is fired to form a hard and durable
coating. The firing temperature of the opaque porcelain is
preferably between 800.degree. C. and 1000.degree. C., more
preferably between 830.degree. C. and 930.degree. C., and most
preferably between 860.degree. C. and 900.degree. C.
[0029] The opaque coating, which forms as a result of this firing
step, has thermal compatibility and thermal stability with a later
applied porcelain veneer layer. By the term, "thermal
compatibility" or "thermally compatible" with respect to the opaque
coating, it is meant that no substantial cracks are visible in the
coating after firing at a temperature between 800.degree. C. and
1000.degree. C. upon examining the coating under an optical
microscope (10.times. magnification); and no substantial cracks,
are visible in the porcelain veneer layer after firing at a
temperature between 700.degree. C. and 1000.degree. C. upon
examining the layer under an optical microscope (10.times.
magnification). The thermal compatibility between the opaque
coating and porcelain veneer layer of this invention is due to
several reasons including the chemical composition of materials and
similar coefficient of thermal expansion (CTE) values. In general,
the CTE of the opaque coating is approximately equal to or slightly
lower than that of the metal substructure and is approximately
equal to or slightly greater than that of the veneering
porcelain.
[0030] By the term, "thermal stability" or "thermally stable" with
respect to the opaque coating, it is meant that the opaque coating
retains its shape and form and remains adhered to the metal
substructure after multiple firings (that is, at least two and up
to five firings) of the subsequently applied porcelain veneer layer
at a temperature between 700.degree. C. and 1000.degree. C. The
thermal stability of the opaque coating can be determined by
examining the restoration coated with the opaque coating and
porcelain veneer layer under optical microscope (10.times.
magnification). If the opaque coating has drifted or migrated away
from the metal substructure, the opaque coating is not considered
to be thermally stable with the porcelain veneer layer. The
porcelain veneer layer can be applied to the opaque coating by
hot-pressing or manual hand-layering as described further
below.
[0031] A preferred opaque porcelain composition is described in the
following Table 1.
TABLE-US-00001 TABLE 1 CHEMICAL COMPOSITION OF OPAQUE WHITE
PORCELAIN PASTE Oxide Concentration Range (Wt. %) SiO.sub.2 42-46%
Al.sub.2O.sub.3 8-12% Na.sub.2O 2-5% K.sub.2O 6-9% Li.sub.2O 0-2%
CaO 0-2% MgO 0-2% ZrO.sub.2 20-30% SnO.sub.2 1-4% Tb.sub.4O.sub.7
0-2% CeO.sub.2 0-3% TiO.sub.2 0-2% Sb.sub.2O.sub.3 0-0.1%
Fluorescing Agent 0-5% Total 100%
[0032] The materials of this invention, including the opaque
porcelain composition, can be used with various metal copings and
substructures. In general, metals and alloys and their mixtures,
such as nobel alloys, palladium-based alloys, cobalt-based alloys,
nickel-based alloys, pure titanium and alloys, gold-based
metal-ceramic alloys, nickel chromium alloys, and the like can be
used as copings and substructures. More particularly, two
commercially-available alloys suitable for use are non-precious
"DeguDent U" and high-noble "UltraCrown SF", both marketed by
Dentsply International. These alloys can be used to make a
framework by conventional casting techniques known to those skilled
in the dental arts. The materials of this invention are
particularly suitable for used with conventional PFM alloys, for
example, having coefficients of thermal expansion (CTE) of about
14.0 ppm/C .degree. at 500.degree. C.
Universal Pressable Ingots
[0033] The universal pressable ingots are used to form a dentin
body layer over the opaqued metal framework in Press-to-Metal (PTM)
protheses or stand-alone, all-ceramic cores using a hot-pressing
technique. An appropriate amount of dentin body ingots, in either 2
gram or 5 gram size, is pressed into the prostheses mold. The shade
of the dentin body ingots is selected so that the resulting layer
will matches the natural color of the dentin in the patient's
teeth. The pressing temperature is preferably between 700.degree.
