US2004109783A1PendingUtilityA1

Method for the manufacture of dental restorations

35
Priority: Jan 10, 2000Filed: Sep 18, 2003Published: Jun 10, 2004
Est. expiryJan 10, 2020(expired)· nominal 20-yr term from priority
Inventors:Arun PrasadShannon RampullaDenise NorthThomas Van Vechten
A61C 5/77A61C 13/0003
35
PatentIndex Score
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Claims

Abstract

Dental restorations are fabricated using metal powder. Preferably, the metal powder is a high fusing metal and preferably, the metal powder comprises a non-oxidizing metal. The metal powder is applied to a die and is covered with a covering material such as a refractory die material preferably in the form of a flowable paste. A second covering material may be sprinkled or dusted onto the paste. The model is then dried prior to firing. After drying, the model is sintered to provide a high strength metal restoration. After sintering, the outer shell can be broken off easily with one's hand to expose the sintered coping.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A method for making a dental restoration comprising: 
 forming a model of one or more teeth;    coating the model with metal or alloy powder;    applying a covering material onto the model coated with metal or alloy powder wherein the covering material is applied at a thickness equal to or less than about 8 mm and wherein the covering material comprises a mixture of refractory powder and fibers;    sintering the model coated with metal or alloy powder and covering material in a furnace to form a coping; and    removing the covering material from the coping.    
     
     
         2 . The method of  claim 1  wherein the fibers are selected from the group consisting of inorganic, organic fibers and mixtures thereof.  
     
     
         3 . The method of  claim 2  wherein the inorganic fibers are selected from the group consisting of glass, glass-ceramic, ceramic, metal and mixtures thereof.  
     
     
         4 . The method of  claim 3  wherein the glass fibers are selected from the group consisting of E glass, S glass, AR glass and mixtures thereof.  
     
     
         5 . The method of  claim 3  wherein the ceramic fibers are selected from the group consisting of alumina, mullite, silica, rock wool and mixtures thereof.  
     
     
         6 . The method of  claim 3  wherein the metal fibers are selected from the group consisting of steel, aluminum and mixtures thereof.  
     
     
         7 . The method of  claim 2  wherein the organic fibers are selected from the group consisting of carbon, polyester, polyolefin, polyetheramide, fluoropolymer, polyether, cellulose, phenolic, polyesteramide, polyurethane, epoxy, aminoplastic, silicone, polysulfone, polyetherketone, polyetheretherketone, polyesterimide, polyphenylene sulfide, polyether acryl ketone, poly(amideimide), polyimide fibers and mixtures thereof.  
     
     
         8 . The method of  claim 1  wherein the fibers range from about 0.1 to about 3 mm in length and from about 1 to about 100 microns in diameter.  
     
     
         9 . The method of  claim 1  wherein the fibers are present in an amount of from about 0.1 to about 25 percent by weight and the refractory powder is present in an amount of from about 75 to about 99.9 percent by weight of the total powder mixture.  
     
     
         10 . The method of  claim 1  wherein the refractory powder comprises a refractory die material.  
     
     
         11 . The method of  claim 1  wherein the covering material further comprises a liquid vehicle.  
     
     
         12 . The method of  claim 11  wherein the liquid vehicle is selected from alcohol and acetone.  
     
     
         13 . The method of  claim 1  further comprising coating the covering material with a high temperature refractory material.  
     
     
         14 . The method of  claim 1  wherein the refractory powder comprises silica, leucite or mixtures thereof.  
     
     
         15 . The method of  claim 14  wherein the silica is selected from the group consisting of quartz, cristobolite and mixtures thereof.  
     
     
         16 . The method of  claim 11  wherein the refractory die material is selected from the group consisting of gypsum-bonded, phosphate-bonded, ethyl silicate-bonded and mixtures thereof.  
     
     
         17 . The method of  claim 1  further comprising applying a die spacer material to the model prior to application of the metal or alloy powder.  
     
     
         18 . The method of  claim 1  wherein applying the covering material onto the model coated with metal or alloy powder comprises painting the covering material onto the metal powder with a brush.  
     
     
         19 . The method of  claim 13  wherein coating the covering material with a high temperature refractory material comprises dusting the high temperature refractory material onto the covering material.  
     
