Highly translucent zirconia material, device, methods of making the same, and use thereof

Patent metadata

Field	Value
Publication number	US-11161789-B2
Application number	US-201916545789-A
Country	US
Kind code	B2
Filing date	Aug 20, 2019
Priority date	Aug 22, 2018
Publication date	Nov 2, 2021
Grant date	Nov 2, 2021

Abstract

A zirconia ceramic material for use in dental applications is provided comprising an yttria-stabilized zirconia material stabilized with 5 mol % yttria to 8 mol % yttria, and methods for making a sintered body from the ceramic material. The zirconia ceramic materials exhibit both enhanced translucency and a flexural strength of at least 300 MPa, or at least 500 MPa, when fully sintered.

First claim

We claim:

1. A sintered ceramic body comprising
a yttria-stabilized zirconia ceramic material, stabilized by 5 mol % to 7.2 mol % yttria, wherein the ceramic material formed as a sintered ceramic body has a flexural strength greater than 500 MPa, and a transmittance greater than 62% at 700 nm (when measured on a 1 mm thick fully sintered ceramic body).

2. The sintered ceramic body of claim 1 , wherein the sintered ceramic body comprises between 63 and 77% transmittance.

3. The sintered ceramic body of claim 1 , wherein the sintered ceramic body has a fracture toughness greater than 1.5 MPa·m −1/2 .

4. The sintered ceramic body of claim 1 , wherein the sintered ceramic body has an average grain size between 1 and 20 μm.

5. The sintered ceramic body of claim 1 , wherein the ceramic material comprises between 5.1 mol % and 7.1 mol % yttria, and wherein the sintered ceramic body comprises between 63% and 77% transmittance at 700 nm.

6. The sintered ceramic body of claim 1 , wherein the ceramic material comprises between 5.2 mol % and 7.2 mol % yttria, and wherein the sintered ceramic body comprises between 63 and 72% transmittance at 700 nm.

7. The sintered ceramic body of claim 1 , wherein the ceramic material comprises between 5.8 mol % and 6.3 mol % yttria and wherein the sintered ceramic body comprises between 63 and 74% transmittance at 700 nm.

8. The sintered ceramic body of claim 7 , wherein the sintered body comprises a fracture toughness of greater than 2 MPa·m −1/2 .

9. The sintered ceramic body of claim 1 , wherein the ceramic material comprises between 5 mol % and 6.4 mol % yttria, and wherein the sintered ceramic body comprises between 63% and 78% transmittance at 700 nm.

10. The sintered ceramic body of claim 1 , wherein the ceramic material comprises between 5.1 mol % and 6.4 mol % yttria, and wherein the sintered ceramic body comprises between 68% and 75% transmittance at 700 nm.

11. The sintered ceramic body of claim 1 , wherein the ceramic material comprises between 5.1 mol % and 6.4 mol % yttria, and wherein the sintered ceramic body comprises between 64% and 70% transmittance at 700 nm.

12. A sintered ceramic body comprising
a yttria-stabilized zirconia ceramic material stabilized by 5.2 mol % to 7.1 mol % yttria,
wherein the sintered ceramic body has a flexural strength greater than or equal to 500 MPa, and
wherein the sintered ceramic body comprising at least 98% theoretical density has an average grain size greater than or equal to 8 μm.

13. The sintered ceramic body of claim 12 , wherein the sintered ceramic body has an average grain size between 8 μm and 20 μm.

14. The sintered ceramic body of claim 12 , wherein the sintered ceramic body has an average grain size between 8 μm and 15 μm.

15. The sintered ceramic body of claim 12 , wherein the yttria-stabilized zirconia ceramic material is shaded by a coloring agent comprising at least one metal selected from Fe, Co, Cu, Pr, Tb, Cr or Er.

16. The sintered ceramic body of claim 12 , wherein the sintered ceramic body comprises greater than 60% transmittance at 700 nm (when measured on a 1 mm thick fully sintered ceramic body).

17. A sintered ceramic body comprising
a shaded yttria-stabilized zirconia ceramic material stabilized by 5.5 mol % to 6.5 mol % yttria, comprising a metal-containing component as a coloring agent, and
wherein the sintered ceramic body comprises at least 98% theoretical density and has an average grain size greater than or equal to 1 μm and a transmittance greater than 58% at 700 nm (when measured on a 1 mm thick sintered body).

18. The sintered ceramic body of claim 17 , wherein the ceramic material is stabilized by 5.8 mol % to 6.3 mol % yttria.

19. The sintered ceramic body of claim 17 , wherein the transmittance is greater than 60% at 700 nm.

20. The sintered ceramic body of claim 17 , wherein the transmittance is greater than 62% at 700 nm.

Assignees

• Glidewell James R Dental Ceramics Inc

Inventors

• Yang Yan
• Balasubramanian Sreeram

Classifications

• C04B2235/762

  Cubic symmetry, e.g. beta-SiC · CPC title

• C04B2235/5463

  Particle size distributions · CPC title

• A61K6/818

  comprising zirconium oxide · CPC title

• C04B2235/6562

  Heating rate · CPC title

• A61K6/824

  comprising transition metal oxides · CPC title