Method of Making a Denture With Nature Bite and Wear Properties and Denture

Abstract

The present invention to a method of denture manufacture that incorporates CAM-formed occlusal inserts, crowns, or overlays made of zirconia, resulting in a natural fit, feel, and wear essentially equivalent to the wear properties of natural teeth.

What is claimed is: 
     
         1 . A method for making dentures with natural bite and feel and improved wear properties, said method comprising the steps of:
 a. Evaluating a patent to determine desired denture parameters;   b. Fabricating a first denture according to said desired denture parameters, wherein said first denture comprises at least one occlusal portion;   c. Electronically storing the three-dimensional shape and size of said first denture;   d. Preparing at least one tooth within said first denture to receive at least one of at least one zirconium crown and at least one zirconium overlay;   e. Preparing at least one of at least one zirconium crown and at least one zirconium overlay for attachment to said at least one tooth, where each said zirconium crown and zirconium overlay is sized and shaped to create a denture with parameters approximating the desired denture parameters when attached to the said at least one prepared tooth; and   f. Attaching said at least one of at least one zirconium crown and at least one zirconium overlay to said at least one prepared teeth to create a second denture, where said second denture approximates said desired denture parameters;   g. wherein, said second denture has improved wear properties compared to dentures comprising plastic artificial teeth.   
     
     
         2 . The method of  claim 1 , further comprising the steps of:
 a. Test fitting said second denture to the patient;   b. Assessing the patient; and   c. Shaping at least one of said zirconium crowns, said zirconium overlays, or both, responsively to said assessment.   
     
     
         3 . The method of  claim 2 , further comprising the step of permanently attaching said at least one of at least one zirconium crown and at least one zirconium overlay to said at least one tooth. 
     
     
         4 . The method of  claim 3 , wherein said step of preparing said at least one tooth comprises at least one of milling, cutting, and forming one tooth. 
     
     
         5 . The method of  claim 3 , wherein said step of preparing said at least one tooth comprises at least one of milling, cutting, and forming two teeth. 
     
     
         6 . The method of  claim 3 , wherein said step of preparing said at least one tooth comprises at least one of milling, cutting, and forming three teeth. 
     
     
         7 . The method of  claim 3 , wherein said step of preparing said at least one tooth comprises at least one of milling, cutting, and forming four or more teeth. 
     
     
         8 . The method of  claim 3 , wherein said step of electronically storing the three-dimensional shape and size of said first denture comprises storing the three-dimensional shape and size of said first denture in a CAD program. 
     
     
         9 . The method of  claim 8 , wherein at least one of the step of fabricating a first denture and the step of forming a holding area is performed by a CAM mill. 
     
     
         10 . The method of  claim 9 , wherein the step of preparing a zirconia crown or overlay comprises the substeps of:
 a. Forming said crown or overlay to a first shape and a first size; and   b. Sintering said crown or overlay to a first shape and a second size, wherein said first shape and second size are selected to create a second denture approximating said desired denture parameters.   
     
     
         11 . The method of  claim 10 , wherein the substep of forming said crown or overlay to a first shape and a first size is performed by a CAM mill. 
     
     
         12 . The method of  claim 11 , wherein said first shape and first size are determined using the electronically stored three-dimensional shape and size of said first denture. 
     
     
         13 . The method of  claim 12 , wherein the substep of sintering further comprises sintering said occlusal insert at approximately 1500 degrees Celsius. 
     
     
         14 . The method of  claim 13 , wherein the substep of sintering further comprises sintering said occlusal insert for between approximately 8 and approximately 12 hours. 
     
     
         15 . The method of  claim 14 , wherein the substep of sintering further comprises sintering said occlusal insert for approximately 10 hours. 
     
     
         16 . The method of  claim 15 , wherein said first size is approximately 15% to approximately 20% larger than said second size. 
     
     
         17 . The method of  claim 16 , wherein said first size is approximately 17.8% larger than said second size. 
     
     
         18 . A custom denture with natural bite and feel and improved wear properties and with one or more of one or more zirconium crowns and one or more zirconium overlays, said denture comprising:
 a base portion configured to overfit at least a portion of a patient's gums, said base portion comprising one or more sockets;   plastic artificial teeth attached to said sockets, at least one of said teeth prepared to receive at least one of at least one zirconium crown and zirconium overlay; and   one or more of one or more zirconium crowns and one or more zirconium overlays attached to said at least one prepared tooth;   
       wherein said custom denture has desired parameters improved wear properties compared to dentures comprising plastic artificial teeth. 
     
     
         19 . The custom denture of  claim 18 , wherein said denture is a full denture. 
     
     
         20 . The custom denture of  claim 19 , wherein said denture is a partial denture.