CA2216976A1

CA2216976A1 - Process for manufacturing prosthetic dental reconstructions

Info

Publication number: CA2216976A1
Application number: CA002216976A
Authority: CA
Inventors: Arnold Wohlwend
Original assignee: Individual
Current assignee: Individual
Priority date: 1995-03-28
Filing date: 1996-03-28
Publication date: 1996-10-03
Also published as: EP0817597B1; DE59603006D1; EP0817597A1; AU5398496A; ATE184178T1; WO1996029951A2; JPH11502733A; US6106747A; DE19511396A1; WO1996029951A3

Abstract

A process for manufacturing a prosthetic dental inlay or prosthetic dental crown (1), or prosthetic dental bridge for fitting in a pre-prepared tooth cavity or on a pre-prepared stump (4), involves the following steps: the three-dimensional profile of the cavity or stump (4) is determined; a three-dimensional template for the inlay or crown, magnified by a predetermined factor, is made from a pre-treated prosthetic dental material and further treated to shrink it to dimensions matching those of the cavity or stump (4).
A working stump, magnified by the predetermined factor and in shape matching the three-dimensional profile of the cavity or stump (4), is produced from a material with more or less the same shrinkage factor as the prosthetic tooth material. The working stump is placed in the template for further treatment, the template being stabilised during the treatment. After the treatment, the working stump is separated from the template. The prosthetic tooth material and, if required, the material for the working stump is an oxide ceramics, specifically a zirconium oxide or aluminium oxide ceramics, or oxyde ceramics alloys.

Description

CA 02216976 1997-09-2~

METHOD FOR PRODUCING PROSTHETIC DENTAL
RECONSTRUCTIONS

The invention relates to a method as specified in the preamble to Claim 1.

Dental prostheses are understood here to refer to prosthetic dental inlays, prosthetic dental crowns and bridges, structural elements of all types, such as ab-ltnnt?nt~ (spacers), and dental devices of all types, with the invention relating especially to framework structures that may or may not be veneered.

A number of methods involving the production of prosthetic dental inlays or prosthetic dental crowns are known in the art. Generally following the grincling down of the dental defect, an impression is made of the tooth, the area around the tooth, and the jaw; the surface of the cavity may also be recorded on a computer using a stereophotogrammetric sc~nning device or laser se~nning device. The desired ~xt~rn~l form of the inlay or crown is either reconstructed using a eomputer~ te~l triaxial ~rin~ling m~- hin~, with the data on the tooth that were gathered and stored prior to the grin~1ing down of the tooth defect, and is then cut directly from a suitable block of m~t~ri~l, such as a ceramic block; or is fashioned out of plastic or plaster using models made from the impression that was taken of the untreated tooth.

The eonventional teehnique of using a precious metal or a Ni-Cr alloy to produee an inlay or a erown involves eertain aesthetic difficulties, whieh may be eountered by overfiring the metal eap with a eeramic layer. This proeess, however, is awkward in terms of produetion meehanies and is suseeptible to waste. Additionally, this method makes further monitoring of the condition of the tooth via x-rays impossible, which is considered a disadvantage, particularly in the case of erowns.

The growing cl~m~nc1 for aesthetically restorative dental prostheses has advanced the use of other m~teri~l~ and methods, such as high-strength glass, which is poured in liquid form into a refractory mold and is then fired; or the firing of ceramic powder onto a refractory model. Such CA 02216976 1997-09-2~

methods produce inlays and crowns that are aesthetically responsive and characterized by a high degree of x-ray opacity.

Ceramic prostheses that are cut out of ceramic blanks can, however, tend to break off as a result of h~nclling - particularly in their marginal areas, which, in order to yield a seamless transition to the surviving tooth, must be as thin as possible. In addition, grinc1ing traces - which are possible even with precision fini~hing - can lead to the formation of fissures, and thus to further risk of breakage.

In contrast, a method is specified in US 5,106,303 in which ceramic powder compact is presintered. The form for the inlay or the crown is then profiled from this prepared block of m~teri~l and is cut in enlarged dimensions to compensate for the ~hrink~ge that will result from the subsequent sintering. Thus, the resulting dental prosthesis will fit into the prepared cavity or onto the prepared tooth stump. The advantage of this method is that the m~t~ri~l can be processed in its so-called green state, which makes it easier to work with, since the density and hardness of the m~t~ri~l necessary for its use as a dental prosthesis are achieved only after Problems can result, however, from the method specified iri US 5,106,303 in that during the re~interin~ process, which is p~lro~ ed at a temperature of ca. 1500~C, the very thin marginal areas may become deformed or susceptible to fractures.

