High-strength dental restorations

Abstract

High strength ceramic components for use in dental applications are provided wherein one or more layers of ceramic material is disposed on a high strength ceramic component to provide a dental restoration. The ceramic material may be applied in the form of powder, putty, tape a pellet.

What is claimed is:  
     
         1 . A dental restorative material comprising: 
 a high strength ceramic component; and    one or more layers of ceramic material disposed on the high strength ceramic component.    
     
     
         2 . The dental material of  claim 1  wherein the high-strength ceramic component is comprised of at least one of alumina, zirconia, SIALON, mullite, titanium oxide, magnesium oxide, and mixtures thereof.  
     
     
         4 . The dental material of claim  3  wherein the one or more layers of ceramic material has a thermal expansion that is slightly lower than a thermal expansion of the high strength ceramic component.  
     
     
         5 . The dental material of claim  3  wherein the ceramic layer is selected from silica, silicates, aluminates, phosphates, fluorates, aluminosilicates, silica-rich glasses, zirconates, titanates and mixtures thereof.  
     
     
         6 . The dental material of  claim 5  wherein the silicates comprise lithium disilicate.  
     
     
         7 . A method of manufacturing a dental restoration comprising: 
 providing a high strength ceramic component;    applying one or more layers of ceramic material on the high strength ceramic component to form the dental restoration.    
     
     
         8 . The method of  claim 7  further comprising modifying the high strength ceramic component by grinding or carving to the desired shape prior to applying one or more layers of ceramic material thereon.  
     
     
         9 . The method of  claim 7  wherein the high strength ceramic component is comprised of at least one of alumina, zirconia, SIALON, mullite, titanium oxide, magnesium oxide and mixtures thereof.  
     
     
         10 . The method of  claim 7  wherein the one or more layers of ceramic material layer comprises a material selected from silica, silicates, aluminates, phosphates, fluorates, aluminosilicates, silica-rich glasses, zirconates, titanates and mixtures thereof.  
     
     
         11 . The method of  claim 10  wherein the silicates comprise lithium disilicate.  
     
     
         12 . The method of  claim 7  wherein the one or more layers of ceramic material are applied by sputtering, chemical vapor deposition, ion bombardment or vacuum deposition.  
     
     
         13 . The method of  claim 7  wherein the one or more layers of ceramic material are applied on the ceramic component by pressing.  
     
     
         14 . The method of  claim 13  wherein pressing is selected from hot pressing by machine, cold pressing by machine or application of pressure by hand.  
     
     
         15 . The method of  claim 13  wherein the one or more layers of ceramic material are fused to the ceramic component during pressing.  
     
     
         16 . The method of  claim 7  wherein the one or more layers of ceramic material are provided in the form of tape, putty or powder.  
     
     
         17 . The method of  claim 7  further comprising etching or abrading the high strength ceramic component prior to application of one or more layers of ceramic material.  
     
     
         18 . The dental material of  claim 7  wherein the high strength ceramic component is in the shape of a bar, pontic, block, or rod.  
     
     
         19 . The dental restorative material of  claim 1  selected from an orthodontic appliance, bridge, space maintainer, tooth replacement appliance, splint, crown, partial crown, denture, post, tooth, jacket, inlay, onlay, facing, veneer, facet, implant, abutment, cylinder, or connector.  
     
     
         20 . A method of making a dental restoration comprising: 
 preparing a wax pattern of the desired dental restoration;    wherein the wax pattern is built around a high strength ceramic component leaving one or more sections of the high strength ceramic component uncovered;    surrounding the wax pattern with investment material;    burning out the wax to provide a mold for the dental restoration;    filling the mold with a first ceramic material; and    sintering the first ceramic material to provide a dental restoration.    
     
     
         21 . The method of  claim 20  further comprising removing the dental restoration from the mold and applying a second ceramic material or a composite material to the one or more uncovered sections of the high strength ceramic component and sintering the second ceramic material or curing the composite material.  
     
     
         22 . The method of  claim 20  wherein the high strength ceramic component comprises zirconia and the first ceramic material comprises lithium disilicate.  
     
     
         23 . The method of  claim 21  wherein the second ceramic material comprises lithium disilicate.  
     
     
         24 . The method of  claim 21  wherein the composite material comprises particulate filled composite material.  
     
     
         25 . The method of  claim 21  wherein filling the mold with a first ceramic material and sintering the first ceramic material to provide a dental restoration comprises pressing a ceramic pellet into the mold space and simultaneously sintering the pressed ceramic pellet.