Dental restorative device and method of using the same

Abstract

A dental restorative device is shown as comprising a first cured or hardened layer in the form of an occlusal surface of the tooth being restored and a second uncured dental composite layer joined to the first layer enabling a dental professional to perform direct dental restoration procedures with results replicating indirect direct dental restoration procedures. A system comprising the multi-layered dental restorative device and packaging provides for sufficient support and protection of the uncured second layer and facilitates positioning and finishing of the dental restorative device by cooling the uncured portions to a rigid state while in the packaging, positioning the dental restorative device, and modifying the second layer to fit, curing the second layer and permanently placing the fully cured and hardened dental crown on the tooth being restored.

1 - 28 . (canceled) 
     
     
         29 . A dental restorative device and packaging system for storing, preparing and dispensing a dental restorative device for use in a restoration of an affected tooth requiring restoration from a damaged state to a restored state replicating a natural, undamaged tooth, the dental restorative device and packaging system comprising:
 a) a dental restorative device comprising a first layer composed of a first dental restoration material prepared and formed into a first end-use configuration and a second layer fixed to the first layer and composed of an uncured dental composite material in a second, end-use configuration forming a plurality of sidewalls replicating a buccal, lingual, mesial, and distal sidewall of the natural, undamaged tooth; and   b) packaging comprising an outer casing and an inner form, the outer casing comprising a lid and a bottom mechanically locked together, and the inner form adhered to the bottom and formed to store and support the uncured, second layer of the dental restorative device in the second end-use configuration.   
     
     
         30 . The dental restorative device and packaging system of  claim 29  wherein the first dental restoration material composing the first layer is a cured dental composite material. 
     
     
         31 . The dental restorative device and packaging system of  claim 29  wherein the first dental restoration material composing the first layer is a hardened dental ceramic. 
     
     
         32 . The dental restorative device and packaging system of  claim 29  wherein the first end-use configuration of the first layer is an anatomical occlusal surface replicating an occlusal surface of the natural, undamaged tooth. 
     
     
         33 . The dental restorative device and packaging system of  claim 32  wherein the second end-use configuration of the second layer forms a plurality of sidewalls replicating a buccal, lingual, mesial and distal sidewall of the natural, undamaged tooth. 
     
     
         34 . The dental restorative device and packaging system of  claim 29  further comprising a handle integrally formed with the second layer. 
     
     
         35 . The dental restorative device and packaging system of  claim 29  further comprising a handle integrally formed with the first layer. 
     
     
         36 . The dental restorative device and packaging system of  claim 29  wherein the first layer is a cured anatomical occlusal layer. 
     
     
         37 . The dental restorative device and packaging system of  claim 29  wherein the first layer is a heat-treated anatomical occlusal layer. 
     
     
         38 . The dental restorative device and packaging system of  claim 29  wherein the second layer is a user configured, uncured sub-layer enabling in situ customization of the dental restorative device. 
     
     
         39 . The dental restorative device and packaging system of  claim 29  wherein the inner form comprises a chamber for receiving the dental restorative device, the chamber composed of a material with a high thermal conductivity rating to facilitate cooling of the dental restorative device stored therein. 
     
     
         40 . The dental restorative device and packaging system of  claim 29  wherein the inner form is composed of a material with a high thermal conductivity rating to facilitate cooling of the dental restorative device stored therein. 
     
     
         41 . The dental restorative device and packaging system of  claim 29  wherein the inner form sits on a platform portion of the bottom of the outer casing and the lid comprises a chamber with a first depth sufficient to receive the inner form chamber. 
     
     
         42 . The dental restorative device and packaging system of  claim 29  wherein the outer casing is composed of a light transmission inhibiting material. 
     
     
         43 . The dental restorative device and packaging system of  claim 29  wherein the inner form is composed of a light transmission inhibiting material. 
     
     
         44 . The dental restorative device and packaging system of  claim 29  wherein the mechanical locking together of the lid and bottom inhibits ambient light transmission into the chamber in the lid. 
     
     
         45 . The dental restorative device and packaging system of  claim 29  wherein the mechanical locking is an annular snap-fit from corresponding ridges on the lid and the bottom of the outer casing. 
     
     
         46 . The dental restorative device and packaging system of  claim 29  wherein the lid comprises a plurality of sidewalls separating the inner chamber into a plurality of compartments. 
     
     
         47 . The dental restorative device and packaging system of  claim 46  wherein the sidewalls extend towards a platform portion of the bottom substantially separating the plurality of compartments when the lid is mechanically locked to the bottom. 
     
     
         48 . A kit for use in restoration of an affected tooth requiring restoration from a damaged state to a restored, undamaged state replicating a natural, undamaged tooth, the kit comprising:
 a) dental restorative devices in a plurality of sizes, each dental restorative device comprising a first layer composed of a first dental restoration material prepared and formed into a first end-use configuration and a second layer fixed to the first layer and composed of an uncured dental composite material in a second, end-use configuration forming a plurality of sidewalls replicating a buccal, lingual, mesial, and distal sidewall of the natural, undamaged tooth and enabling customized shaping and finishing of the second layer;   b) packaging comprising an outer casing and an inner form, the outer casing comprising a lid and a bottom each with corresponding grooves to mechanically join and lock the top to the bottom, and the inner form adhered to the bottom and formed to support the uncured, second layer of the dental restorative device in the second end-use configuration; and   c) a selector key corresponding to the plurality of sizes of dental restorative devices in the kit.   
     
     
         49 . The kit of  claim 48  further comprising a carving tool for shaping the second layer and removing uncured dental composite material during preparation of the dental restorative device, and a separating agent to be applied to the affected tooth and adjacent dentition during preparing and installation of the dental restorative device. 
     
     
         50 . The kit of  claim 48  wherein the selector key comprises a first edge and a second, stepped edge opposing the first edge and forming a plurality of widths of varying dimension between the first and second edges and each of the varying dimensions corresponds to a size of the plurality of dental restorative devices in the kit.