C. and 1000.degree. C., and more preferably between 840.degree. C.
and 940.degree. C., and most preferably between 870.degree. C. and
910.degree. C. The typical pressing conditions are as follows:
700.degree. C. (low temperature); 890.degree. C. (high
temperature); 60.degree. C. per minute (heat rate); 20 minutes
(time at high temperature); 10 to 30 minutes (pressing time) and
2.5 to 4.25 bars (pressing time). The prosthesis is then divested
of the molding material for subsequent veneering porcelain
application as discussed further below.
[0034] After the ingot has been pressed at a temperature in the
range of 870.degree. C. to 910.degree. C., the pressed ingot
material forms a dentin body layer that is thermally compatible
with the other porcelain layers, that is, the opaque coating, and
the subsequently applied veneering, and stain layers. The dentin
body layer is also thermally stable when the veneering and stain
layers are subsequently applied and fired.
[0035] By the term, "thermal compatibility" or "thermally
compatible" with respect to the dentin body layer, it is meant that
no substantial cracks are visible in the dentin body layer after
the layer has been pressed at a temperature between 870.degree. C.
and 910.degree. C. upon examining the pressed layer under an
optical microscope (10.times. magnification); and no substantial
cracks, are visible in the porcelain veneer layer after firing at a
temperature between 810.degree. C. and 860.degree. C. upon
examining the layer under an optical microscope (10.times.
magnification).
[0036] By the term, "thermal stability" or "thermally stable" with
respect to the dentin body layer, it is meant that the dentin body
layer retains its shape and form and remains adhered to the opaqued
metal substructure after multiple firings (that is, at least two
and up to five firings) of the subsequently applied porcelain
veneering layer at a temperature between 810.degree. C. and
860.degree. C.,
[0037] A preferred ingot porcelain composition that can be used in
accordance with this invention is described in the following Table
2
TABLE-US-00002 TABLE 2 CHEMICAL COMPOSITION OF INGOT PORCELAIN
COMPOSITION FOR MAKING DENTIN BODY LAYER Oxide Concentration Range
(Wt. %) SiO.sub.2 63-66% Al.sub.2O.sub.3 10-14% Na.sub.2O 3-7%
K.sub.2O 9-12% Li.sub.2O 0-2% CaO 1-4% BaO 0-3% Tb.sub.4O.sub.7
0-2% CeO.sub.2 0-2% Total 100%
Universal Veneering Porcelain
[0038] The universal veneering porcelain composition is used to
form a veneer layer over the opaqued metal substructure or all
ceramic core. The veneering porcelain composition is applied to the
dental prosthesis to form a dentin-enamel layer (PPM applications
where a dentin body layer has not been formed previously) or enamel
layer (PTM and all-ceramic applications where a dentin body layer
has been formed previously.) After the composition has been fired
to a temperature in the range of 800.degree. to 850.degree. C., the
coating forms a hard and durable layer having a shade that matches
the shade and translucency of the patient's natural teeth. The
resulting layer is thermally compatible and thermally stable with
the opaqued metal substructure and all-ceramic core.
[0039] By the term, "thermal compatibility" or "thermally
compatible" with respect to the veneering porcelain dentin-enamel
or enamel layer, it is meant that no substantial cracks are visible
in the dentin-enamel or enamel layer after the layer has been fired
at a temperature between 810.degree. C. and 860.degree. C. upon
examining the fired layer under an optical microscope at 10.times.
magnification; and no substantial cracks, are visible in the dentin
body layer after pressing at a temperature between 870.degree. C.
and 910.degree. C. upon examining the layer under an optical
microscope at 10.times. magnification.
[0040] By the term, "thermal stability" or "thermally stable" with
respect to the veneering porcelain dentin-enamel or enamel layer,
it is meant that the dentin-enamel or enamel layer retains its
shape and form and remains adhered to either the opaqued metal
substructure or dentin body layer after firing the subsequently
applied shade stain and glaze overlayer at a temperature between
780.degree. C. and 840.degree. C.
[0041] A preferred veneering porcelain composition is described in
the following Table 3.
