Hardenable self-supporting structures and methods

Abstract

Compositions, particularly for forming dental products, having a hardenable self-supporting structure with sufficient malleability to be subsequently customized into a second shape and then hardened, and methods.

1 . A method of preparing a preformed dental product comprising:
 combining a resin system, a filler system, and an initiator system to form a mixture; and   forming the mixture into a hardenable self-supporting structure having a first shape of a preformed dental product;   wherein the hardenable self-supporting structure having a first shape has sufficient malleability to be formed into a second shape;   wherein the filler system comprises an inorganic material comprising nanoscopic particles having an average primary particle size of no greater than about 50 nm; and   wherein the preformed dental product is one that is provided to a dentist in a desired semi-finished shape, which is a facsimile of what the final shaped dental product is to be.   
     
     
         2 . The method of  claim 1  wherein the mixture further comprises a surfactant system. 
     
     
         3 . The method of  claim 1  wherein the filler system is present in the mixture in an amount of greater than 70 wt-%. 
     
     
         4 . The method of  claim 1  wherein the nanoscopic particles comprise fumed silica. 
     
     
         5 . The method of  claim 1  wherein the preformed dental product is dimensionally stable at room temperature for at least about two weeks when free standing. 
     
     
         6 . The method of  claim 1  wherein the preformed dental product is a preformed crown, a preformed inlay, a preformed onlay, a preformed bridge, a preformed veneer, a preformed maxillofacial prosthesis, a preformed orthodontic appliance, a preformed tooth facsimile, or a preformed tooth splint. 
     
     
         7 . The method of  claim 6  wherein the preformed dental product is a preformed crown. 
     
     
         8 . The method of  claim 1  wherein the initiator system comprises one or more photoinitiators. 
     
     
         9 . The method of  claim 1  wherein the resin system comprises a mono-, di-, or poly- (meth)acrylate. 
     
     
         10 . The method of  claim 9  wherein the resin system comprises bisphenol A glycidyl methacrylate. 
     
     
         11 . The method of  claim 1  wherein the resin system comprises a crystalline component. 
     
     
         12 . The method of  claim 11  wherein the crystalline resin component comprises polyesters, polyethers, polyolefins, polythioethers, polyarylalkylenes, polysilanes, polyamides, polyurethanes, or combinations thereof. 
     
     
         13 . The method of  claim 12  wherein the crystalline resin component comprises a polycaprolactone. 
     
     
         14 . A method of preparing a preformed dental product comprising:
 combining a resin system, greater than 70 wt-% of a filler system, and an initiator system to form a mixture; with the proviso that if the filler system comprises fibers, the fibers are present in an amount of less than 20 wt-%, based on the total weight of the composition; and   forming the mixture into a hardenable self-supporting structure having a first shape of a preformed dental product;   wherein the hardenable self-supporting structure having a first shape has sufficient malleability to be formed into a second shape; and   wherein the preformed dental product is one that is provided to a dentist in a desired semi-finished shape, which is a facsimile of what the final shaped dental product is to be.   
     
     
         15 . The method of  claim 14  wherein the mixture further comprises a surfactant system. 
     
     
         16 . The method of  claim 14  wherein the preformed dental product is dimensionally stable at room temperature for at least about two weeks when free standing. 
     
     
         17 . The method of  claim 14  wherein the preformed dental product is a preformed crown, a preformed inlay, a preformed onlay, a preformed bridge, a preformed veneer, a preformed maxillofacial prosthesis, a preformed orthodontic appliance, a preformed tooth facsimile, or a preformed tooth splint. 
     
     
         18 . The method of  claim 17  wherein the preformed dental product is a preformed crown. 
     
     
         19 . The method of  claim 14  wherein the initiator system comprises one or more photoinitiators. 
     
     
         20 . The method of  claim 14  wherein the resin system comprises a mono-, di-, or poly- (meth)acrylate. 
     
     
         21 . The method of  claim 20  wherein the resin system comprises bisphenol A glycidyl methacrylate. 
     
     
         22 . The method of  claim 14  wherein the resin system comprises a crystalline component. 
     
     
         23 . The method of  claim 22  wherein the crystalline resin component comprises polyesters, polyethers, polyolefins, polythioethers, polyarylalkylenes, polysilanes, polyamides, polyurethanes, or combinations thereof. 
     
     
         24 . The method of  claim 23  wherein the crystalline resin component comprises a polycaprolactone.