Dental model and die assembly and method of making the same

Patent metadata

Field	Value
Publication number	US-2021282897-A1
Application number	US-201816606317-A
Country	US
Kind code	A1
Filing date	Mar 28, 2018
Priority date	Apr 21, 2017
Publication date	Sep 16, 2021
Grant date	—

Abstract

An assembly useful for preparing a prosthetic crown for fitting to a tooth of a patient is accordingly described herein. The assembly includes (a) a polymer dental model having a shape corresponding to at least a portion of a dental arch of a patient and a socket formed therein, the socket having a socket wall, and (b) a polymer die having an upper portion configured in the shape of a tooth of a patient and a lower stem configured for insertion into the socket. At least one of the stem and the socket wall are configured to have both a relaxed position when the die is not in the socket, and a tensioned position when the die is fully inserted in the socket, so that the stem is firmly and accurately engaged by the socket when the die is inserted therein.

First claim

1 . In an assembly useful for preparing a prosthetic crown for fitting to a tooth of a patient comprising (a) a polymer dental model having a shape corresponding to at least a portion of a dental arch of a patient and a socket formed therein, the socket having a socket wall, and (b) a polymer die having an upper portion configured in the shape of a tooth of a patient and a lower stem configured for insertion into said socket, the improvement comprising:
configuring at least one of said stem and said said socket wall to have both a relaxed position when said die is not in said socket, and a tensioned position when said die is fully inserted in said socket, so that said stem is firmly and accurately engaged by said socket when said die is inserted therein.

2 . An assembly useful for preparing a prosthetic crown for fitting to a tooth of a patient of claim 1 , comprising:
(a) a polymer dental model having a shape corresponding to at least a portion of a dental arch of a patient, said model having (i) a bottom surface portion and (ii) a socket formed in said model in a location corresponding to a tooth of a patient, to which tooth a crown is to be fitted, with said socket extending through said bottom surface portion, and with said socket having a side wall and an irregularly shaped circumference; and (b) a polymer die having an upper portion configured in the shape of a tooth of a patient prepared to receive a crown and a lower stem configured for insertion into said socket, with said stem having (i) a bottom surface portion and (ii) an irregularly shaped circumference corresponding to that of said socket, the stem and socket together configured so that said die inserts into said socket in one orientation only; with said stem comprising at least two separate elongate prongs configured for insertion into said socket, each said prongs having a laterally relaxed position and a laterally tensioned position; and with said prongs configured so that upon insertion into said socket with said stem bottom portion co-planar with said dental model bottom portion, said prongs in said tensioned position frictionally engage said socket wall and securely position said die in said model in a predetermined position.

3 . The assembly of claim 2 , wherein said prongs are either (i) free of one another adjacent said bottom surface portion, or (ii) connected to one another adjacent said bottom surface portion.

4 . The assembly of claim 2 , wherein said prongs in said relaxed position are warped away from one another.

5 . An assembly useful for preparing a prosthetic crown for fitting to a tooth of a patient of claim 1 , comprising:
(a) a polymer dental model having a shape corresponding to at least a portion of a dental arch of a patient, said model having (i) a bottom surface portion and (ii) a socket formed in said model in a location corresponding to a tooth of a patient, to which tooth a crown is to be fitted, with said socket extending through said bottom surface portion, and with said socket having a side wall and an irregularly shaped circumference; and (b) a polymer die having an upper portion configured in the shape of a tooth of a patient prepared to receive a crown and a lower stem configured for insertion into said socket, with said stem having (i) a bottom surface portion and (ii) an irregularly shaped circumference corresponding to that of said socket, the stem and socket together configured so that said die inserts into said socket in one orientation only; with said socket comprising at least one, or a plurality of, wall portions having a laterally relaxed position and a laterally tensioned position; and with said wall portions configured so that upon insertion into said socket with said stem bottom portion co-planar with said dental model bottom portion, said wall portions in said tensioned position frictionally engage said stem and securely position said die in said model in a predetermined position (plus or minus 20 microns in the mesial distal axis, and/or plus or minus 20 microns in the buccal lingual axis).

6 . The assembly of claim 1 , wherein said stem in said tensioned position, and said socket, are inwardly tapered in a corresponding mating configuration.

7 . The assembly of claim 1 , wherein:
said socket has a top opening and a bottom opening, said socket top opening has a circumference greater than said socket bottom opening, said socket side wall tapers inwardly from said socket top opening to said socket bottom opening; and said stem bottom portion has a circumference intermediate between that of said socket top opening and that of said socket bottom opening.

8 . The assembly of claim 1 , wherein said stem further comprises a narrowed foot portion adjacent said bottom surface portion.

9 . The assembly of claim 1 , wherein both said model and said die are comprised of poly(acrylate), poly(methacrylate), poly(urethane acrylate), poly(urethane methacrylate), poly(epoxy acrylate), or poly(epoxy methacrylate).

10 . The assembly of claim 1 , wherein both said model and said die consist of a polymer having:
a tensile modulus of 1200 or 1600 MPa to 3000 MPa, or more; an elongation at break of 2% to 100 or 140%, or more; a flexural strength of 40 or 60 MPa, to 100 or 120 MPa, or more; and/or a flexural modulus (chord, 0.5%-1% strain) of 1500 or 2000 MPa, to 3000 MPa, or more.

11 . The assembly of claim 1 , wherein both said dental model and said die are produced by additive manufacturing from a polymerizable resin.

12 . The assembly of claim 1 , wherein said dental model is layerless, said die is layerless, or both said dental model and said die are layerless.

13 . A method of making an assembly of claim 1 , comprising:
(a) producing both said die and said model from a light-polymerizable resin by stereolithography, preferably bottom-up stereolithography, and then (b) optionally washing said die and said model.

14 . The method of claim 13 , wherein said resin shrinks during or after said producing step, and wherein said prongs warp away from one another during or after said producing step.

15 . The method of claim 13 , wherein said producing step is carried out in a time of not more than one hour.

16 . The method of claim 13 , wherein said producing step is carried out on a stereolithography apparatus including a carrier platform, and said producing step comprises simultaneously producing said die and said model on the same carrier platform.

17 . The method of claim 13 , wherein said bottom-up stereolithography comprises continuous liquid interface production.

18 . The assembly of claim 1 , wherein said stem is firmly and accurately engaged at plus or minus 20 microns in the mesial-distal axis of the arch or arch portion, and/or plus or minus 20 microns in the buccal-lingual axis of the arch or arch portion by said socket when said die is inserted therein.

Assignees

• Carbon Inc

Inventors

• Laaker Kyle

Classifications

• A61C13/0013

  using stereolithographic techniques · CPC title

• A61C5/70 Primary

  Tooth crowns; Making thereof · CPC title

• A61C13/087

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

• A61C13/0019

  using three dimensional printing · CPC title

• A61C13/34 Primary

  Making or working of models, e.g. preliminary castings, trial dentures; Dowel pins [4] · CPC title