TABLE-US-00003 TABLE 3 CHEMICAL COMPOSITION OF INGOT VENEERING
PORCELAIN FOR MAKING DENTIN-ENAMEL OR ENAMEL LAYERS Oxide
Concentration Range (Wt. %) SiO.sub.2 62-65% Al.sub.2O.sub.3 8-11%
Na.sub.2O 8-11% K.sub.2O 4-7% Li.sub.2O 0-2% CaO 2-5% BaO 0-3% MgO
1-4% SnO.sub.2 0-2% Tb.sub.4O.sub.7 0-2% CeO.sub.2 0-2%
Sb.sub.2O.sub.3 0-2% P.sub.2O.sub.5 0-0.1% TiO.sub.2 0-0.1% F 0-1%
Total 100%
[0042] In addition, a one-step fired shade stain material paired
with a glaze porcelain material can be applied over PTM and/or
all-ceramic full-contour crowns and bridges made with full-contour
technique to complete the restoration. The shade stain porcelain
composition provides the restoration with the proper color shade so
that the restoration matches the color shade of neighboring teeth.
Meanwhile, the glaze porcelain provides the restoration with a hard
and smooth film coating. The finished restoration has a shiny and
glossy appearance after the shade stain and glaze materials have
been applied. The shade stain and glaze are separate and distinct
materials, but they are normally applied together and are
collectively and singularly referred to herein as forming an
overlayer. Once the shade stain and porcelain materials are
applied, they are fired in a single step. The firing temperature of
the shade stain and glaze overlayer is preferably between
750.degree. C. and 950.degree. C., more preferably between
800.degree. C. and 900.degree. C., and most preferably between
780.degree. C. and 840.degree. C. It is also recognized that, the
same glaze porcelain can be applied over PFM, incisal cutback PTM
and/or all-ceramic cores to complete these restorations. In the
case of PFM, incisal cutback PTM and/or all-ceramic cores, it is
not necessary to apply the shade stain porcelain material, because
these products are already shaded. Additional shade stain does not
need to be applied to these restorations. The components used to
make the shade stain and glaze porcelain materials are listed
generally in the following Table 4. It should be understood that
the shade stain composition will differ from the glaze porcelain
composition in view of the different oxides and/or weight
percentage of ingredients used in the respective compositions.
TABLE-US-00004 TABLE 4 COMPONENTS USED IN SHADE STAIN AND GLAZE
PORCELAIN MATERIALS Oxide Concentration Range (Wt. %) SiO.sub.2
56-64% Al.sub.2O.sub.3 6-13% Na.sub.2O 7-15% K.sub.2O 7-15%
Li.sub.2O 0-5% CaO 0-3% MgO 2-5% SnO.sub.2 0-4% Tb.sub.4O.sub.7
0-3% CeO.sub.2 0-2% B.sub.2O.sub.3 0-5% Sb.sub.2O.sub.3 0-0.5% F
0-2.5% TiO.sub.2 0-1% Total 100%
[0043] Referring now to the Figures, the dental prostheses made in
accordance with this invention are shown in detail. FIG. 1 shows a
crown (8) made by a porcelain fused-to-metal (PFM) process is shown
positioned on a die model (10). The crown includes a metal coping
or substructure (12) which is coated with a universal opaquing
porcelain layer (14), universal dentin veneering porcelain layer
(16), universal enamel veneering porcelain layer (18), and
overglaze porcelain layer (20).
[0044] FIG. 2 shows a PTM crown (8) made using a full-contour
technique on a die model (10). The crown (8) has a metal coping
(12) with a universal opaquing porcelain (14), universal pressable
ingot that forms a dentin body layer (22), and a shade stain/glaze
porcelain (24).
[0045] FIG. 3 shows a PTM crown (8) made using an incisal cutback
technique on a die model 10. The crown (8) has a metal coping (12)
with a universal opaquing porcelain (14), universal pressable ingot
that forms a dentin body layer (22), universal enamel veneering
porcelain (18), and overglaze porcelain (20).
[0046] FIG. 4 shows an all-ceramic crown (8) made using a
full-contour technique on a die model (10). The crown (8) has an
all-ceramic coping pressed using a universal pressable ingot that
forms a dentin body layer (22), and shade stain/glaze porcelain
(24).
[0047] FIG. 5 shows an all-ceramic crown (8) made using an incisal
cutback technique on a die model (10). The crown (8) has an
all-ceramic coping pressed using a universal pressable ingot that
forms a dentin body layer (22); a universal enamel veneering
porcelain that forms an enamel layer (18); and overglaze porcelain
(20).
