Multiple layered denture block and/or disk

Patent metadata

Field	Value
Publication number	US-10433939-B2
Application number	US-201715641575-A
Country	US
Kind code	B2
Filing date	Jul 5, 2017
Priority date	Jul 5, 2016
Publication date	Oct 8, 2019
Grant date	Oct 8, 2019

Abstract

This invention designs and builds multiple layers (two layers or more) of millable dental blocks or disks for milling of various dental devices, specifically denture base blocks or disks of denture base material, where milled teeth cavities to receive artificial denture tooth materials to form final dental devices, such as partial and full dentures. This invention also designs and builds multiple layers (two layers or more) of millable denture base or denture blocks or disks comprised of denture base or/and denture tooth materials to form final dental devices, such as partial and full dentures. A method for manufacturing a layered denture is provided. The invention provides a multiple layered denture base block (or disk) for milling a denture base. The invention also provides a multiple layered denture block (or disk) for milling a denture. Highly shape adjustable or shape memory polymer layer(s) may be used in these multiple layered forms. Different layer of material has different mechanical and physical properties to meet different need, which provide added benefits to the patients, dental professional and dental laboratory.

First claim

The invention claimed is:

1. A method for making a multilayered block or disk comprising the steps of:
providing a mold;
placing a first polymerizable material in the mold to form a first layer, the first polymerizable material including a mixture of:
a powder blend of 65% to 85% by wt a [methyl (meth)acrylate, ethyl (meth)acrylate and butyl (meth)acrylate] copolymer; and a first initiator; and
a liquid blend of 4-15% by wt a first rubber impact modifier; at least one monomer; and
a second initiator;

placing a second polymerizable material in contact with the first layer of the polymerizable material to form a second polymerizable layer, wherein the second polymerizable material is different than the first polymerizable material and includes a mixture of:
a powder blend having of 75% to about 95% by wt [methyl (meth)acrylate, ethyl (meth)acrylate and butyl (meth)acrylate] copolymer; and a third initiator;
a liquid blend of 4-12% by wt a second rubber impact modifier being different than the first rubber impact modifier; 1-10% by wt of at least one dimethacrylate component; and 20-70% by wt at least one methacrylate based component, and a fourth initiator;

curing the first polymerizable material to form a cured first polymerizable material;
curing the second polymerizable material to form a second polymerizable material, the cured first polymerizable material and the cured second polymerizable material form the multilayered block or disk;
wherein the cured second polymerizable material has a higher Tg than the cured first polymerizable material.

2. The method of claim 1 , wherein the cured first polymerizable material has flexural strength ranging from 70 to 110 MPa.

3. The method of claim 1 , wherein the cured first polymerizable material has a flexural modulus ranging from 2000 to 3500 MPa.

4. The method of claim 1 , wherein the cured second polymerizable material has flexural strength ranging from 115 MPa to 200 MPa.

5. The method of claim 1 , wherein the cured second polymerizable material has a flexural modulus ranging from 2400 MPa to 3700 MPa.

6. The method of claim 1 , wherein the first polymerizable material is cured prior to the curing of the second polymerizable material.

7. The method of claim 1 , wherein the step of placing the second polymerizable material occurs after the step of curing the first polymerizable material.

8. The method of claim 1 , wherein the first layer of polymerizable material, after being cured includes recesses for receiving the second polymerizable material.

9. The method of claim 8 , wherein the cured first layer of polymerizable material forms a denture base and the cured second layer of polymerizable material forms a plurality of teeth after a further step of milling or grinding the multilayered block or disk.

10. The method of claim 8 , wherein the second polymerizable material extends above the recesses while forming the second layer of polymerizable material.

11. The method of claim 1 , wherein the step of curing the first polymerizable material and the step of curing the second polymerizable material occur at the same time.

12. The method of claim 1 , further comprising the step of placing a third polymerizable material in contact with the second layer of polymerizable material to form a third layer of polymerizable material.

13. The method of claim 12 , wherein the step of placing the third polymerizable material occurs after the step of curing the second layer of polymerizable material.

14. The method of claim 13 , further comprising the step of curing the third layer of polymerizable material.

15. The method of claim 1 , wherein the cured first layer of polymerizable material around recesses formed therein having the cured second polymerizable material, after being milled or grinded is adjustable while the remaining areas of the cured first polymerizable material and the cured second polymerizable material remain shape stable at elevated temperatures up to 100° C.

16. The method of claim 1 , wherein the curing steps, the first polymerizable material and the second polymerizable material are partially cured to form a partially cured multilayered disk or block.

17. The method of claim 1 , further comprising the steps of:
milling or grinding the partially cured multilayered block or disk to form a partially cured dental component; and
curing the milled or ground partially cured block or disk to form a fully cured dental component.

18. The method of claim 17 , wherein the fully cured dental component is a denture having a denture base formed for the milled or ground fully cured first polymerizable material and a plurality of teeth formed from the milled or ground fully cured second polymerizable material.

19. The method of claim 18 , wherein the top surface of the teeth formed from the milled or ground fully cured second polymerizable material has a high wear resistance determined by volume loss ranging from 0.045-0.120 mm3 at 37° C. (after 400,000 cycles at 50 RPM).

Assignees

• Dentsply Sirona Inc

Inventors

• Sun Benjamin Jiemin
• Ammon Dan

Classifications

• A61C13/0022 Primary

  Blanks or green, unfinished dental restoration parts · CPC title

• B29K2033/08

  Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate · CPC title

• A61C13/087

  Artificial resin teeth {(A61C13/081 takes precedence; preparations A61K6/80)} · CPC title

• A61C13/081

  Making teeth by casting or moulding · CPC title

• A61C13/09

  {Composite teeth, e.g. front and back section (A61C13/0835, A61C13/1023 take precedence)}; Multilayer teeth · CPC title