     
         20 . A dental restoration formed by the process of  claim 1 .  
     
     
         21 . A method for making a dental restoration comprising: 
 forming a model of one or more teeth;    coating the model with metal or alloy powder;    covering the model coated with metal powder with a covering material wherein the covering material comprises a mixture of refractory powder and fibers;    allowing the metal powder and covering material to dry to form a unit;    removing the dried metal powder and covering material unit from the model;    filling the understructure of the unit with covering material wherein the covering material comprises a mixture of refractory powder and fibers;    sintering the unit in a furnace to form a coping; and    removing the covering material from the coping.    
     
     
         22 . The method of  claim 21  wherein the fibers are selected from the group consisting of inorganic, organic fibers and mixtures thereof.  
     
     
         23 . The method of  claim 22  wherein the inorganic fibers are selected from the group consisting of glass, glass-ceramic, ceramic, metal and mixtures thereof.  
     
     
         24 . The method of  claim 23  wherein the glass fibers are selected from the group consisting of E glass, S glass, AR glass and mixtures thereof.  
     
     
         25 . The method of  claim 23  wherein the ceramic fibers are selected from the group consisting of alumina, mullite, silica, rock wool and mixtures thereof.  
     
     
         26 . The method of  claim 23  wherein the metal fibers are selected from the group consisting of steel, aluminum and mixtures thereof.  
     
     
         27 . The method of  claim 22  wherein the organic fibers are selected from the group consisting of carbon, polyester, polyolefin, polyetheramide, fluoropolymer, polyether, cellulose, phenolic, polyesteramide, polyurethane, epoxy, aminoplastic, silicone, polysulfone, polyetherketone, polyetheretherketone, polyesterimide, polyphenylene sulfide, polyether acryl ketone, poly(amideimide), polyimide fibers and mixtures thereof.  
     
     
         28 . The method of  claim 21  wherein the fibers range from about 10 nm to about 3 mm in length and from about 5 nm to about 100 microns in diameter.  
     
     
         29 . The method of  claim 21  wherein the fibers are present in an amount of from about 0.1 to about 25 percent by weight and the refractory powder is present in an amount of from about 75 to about 99.9 percent by weight of the total powder mixture.  
     
     
         30 . The method of  claim 21  wherein the refractory powder comprises a refractory die material.  
     
     
         31 . The method of  claim 21  wherein the covering material further comprises a liquid vehicle.  
     
     
         32 . The method of  claim 31  wherein the liquid vehicle is selected from alcohol and acetone.  
     
     
         33 . The method of  claim 21  further comprising coating the covering material with a high temperature refractory material.  
     
     
         34 . The method of  claim 21  wherein the refractory powder comprises silica, leucite or mixtures thereof.  
     
     
         35 . The method of  claim 34  wherein the silica is selected from the group consisting of quartz, cristobolite and mixtures thereof.  
     
     
         36 . The method of  claim 30  wherein the refractory die material is selected from the group consisting of gypsum-bonded, phosphate-bonded, ethyl silicate-bonded and mixtures thereof.  
     
     
         37 . The method of  claim 21  further comprising applying a die spacer material to the model prior to application of the metal or alloy powder.  
     
     
         38 . The method of  claim 21  wherein applying the covering material onto the model coated with metal or alloy powder comprises painting the covering material onto the metal powder with a brush.  
     
     
         39 . The method of  claim 33  wherein coating the covering material with a high temperature refractory material comprises dusting the high temperature refractory material onto the covering material.  
     
     
         40 . A dental restoration formed by the process of  claim 21 .  
     
     
         41 . A method for making a dental restoration comprising: 
 forming a model of one or more teeth;    coating the model with powder of a first metal or alloy;    placing a reservoir of a second metal or alloy onto the model coated with the powder of the first metal or alloy, wherein the second metal or alloy has a fusing temperature lower than the fusing temperature of the first metal or alloy;    covering the model coated with the powder of first metal or alloy and the reservoir of the second metal or alloy with covering material wherein the covering material comprises a mixture of refractory powder and fibers; and    sintering the model to form a coping.    
     