Overcoming the problems associated with the methods presented above is the filncl~mental objective of the present invention and is attained in the realization of the characterizing features of Claim 1.

Further, advantageous or ~lt~ rn~tive improvements on the invention are specified in the characterizing features of the contingent claims.

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-3- PCT~P96/01367 Because the enlarged form produced from a prekeated reconstructive material is positioned for subsequent treatment on the working stump andlor within a working pack, which is also enlarged by one and the same enlargement ratio, wherein the material of the working stump or the working pack possesses a shrinkage factor that is basically equal to that of the reconstructive material, this form becomes completely stabilized during the subsequent treatment - in which chrinkz~ge of the form that is dependent upon the material or the treatment takes place - and this protects against the above-mentioned damage resulting from handling, even in the critical marginal areas. And enc~in~ the presintered form with a working pack of this type permits control of the shrinking process.

If an oxide ceramic, such as ZrO2 or A1203, is used as the reconstructive m~t~ri~l, and preferably also as the m~t~ri~l for the working stump or the working pack, then the prosthetic dental reconstruction that is produced will exhibit a high degree of stability and density and a low level of porosity, with x-ray opacity and a choice coloration desirable for overall aesthetic ,les~ion.

According to the present invention, other hard m~t.ori~l~ are also suitable to be used as reconstructive m~tl~ri~ or as m~teri~l~ for the working stump or the working pack, such as SiC, TiN, TiC, TiB2, Si3N4, or other biocompatible carbides or nitrides from the 4th, 5th, or 6th main groups, as well as mixtures or multicomponent systems of oxide ceramics, if necessary with dirr~le~ miX~lres, such as is also specified in US 5,106,303, but the process specified in the present invention is also suited to the use of pure feldspar ceramics, or so-called infiltration ceramics, that is, oxide ceramics, into which glass mass is infiltrated.

It is characteristic of oxide ceramics (and others of the above-mentioned hard materials) that molded parts produced as a result of a variety of hardening processes - compacting or pre~int~rinE - possess a low level of density or stability and are easy to work with in this so-called green stage. If the form and, if necessary, the working stump or the working pack can be cut out of such a molded piece, this represents an advantage in terms of processing technique.

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The method specified in the invention is also and especially advantageous for the production of abutments. Abutments that are sintered intermediately permit each forrn, which is equally complex, to be pl~aLed during the integration phase of the fixture installation (implantation), and thereafter to be sintered, so that afterward - after the abutment has been set in - a direct incorporation of the crown or bridge is enabled. This is advantageous in terms of labor economics, as well as from the point of view of duration of treatment and aesthetic requirements, which are particularly applicable in the case of slender anchorage teeth.

If the m~t~ri~l necessary for the working stump or the working pack is cut out of the molded part in a powder or chip form, and is pressed into the shape of the working stump or is packed around the presintered reconstruction form - especially as a prepared block mold - then this material is simply sintered together, more or less point by point, in the subsequent treatment, the resintering, in which the necessary compacting takes place, and can be eluted or released, or abraded out or off of the inlay or crown or from the finished, sintered reconstruction following sintering. To facilitate this, the form can be provided on its inner surface and/or on its outer surface with a thin layer of lacquer, for example a zapon or cellulose lacquer, as a parting compound, prior to placement on the working stump or packing into the working pack.

Below, the invention is specified in detail, by example, with the help of diagrams, for the production of a crown form. The ~ r~m~ show:

Fig. la through le: the production of an enlarged crown form;
Fig. 2: a p~ e~led molded piece, from which the crown form and the m~teri~l for a working stump or a working pack will be produced; and Fig. 3: a crown form resting on top of a working stump, and a dental crown obtained from further tre~tment In Figures la through le, the production of an enlarged crown form 2 - as an example for the production of inlays, dental units, bridges, and for reconstructions in general - can be seen. After the grincling down of a carious tooth 3, the tooth becomes a tooth stump 4, from which an WO 96/29951 -5- PCT~P96/01367 impression 4a is taken, this impression is then filled with a casting material. The resulting model 4b (which corresponds to the ground down tooth 4) of the cavity or the tooth condition then serves as the basis for the shaping of a wax or plastic model S for the crown. This wax model 5 is then scanned using a copy-milling system 6 - for example via a laser distance device 7 - (use of co~Lventional, m~n~l~l, or optical sc~nning via a pantograph system or some other suitable system is also possible), the data are stored in a computer 9, processed, and, enlarged applopliately for the material being used, transmitted to a milling spindle 8, which cuts a representation of the wax model S out of an oxide ceramic molded piece 10, enlarged by the ~plO~ liate enlargement factor. As was described above, the intermediate step of ~l~aling a wax or plastic model may be omitted, and the form can be directly modeled using computer assisted means. After the cutting of the upper side of the crown form 2 (Fig. 2), the inside shape is produced in the same manner.