[0048] FIG. 6 shows an all-ceramic crown (8) made using a
machinable block on a die model (10). The crown (8) has an
all-ceramic full-contour coping machined using machinable block
(26) with a shade stain/glaze porcelain 24.
[0049] FIG. 7 shows an all-ceramic crown (8) made using machinable
block on a die model (10). The crown (8) has an all-ceramic coping
machined using machinable block (26); a universal enamel veneering
porcelain that forms an enamel layer (18); and overglaze porcelain
(20).
[0050] The finished restoration made in accordance with this
invention can be subjected to a "thermal shock" test to further
evaluate its thermal properties. In this test, the finished
restoration is heated to a given temperature in a furnace. After
the restoration has been removed, it is quenched into iced water
(normally having a temperature between 0.degree. C. and 5.degree.
C.). Then, the restoration is examined under an optical microscope
(10.times. magnification) to determine if any cracks have formed in
the restoration. For example, the restoration can heated to
80.degree. C. in the furnace, removed, and quenched in cool water.
If no cracks are visible upon microscopic examination, the
restoration is placed back in the furnace and heated to a higher
temperature. Normally, the temperature is incrementally increased
by ten degrees (10.degree. C.). Thus, the restoration is heated to
90.degree. C. in the furnace, removed, and quenched in cool water.
The restoration is microscopically examined for cracks. This
sequence of heating and quenching is repeated until the critical
quenching temperature (temperature at which cracks first appear) is
determined. Preferably, both single unit crowns and three-unit
bridges made in accordance with this invention have a critical
quenching temperature of about 110.degree. C.
Physical/Mechanical Properties
[0051] The physical/mechanical properties of the integrated dental
porcelain system of this invention are described in the following
Table 5. The components were tested for different properties
according to the methods described in ISO 6872 (1995-09-01) for
dental porcelains and ISO 9693 (1999) for metal-ceramic dental
restorative systems. The components meet all ISO requirements as
shown in Table 5.
TABLE-US-00005 TABLE 5 PHYSICAL/MECHANICAL PROPERTIES OF INTEGRATED
DENTAL PORCELAIN SYSTEM Universal Machinable ISO Universal dentin/
Universal block all- Property Requirement Opaque enamel Ingot
ceramic Flexural strength 50 (PFM/PTM) 162 80 135 115 (MPa) 100
(all-ceramic core) Thermal .+-.0.5 (2x & 4x- 12.9 .+-. 0.4 12.1
.+-. 0.4 12.0 .+-. 0.4 12.5 .+-. 0.4 expansion applies to
(as-sintered) (@ 25-480.degree. C.) (as- coefficient opaque &
13.1 .+-. 0.4 sintered) @ 25-500.degree. C. dentin) (simulated 13.0
.+-. 0.4 (ppm/.degree. C.) pressing) (simulated pressing) Glass
transition .+-.20 540 .+-. 20 500 .+-. 20 600 .+-. 20 575 .+-. 20
temperature (.degree. C.) Chemical 100 (dentin & 17.7 22.6 33.1
40.4 solubility opaque) (.mu.g/cm.sup.2) 2,000 (ingot &
machinable block)
[0052] The integrated dental porcelain system of the present
invention is designed for making PFM, PTM, and all-ceramic
restorations in a simplified manner. As described above, the system
includes three major universal components: opaque coating,
dentin/enamel porcelain, and pressable ingots that can be used
interchangeably. For example, the same pressing temperature and
same ingot can be used to press either the dentin body when making
a PTM restoration and/or all-ceramic core. Furthermore, the same
firing temperature and the same opaque coating can be used to
overlay metal substructures for making PFM and/or PTM restorations.
And, the same firing temperature and same dentin/enamel porcelain
can be used to veneer over an opaqued metal substructure for making
PFM restorations and/or it can be used to veneer over either
pressed and/or machined all-ceramic cores for making all-ceramic
restorations.
[0053] It should be understood that while the present invention has
been described in considerable detail with respect to certain
specific embodiments thereof, it should not be considered limited
to such embodiments but may be used in other ways without departing
from the spirit of the invention and scope of the appended
claims.
* * * * *