     
         42 . The method of  claim 41  wherein the fibers are selected from the group consisting of inorganic, organic fibers and mixtures thereof.  
     
     
         43 . The method of  claim 42  wherein the inorganic fibers are selected from the group consisting of glass, glass-ceramic, ceramic, metal and mixtures thereof.  
     
     
         44 . The method of  claim 43  wherein the glass fibers are selected from the group consisting of E glass, S glass, AR glass and mixtures thereof.  
     
     
         45 . The method of  claim 43  wherein the ceramic fibers are selected from the group consisting of alumina, mullite, silica, rock wool and mixtures thereof.  
     
     
         46 . The method of  claim 43  wherein the metal fibers are selected from the group consisting of steel, aluminum and mixtures thereof.  
     
     
         47 . The method of  claim 42  wherein the organic fibers are selected from the group consisting of carbon, polyester, polyolefin, polyetheramide, fluoropolymer, polyether, cellulose, phenolic, polyesteramide, polyurethane, epoxy, aminoplastic, silicone, polysulfone, polyetherketone, polyetheretherketone, polyesterimide, polyphenylene sulfide, polyether acryl ketone, poly(amideimide), polyimide fibers and mixtures thereof.  
     
     
         48 . The method of  claim 41  wherein the fibers range from about 10 nm to about 3 mm in length and from about 5 nm to about 100 microns in diameter.  
     
     
         49 . The method of  claim 41  wherein the fibers are present in an amount of from about 0.1 to about 25 percent by weight and the refractory powder is present in an amount of from about 75 to about 99.9 percent by weight of the total powder mixture.  
     
     
         50 . The method of  claim 41  wherein the refractory powder comprises a refractory die material.  
     
     
         51 . The method of  claim 41  wherein the covering material further comprises a liquid vehicle.  
     
     
         52 . The method of  claim 51  wherein the liquid vehicle is selected from alcohol and acetone.  
     
     
         53 . The method of  claim 41  further comprising coating the covering material with a high temperature refractory material.  
     
     
         54 . The method of  claim 41  wherein the refractory powder comprises silica, leucite or mixtures thereof.  
     
     
         55 . The method of  claim 54  wherein the silica is selected from the group consisting of quartz, cristobolite and mixtures thereof.  
     
     
         56 . The method of  claim 50  wherein the refractory die material is selected from the group consisting of gypsum-bonded, phosphate-bonded, ethyl silicate-bonded and mixtures thereof.  
     
     
         57 . The method of  claim 41  further comprising applying a die spacer material to the model prior to application of the metal or alloy powder.  
     
     
         58 . The method of  claim 41  wherein applying the covering material onto the model coated with metal or alloy powder comprises painting the covering material onto the metal powder with a brush.  
     
     
         59 . The method of  claim 53  wherein coating the covering material with a high temperature refractory material comprises dusting the high temperature refractory material onto the covering material.  
     
     
         60 . A dental restoration formed by the process of  claim 41 .  
     
     
         61 . A method for making a dental restoration comprising: 
 forming a model of one or more teeth, wherein the model comprises a margin area;    coating the model with powder of a metal or alloy to a point above the margin area;    covering the model coated with powder with a covering material wherein the covering material comprises a mixture of refractory powder and fibers;    sintering the model coated with powder in a furnace to form a metal coping;    removing the covering material from the metal coping;    applying a first porcelain material on the metal coping;    applying a second porcelain material on the model along the margin area; and    firing the coping and die coated with first and second porcelain material in a furnace.    
     
     
         62 . The method of  claim 61  wherein the fibers are selected from the group consisting of inorganic, organic fibers and mixtures thereof.  
     
     
         63 . The method of  claim 62  wherein the inorganic fibers are selected from the group consisting of glass, glass-ceramic, ceramic, metal and mixtures thereof.  
     
     
         64 . The method of  claim 63  wherein the glass fibers are selected from the group consisting of E glass, S glass, AR glass and mixtures thereof.  
     
     
         65 . The method of  claim 63  wherein the ceramic fibers are selected from the group consisting of alumina, mullite, silica, rock wool and mixtures thereof.  
     