As was described in the introduction, the taking of an impression and the production of a model can also be omitted if the outer shape of the inlay, the shape of the cavity, or the shape of pL~ed teeth are recorded using a~pLopliate sc~nning devices directly in the mouth of the patient.

In Figure 2a molded piece 10 is illustrated, which has been compacted, for example, at room temperature, at approximately 2,000 bar. From the molded piece 10, for example zircon oxide ceramic, shavings 1 1, for example in a length of 2/10 mm, are milled off via cutting. In the manner described above in reference to Fig. la - le, the crown form 2 is produced.

In place of the shavings 11, powder m~t~n~l having particle sizes, for example, of, for example [sic], 30 to S00 ,um may be used.

The crown form 2 and the shavings 11 are now presintered, for zircon oxide ceramics at approx.
11 80~C. If necessary, the crown form 2 and the shavings 11 may also be produced from an already presintered molded piece 10.

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Working with the ceramic material in its so-called green state, that is, in a non-presintered state, and working with the material in a half-sintered (presintered) state, have the advantage over methods that produce the desired prosthetic dental forrns or reconstructions directly from the finally sintered working block via cutting that in processing the ceramic fewer micro cracks become incorporated in the surface, and the naturally high level of tool abrasion that occurs in the processing of the high-strength m~t~ri~l~ is reduced.

As illustrated in Fig. 3, the shavings 11 are then mixed with water to form a thick paste - such as can be used to form a working stump 12 - which is filled into the crown form 2. The water that is added to the shavings 11 or the powder grains may contain various ~tlmiXlllres, for example, with an admixture of approx. 1% acetic acid, the handling of the paste is facilitated, resulting in a thixotropic performance. With the ~(l" ,i x Ll l, e of alcohols, for example, the stability or the compactness of the mixture can be increased. The type and quantity of the ~ll " ,i x ~ s are to be selected based upon the desired or required properties. A thin layer of lacquer 13, 10 to 50 ,u, applied to the inner side of the crown form 2, closes the pores in the surface of the inner side and serves as a parting compound for the working stump 12. In the subsequent re.sint~ring, which is implemented for zircon oxide at a temperature of approx. 1 500~C, and causes the same amount of .~hrink~ge in the crown form 2 and the working stump 12, the lacquer 13 burns without residue, with a minim~l gap forming between the crown form 2 and the working stump 12, so that the working stump can be easily removed from the crown form 2, or - particularly due to its porous consistency - can be blasted off.

As is indicated in Fig. 3 with a dotted line, the crown form 2 - for the controlled support of the ~interin~-~hrink~ge process - may also lie within a working pack 14 of predetermined dimensions. The crown form 2 is then coated on the outside with the parting layer of lacquer, as described above. The working pack, which may be in block form, is then finally sintered together with the crown form and the working stump that may be positioned inside it. The ~interin~ process can be well controlled with such a working pack, since the changes in the outside dimensions permit direct control of the ~hrink~~e process. It goes without saying that CA 02216976 1997-09-2~

other reconstructive forms which may have no, or only the smallest, hollow cavities, such as abutments, can be finally sintered, if necessary, only packed in the working pack.

The dental crown 1 obtained in this manner, or the framework structure for the crown, fits precisely onto the prepared tooth 4 (Fig. 1). If desired, it may be veneered via known-in-the-art methods, at approx. 700 to 1200~C, using feldspar ceramic, glass ceramics, or zircon-con~inin~
veneer materials in powder form. If this is the case, the veneer material must be selected to correspond to the coefficient of thermal expansion of the crown or framework materials; the coefficient of thermal expansion of the veneer materials should lie within the corresponding range, or slightly below this range.

Effective in terms of time and aesthetically particularly responsive results are obtained when the known-in-the-art hot-press method is used, in which the veneer ceramic is applied in a hot, plastic, formable state. To this end, the outer form of the framework structure, to which a layer of color may already have been prelimin~rily applied to correspond to the desired tooth color, is constructed in wax, the framework structure is then embedded in a refractory pack that is heated to 800~C. Following application of the veneer m~t.-ri~l ~, the temperature is increased to a level that is 100 to 300~C below the sintering temperature for the framework structure, in order to prevent deformations of the latter. The now plastic veneer mass is pressed onto the framework structure. The veneer m~teri~l blanks are advantageously already colored with enamel colors, whitish-translucent, to match the color of the enamel of natural teeth. In order that the framework structure can be veneered with wax prior to the pressing on of the veneer m~teri~
functional conditions of the finished tooth may be incorporated.

