Denture with double-layer structure and preparation method thereof

Abstract

The application discloses a denture with a double-layer structure, which comprises an inner-layer structure base and an outer surface layer, wherein the inner-layer structure base is an inner base of the double-layer structure denture, the inner-layer structure base is a preliminary contour of the double-layer structure denture, and the overall shape of the inner-layer structure base is smaller than that of the double-layer structure denture; the outer surface layer is covered on the outer side of the inner-layer structure base, and the outer surface layer and the inner-layer structure base form a complete double-layer structure denture; the inner-layer structure base is engraved by using a hot-pressing casting zirconia blank, and the surface of the inner-layer structure base is engraved with a surface rough surface for increasing adsorption force; and the outer surface layer is formed by using zirconia slurry for 3D printing, and after printing, high-temperature sintering, natural cooling and cleaning are carried out to form the outer surface layer of the zirconia denture. The double-layer structure denture is adopted, the advantages of two manufacturing methods are utilized, the product quality is improved, and the cost is saved.

Description

Technical Field

[0001] This invention relates to the field of zirconia denture manufacturing technology, specifically to a denture with a double-layer structure and its preparation method. Background Technology

[0002] Dentures are an important method for restoring damaged teeth. Metal is currently the most common material for dentures, with the main materials being nickel-chromium alloys, titanium alloys, and cobalt-chromium alloys. Existing denture processing methods are cumbersome, have long production cycles, and produce dentures with unstable quality. They are not very wear-resistant during use, and are prone to deformation or cracking during use, resulting in low overall stability. In addition, dentures are not easy to maintain their luster during daily use, have poor oxidation resistance, and have a short lifespan.

[0003] While ceramics offer significant natural advantages as a dental prosthesis material, their complex processing characteristics drastically increase the cost of ceramic teeth. Current processing methods for ceramic dentures include thermoforming of the preform and 3D printing of the slurry. Thermoforming of the preform is a mature and relatively inexpensive technique, but it is cumbersome and results in dentures with low similarity to metal. 3D-printed zirconia-based ceramic dentures, compared to metal dentures, retain the high hardness and wear resistance of ceramics while overcoming the processing difficulties of traditional ceramic dentures. 3D printing rapid prototyping technology, utilizing additive manufacturing, allows for the direct printing of personalized ceramic preforms for patients, shortening the processing cycle and improving accuracy, but its manufacturing cost is high. Summary of the Invention

[0004] The purpose of this invention is to provide a denture with a double-layer structure and a method for preparing the same, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a denture with a double-layer structure, comprising: an inner layer structure substrate and an outer surface layer, wherein the inner layer structure substrate is the internal substrate of the double-layer structure denture, the inner layer structure substrate is the preliminary outline of the double-layer structure denture, the overall shape of the inner layer structure substrate is smaller than that of the double-layer structure denture, and the outer surface layer covers the outside of the inner layer structure substrate, the outer surface covering and the inner structure substrate together form a complete double-layer structure denture.

[0006] Furthermore, the inner layer structure substrate is carved from a zirconia blank formed by hot pressing, and the surface of the inner layer structure substrate is carved with a rough surface to increase the adsorption force.

[0007] Furthermore, the outer surface layer is 3D printed using zirconia slurry. After printing, it is sintered at high temperature, naturally cooled, and cleaned to form the outer surface layer of the zirconia denture.

[0008] A method for preparing a denture with a double-layer structure, comprising the following steps:

[0009] The first step is to manufacture the blank. Zirconia powder is die-cast to form a preliminary blank, and then the preliminary blank is sintered to form a finished zirconia blank block for later use.

[0010] The second step is to manufacture the inner structure substrate. The obtained zirconia preform is carved according to the pre-designed shape of the inner structure substrate to form the inner structure substrate. During the carving process, the surface of the inner structure substrate does not need to be smoothed. Instead, a rough surface should be carved to increase the adsorption force.

[0011] The third step is to print the outer surface layer. Using the obtained inner structure substrate as the base, zirconia slurry is used to 3D print the inner structure substrate to form a preliminary outer surface layer on the outside of the inner structure substrate.

[0012] The fourth step is the outer surface layer forming. After printing, the entire denture is sintered at high temperature, cooled naturally, and cleaned to form the outer surface layer of the zirconia denture, thus obtaining a complete double-layer zirconia denture.

[0013] Furthermore, the zirconia slurry includes zirconia ceramic powder, binder, and solvent.