     
         66 . The method of  claim 63  wherein the metal fibers are selected from the group consisting of steel, aluminum and mixtures thereof.  
     
     
         67 . The method of  claim 62  wherein the organic fibers are selected from the group consisting of carbon, polyester, polyolefin, polyetheramide, fluoropolymer, polyether, cellulose, phenolic, polyesteramide, polyurethane, epoxy, aminoplastic, silicone, polysulfone, polyetherketone, polyetheretherketone, polyesterimide, polyphenylene sulfide, polyether acryl ketone, poly(amideimide), polyimide fibers and mixtures thereof.  
     
     
         68 . The method of  claim 61  wherein the fibers range from about 10 nm to about 3 mm in length and from about 5 nm to about 100 microns in diameter.  
     
     
         69 . The method of  claim 61  wherein the fibers are present in an amount of from about 0.1 to about 25 percent by weight and the refractory powder is present in an amount of from about 75 to about 99.9 percent by weight of the total powder mixture.  
     
     
         70 . The method of  claim 61  wherein the refractory powder comprises a refractory die material.  
     
     
         71 . The method of  claim 61  wherein the covering material further comprises a liquid vehicle.  
     
     
         72 . The method of  claim 71  wherein the liquid vehicle is selected from alcohol and acetone.  
     
     
         73 . The method of  claim 61  further comprising coating the covering material with a high temperature refractory material.  
     
     
         74 . The method of  claim 61  wherein the refractory powder comprises silica, leucite or mixtures thereof.  
     
     
         75 . The method of  claim 74  wherein the silica is selected from the group consisting of quartz, cristobolite and mixtures thereof.  
     
     
         76 . The method of  claim 70  wherein the refractory die material is selected from the group consisting of gypsum-bonded, phosphate-bonded, ethyl silicate-bonded and mixtures thereof.  
     
     
         77 . The method of  claim 61  further comprising applying a die spacer material to the model prior to application of the metal or alloy powder.  
     
     
         78 . The method of  claim 61  wherein applying the covering material onto the model coated with metal or alloy powder comprises painting the covering material onto the metal powder with a brush.  
     
     
         79 . The method of  claim 73  wherein coating the covering material with a high temperature refractory material comprises dusting the high temperature refractory material onto the covering material.  
     
     
         80 . A dental restoration formed by the process of  claim 61 .  
     
     
         81 . A method for making a dental restoration comprising: 
 forming a model of one or more teeth;    placing a bar or pontic on the model;    coating the model and bar or pontic with metal or alloy powder;    applying a covering material onto the model coated with metal or alloy powder wherein the covering material comprises a mixture of refractory powder and fibers;    sintering the model coated with metal or alloy powder and covering material in a furnace to form a coping; and    removing the covering material from the coping.    
     
     
         82 . The method of  claim 81  wherein the fibers are selected from the group consisting of inorganic, organic fibers and mixtures thereof.  
     
     
         83 . The method of  claim 82  wherein the inorganic fibers are selected from the group consisting of glass, glass-ceramic, ceramic, metal and mixtures thereof.  
     
     
         84 . The method of  claim 83  wherein the glass fibers are selected from the group consisting of E glass, S glass, AR glass and mixtures thereof.  
     
     
         85 . The method of  claim 83  wherein the ceramic fibers are selected from the group consisting of alumina, mullite, silica, rock wool and mixtures thereof.  
     
     
         86 . The method of  claim 83  wherein the metal fibers are selected from the group consisting of steel, aluminum and mixtures thereof.  
     
     
         87 . The method of  claim 82  wherein the organic fibers are selected from the group consisting of carbon, polyester, polyolefin, polyetheramide, fluoropolymer, polyether, cellulose, phenolic, polyesteramide, polyurethane, epoxy, aminoplastic, silicone, polysulfone, polyetherketone, polyetheretherketone, polyesterimide, polyphenylene sulfide, polyether acryl ketone, poly(amideimide), polyimide fibers and mixtures thereof.  
     
     
         88 . The method of  claim 81  wherein the fibers range from about 10 nm to about 3 mm in length and from about 5 nm to about 100 microns in diameter.  
     