Below, various enlargement factors, based upon the type of pretre~tmen~ used, for the production of a crown form 2 (Fig. 2), are given for zircon and alllminllm oxide, as an example:

~ CA 02216976 1997-09-2~
A

Enlargement factor (ca) for Pretreatment: zircon oxide al-lminllm oxide not ple~il"~led, isostatically pressed 30% 20%
presintered at 1080~C 27% 16%
1 1 00~C 26% 1 5%
1 150~C 21% 1 1%
1200~C 13% 7%

As can be seen from the above table, which gives data on zircon and alllminllm oxide as an example for possible other m~teri~l~ or alloys, a crown form produced from zircon oxide in accordance with Fig. 1 can also be further treated on a working stump made of aluminum oxide shavings, as long as the ~hrink~ge that will occur as a result of the subsequent tre~tment is the same for both. The fact that this is dependent upon the type of pretreatment used is apparent from the above table.

It is also apparent that - as mentioned in the introduction - other m~tt?ri~lc may also be used in the production of the crown form, as well as in the production of the working stump or the working pack. For example, an alloy of 95% Zro2 and 5% yttrium oxide may be used.

The working stump or the working pack may also be designed as a single piece, as long as it can be flawlessly removed from the crown form following the subsequent processing - if necessary by means of a separating agent applied in the me~ntime - or blasted off following heat tre~tment

Claims

1. Method for producing prosthetic dental reconstructions, such as dental inlays, crowns (1), bridges, or abutments, to fit into a prepared dental cavity or onto a prepared tooth stump (4), or onto a corresponding mounting, wherein the three-dimensional contours of the cavity or the tooth stump (4) or the form of the abutment are determined, and a three-dimensional form (2) of the dental inlay or the crown or the abutment, enlarged by a predetermined enlargement factor, is produced from a pretreated, in other words presintered and/or compacted, tooth replacement material, with the form (2) being subjected to subsequent treatment, in other words resintering, in which shrinkage to a dimension that corresponds to the cavity or the tooth stump (4) or the abutment occurs, and wherein a working stump (12) that is enlarged by the predetermined enlargement factor and that corresponds to the three-dimensional contours of the cavity or the tooth stump (4), or has an opening that is specially designed to hold a part of the mounting in the abutment, and/or a working pack (14) that is enlarged by the predetermined enlargement factor and that corresponds to the three-dimensional contour of the relevant outer shape, is produced from a material, characterized in that the material possesses approximately the same shrinkage factor as the tooth replacement material, and that ~ the working stump (12) is placed in the form for further processing, in other words resintering of the form (2), and/or the working pack (14) is packed around the form (2) from the outside, completely covering the form, for further processing, whereby the form (2) becomes stabilized during the subsequent processing, and ~ the working stump (12) or the working pack (14), after subsequent processing, is separated from the form (2).

2. Method in accordance with Claim 1, characterized in that as the tooth replacement material, and if necessary as the material used for the working stump (12) or for the working pack (14), a hard material, such as an oxide ceramic, particularly zircon oxide or aluminum oxide ceramic, or such as a nitride or carbide, or an alloy of an oxide ceramic, is used.

3. Method in accordance with Claim 2, characterized in that the pretreatment comprises a compacting of the hard material into a green state and/or - for example when oxide ceramics are being used - a presintering, especially at a temperature of between 1000 and 1300°C.

4. Method in accordance with Claim 2 or 3, characterized in that the material used for the working stump (12) or for the working pack (14) is comprised of compacted and/or - especially at a temperature of between 1000 and 1300°C - presintered oxide ceramics.

5. Method in accordance with Claim 4, characterized in that the compacted and/or presintered material for the working stump (12) or for the working pack (14) is in the form of a powder or shavings.

6. Method in accordance with one of the preceding claims, characterized in that prior to the positioning of the working stump (12), or prior to the positioning of the form (2) in the working pack (14), the form (2) is coated on its inner surface or on its outer surface with a thin layer of a parting compound (13), wherein, if necessary, the working pack (14) may be shaped in the form of a block - following positioning of the form (2) in the pack.

7. Method in accordance with one of Claims 2 through 6, characterized in that the subsequent treatment comprises a resintering at a sintering temperature that is appropriate for the tooth replacement material - for zircon oxide at approximately 1500°C.

8. Method in accordance with one of the preceding claims, characterized in that following subsequent further processing, the working stump (12) is removed from the form (2) or the form is separated from the working pack (14), after which, if necessary, the form is provided with a veneer comprised, for example, of feldspar ceramic, wherein especially a hot-press method is applied.