[0014] Furthermore, the zirconia ceramic powder is composed of the following components: 15%-30% Al2O3, 40%-70% ZrO2, 1%-20% Y2O3, 1%-10% Si3N4, and 1%-10% SiC.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: The denture with a double-layer structure and its preparation method of the present invention produce a gadolinium oxide denture with a double-layer structure. The inner layer is the inner layer structure matrix, which is carved from a zirconia blank formed by hot pressing. Since it is located in the inner layer of the denture, only its shape needs to be considered, and no other factors are required, which greatly reduces the production cost and simplifies the processing steps. The outer layer is the outer surface layer, which is 3D printed using zirconia slurry. 3D printing is only performed on the outer side, which reduces the cost and improves the performance of the denture, making its shape more realistic, thereby improving the quality of the product. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the double-layer denture structure in this invention;

[0017] In the diagram: 1 - Inner structural matrix; 2 - Outer surface layer. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Please see Figure 1 The present invention provides a denture with a double-layer structure, comprising: an inner layer structure substrate 1 and an outer surface layer 2. The inner layer structure substrate 1 is the internal substrate of the double-layer structure denture and forms the preliminary outline of the double-layer structure denture. The overall shape of the inner layer structure substrate 1 is smaller than that of the double-layer structure denture. The outer surface layer 2 covers the outside of the inner layer structure substrate 1. The outer surface layer 2 and the inner structure substrate 1 together form a complete double-layer structure denture.

[0020] Furthermore, the inner layer structure substrate 1 is carved from a zirconia blank formed by hot pressing, and the surface of the inner layer structure substrate is carved with a rough surface to increase the adsorption force.

[0021] Furthermore, the outer surface layer 2 is 3D printed using zirconia slurry. After printing, it is sintered at high temperature, cooled naturally, and cleaned to form the outer surface layer of the zirconia denture.

[0022] A method for preparing a denture with a double-layer structure, comprising the following steps:

[0023] The first step is to manufacture the blank. Zirconia powder is die-cast to form a preliminary blank, and then the preliminary blank is sintered to form a finished zirconia blank block for later use.

[0024] The second step is to manufacture the inner structure substrate. The obtained zirconia preform is carved according to the pre-designed shape of the inner structure substrate to form the inner structure substrate. During the carving process, the surface of the inner structure substrate does not need to be smoothed. Instead, a rough surface should be carved to increase the adsorption force.

[0025] The third step is to print the outer surface layer. Using the obtained inner structure substrate as the base, zirconia slurry is used to 3D print the inner structure substrate to form a preliminary outer surface layer on the outside of the inner structure substrate.

[0026] The fourth step is the outer surface layer forming. After printing, the entire denture is sintered at high temperature, cooled naturally, and cleaned to form the outer surface layer of the zirconia denture, thus obtaining a complete double-layer zirconia denture.

[0027] Furthermore, the zirconia slurry includes zirconia ceramic powder, binder, and solvent.

[0028] Furthermore, the zirconia ceramic powder is composed of the following components: 15%-30% Al2O3, 40%-70% ZrO2, 1%-20% Y2O3, 1%-10% Si3N4, and 1%-10% SiC.

[0029] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A denture with a double-layer structure, characterized in that, The application relates to a zirconia denture with a double-layer structure, which comprises the following parts: an inner-layer structure base and an outer surface layer, wherein the inner-layer structure base is the inner base of the double-layer structure denture, the inner-layer structure base is the preliminary contour of the double-layer structure denture, the overall shape of the inner-layer structure base is smaller than that of the double-layer structure denture, the outer surface layer is covered on the outer side of the inner-layer structure base, and the outer surface layer and the inner-layer structure base constitute the complete double-layer structure denture. The application further relates to a preparation method of the zirconia denture with the double-layer structure, which comprises the following steps: In the first step, a preliminary embryo is formed by pressure casting zirconia powder, and then the preliminary embryo is sintered to form a zirconia embryo block for use; In the second step, the obtained zirconia embryo block is carved according to the shape of the inner-layer structure base to form the inner-layer structure base, and the surface of the inner-layer structure base is not required to be carved smooth, but should be carved with a rough surface for increasing adsorption force; In the third step, the outer surface layer is printed by taking the obtained inner-layer structure base as a seat and using zirconia slurry to perform 3D printing on the inner-layer structure base to form a preliminary outer surface layer outside the inner-layer structure base; In the fourth step, the outer surface layer is formed by performing high-temperature sintering on the whole denture after printing, naturally cooling, cleaning and forming the outer surface layer of the zirconia denture, so that the complete double-layer structure zirconia denture is obtained. The zirconia slurry comprises zirconia ceramic powder, a binder and a solvent. The zirconia ceramic powder is composed of the following components: 15%-30% Al2O3, 40%-70% ZrO2, 1%-20% Y2O3, 1%-10% Si3N4 and 1%-10% SiC. ​

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