     
         89 . The method of  claim 81  wherein the fibers are present in an amount of from about 0.1 to about 25 percent by weight and the refractory powder is present in an amount of from about 75 to about 99.9 percent by weight of the total powder mixture.  
     
     
         90 . The method of  claim 81  wherein the refractory powder comprises a refractory die material.  
     
     
         91 . The method of  claim 81  wherein the covering material further comprises a liquid vehicle.  
     
     
         92 . The method of  claim 91  wherein the liquid vehicle is selected from alcohol and acetone.  
     
     
         93 . The method of  claim 81  further comprising coating the covering material with a high temperature refractory material.  
     
     
         94 . The method of  claim 81  wherein the refractory powder comprises silica, leucite or mixtures thereof.  
     
     
         95 . The method of  claim 94  wherein the silica is selected from the group consisting of quartz, cristobolite and mixtures thereof.  
     
     
         96 . The method of  claim 90  wherein the refractory die material is selected from the group consisting of gypsum-bonded, phosphate-bonded, ethyl silicate-bonded and mixtures thereof.  
     
     
         97 . The method of  claim 81  further comprising applying a die spacer material to the model prior to application of the metal or alloy powder.  
     
     
         98 . The method of  claim 81  wherein applying the covering material onto the model coated with metal or alloy powder comprises painting the covering material onto the metal powder with a brush.  
     
     
         99 . The method of  claim 81  wherein coating the covering material with a high temperature refractory material comprises dusting the high temperature refractory material onto the covering material.  
     
     
         100 . A dental restoration formed by the process of  claim 81 .  
     
     
         101 . A method for making a dental restoration comprising: 
 forming a model of one or more teeth;    coating the model with powder of a first metal or alloy;    attaching a sprue to the model coated with the powder of the first metal or alloy;    attaching a reservoir of a second metal or alloy onto the sprue, wherein the second metal or alloy has a fusing temperature lower than the fusing temperature of the first metal or alloy;    covering the model coated with the powder of the first metal or alloy and the mass of the second metal or alloy with covering material, wherein the covering material comprises a mixture of refractory powder and fibers; and    sintering the model.    
     
     
         102 . The method of  claim 101  wherein the fibers are selected from the group consisting of inorganic, organic fibers and mixtures thereof.  
     
     
         103 . The method of  claim 102  wherein the inorganic fibers are selected from the group consisting of glass, glass-ceramic, ceramic, metal and mixtures thereof.  
     
     
         104 . The method of  claim 103  wherein the glass fibers are selected from the group consisting of E glass, S glass, AR glass and mixtures thereof.  
     
     
         105 . The method of  claim 103  wherein the ceramic fibers are selected from the group consisting of alumina, mullite, silica, rock wool and mixtures thereof.  
     
     
         106 . The method of  claim 103  wherein the metal fibers are selected from the group consisting of steel, aluminum and mixtures thereof.  
     
     
         107 . The method of  claim 102  wherein the organic fibers are selected from the group consisting of carbon, polyester, polyolefin, polyetheramide, fluoropolymer, polyether, cellulose, phenolic, polyesteramide, polyurethane, epoxy, aminoplastic, silicone, polysulfone, polyetherketone, polyetheretherketone, polyesterimide, polyphenylene sulfide, polyether acryl ketone, poly(amideimide), polyimide fibers and mixtures thereof.  
     
     
         108 . The method of  claim 101  wherein the fibers range from about 10 nm to about 3 mm in length and from about 5 nm to about 100 microns in diameter.  
     
     
         109 . The method of  claim 101  wherein the fibers are present in an amount of from about 0.1 to about 25 percent by weight and the refractory powder is present in an amount of from about 75 to about 99.9 percent by weight of the total powder mixture.  
     
     
         110 . The method of  claim 101  wherein the refractory powder comprises a refractory die material.  
     
     
         111 . The method of  claim 101  wherein the covering material further comprises a liquid vehicle.  
     
     
         112 . The method of  claim 111  wherein the liquid vehicle is selected from alcohol and acetone.  
     
     
         113 . The method of  claim 101  further comprising coating the covering material with a high temperature refractory material.  
     
     
         114 . The method of  claim 101  wherein the refractory powder comprises silica, leucite or mixtures thereof.  
     
     
         115 . The method of  claim 114  wherein the silica is selected from the group consisting of quartz, cristobolite and mixtures thereof.  
     
     
         116 . The method of  claim 1   10  wherein the refractory die material is selected from the group consisting of gypsum-bonded, phosphate-bonded, ethyl silicate-bonded and mixtures thereof.  
     
     
         117 . The method of  claim 101  further comprising applying a die spacer material to the model prior to application of the metal or alloy powder.  
     
     
         118 . The method of  claim 101  wherein applying the covering material onto the model coated with metal or alloy powder comprises painting the covering material onto the metal powder with a brush.  
     
     
         119 . The method of  claim 113  wherein coating the covering material with a high temperature refractory material comprises dusting the high temperature refractory material onto the covering material.  
     
     
         120 . A dental restoration formed by the process of  claim 101 .  
     
     
         121 . A method for making a dental restoration comprising: 
 forming a model of one or more teeth;    applying a first layer of a heat-absorbing material to the model;    applying a powder of a first metal or alloy onto the heat-absorbing material;    covering the model coated with the powder of the first metal or alloy with covering material, wherein the covering material comprises a mixture of refractory powder and fibers; and    sintering the model.    
     
     
         122 . The method of  claim 121  wherein the fibers are selected from the group consisting of inorganic, organic fibers and mixtures thereof.  
     
     
         123 . The method of  claim 122  wherein the inorganic fibers are selected from the group consisting of glass, glass-ceramic, ceramic, metal and mixtures thereof.  
     
     
         124 . The method of  claim 123  wherein the glass fibers are selected from the group consisting of E glass, S glass, AR glass and mixtures thereof.  
     
     
         125 . The method of  claim 123  wherein the ceramic fibers are selected from the group consisting of alumina, mullite, silica, rock wool and mixtures thereof.  
     
     
         126 . The method of  claim 123  wherein the metal fibers are selected from the group consisting of steel, aluminum and mixtures thereof.  
     
     
         127 . The method of  claim 122  wherein the organic fibers are selected from the group consisting of carbon, polyester, polyolefin, polyetheramide, fluoropolymer, polyether, cellulose, phenolic, polyesteramide, polyurethane, epoxy, aminoplastic, silicone, polysulfone, polyetherketone, polyetheretherketone, polyesterimide, polyphenylene sulfide, polyether acryl ketone, poly(amideimide), polyimide fibers and mixtures thereof.  
     
     
         128 . The method of  claim 121  wherein the fibers range from about 10 nm to about 3 mm in length and from about 5 nm to about 100 microns in diameter.  
     
     
         129 . The method of  claim 121  wherein the fibers are present in an amount of from about 0.1 to about 25 percent by weight and the refractory powder is present in an amount of from about 75 to about 99.1 percent by weight of the total powder mixture.  
     
     
         130 . The method of  claim 121  wherein the refractory powder comprises a refractory die material.  
     
     
         131 . The method of  claim 121  wherein the covering material further comprises a liquid vehicle.  
     
     
         132 . The method of  claim 131  wherein the liquid vehicle is selected from alcohol and acetone.  
     
     
         133 . The method of  claim 121  further comprising coating the covering material with a high temperature refractory material.  
     
     
         134 . The method of  claim 121  wherein the refractory powder comprises silica, leucite or mixtures thereof.  
     
     
         135 . The method of  claim 134  wherein the silica is selected from the group consisting of quartz, cristobolite and mixtures thereof.  
     
     
         136 . The method of  claim 130  wherein the refractory die material is selected from the group consisting of gypsum-bonded, phosphate-bonded, ethyl silicate-bonded and mixtures thereof.  
     
     
         137 . The method of  claim 121  further comprising applying a die spacer material to the model prior to application of the metal or alloy powder.  
     
     
         138 . The method of  claim 121  wherein applying the covering material onto the model coated with metal or alloy powder comprises painting the covering material onto the metal powder with a brush.  
     
     
         139 . The method of  claim 134  wherein coating the covering material with a high temperature refractory material comprises dusting the high temperature refractory material onto the covering material.  
     
     
         140 . A dental restoration formed by the process of  claim 121.

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