Unified crown abutment

Abstract

The present disclosure provides methods for manufacturing of gap free, cement free, abrasion free dental implant devices. Dental implant devices manufactured according to the disclosed methods are also provided.

Description

UNIFIED CROWN ABUTMENTFIELD OF THE INVENTION

[0001] The present invention relates to methods and systems of manufacturing a dental implant device, and to the product resulting from said methods.BACKGROUND

[0002] The existing abutments and dental implants are prone to the prevalence of Peri-Implantitis, an irreversible condition causing bone loss that poses a significant challenge, affecting ca. 20% of implant cases and ultimately leading to dental implant failure.

[0003] The most common material for dental implants is titanium due to its strength, durability, and biocompatibility. Titanium implants can fuse to bone through a process called osseointegration, providing a stable foundation for replacement teeth. Recently, zirconia implants have also gained popularity as an alternative to titanium, particularly for patients with metal sensitivities or aesthetic concerns, as zirconia is tooth-colored.

[0004] While titanium boasts favorable characteristics, its gray color remains a drawback. On the other hand, zirconia presents an appealing color, superior tissue compatibility, enhanced soft tissue integration, and reduced bacterial plaque adhesion. However, zirconia comes with the challenge of aging or LTD (low thermal degradation), with a potential risk of breakage between about 5 and 10 years.

[0005] In dental practice, the titanium base is manufactured by the implant company, while the zirconia component is crafted by the dental laboratory. Typically, these two parts are then cemented together using resin cement and sometimes in combination with a screw, leaving at least a 50-micron gap between them which creates an abrasive surface at the interface between the implant and the patient’s mouth. The use of resin cement, while effective, raises concerns about bio-incompatibility and an increased accumulation of bacterial plaque in the gap between the crown and abutment portions of the implant, posing biological undesirability.

[0006] It is therefore desirable to provide methods of manufacturing dental implant devices that address at least some of these challenges.SUMMARY

[0007] According to a first aspect of the present disclosure there is provided a method of manufacturing a dental implant device, comprising affixing a first implant member and an second implant member using a laser welding, joining, or soldering technique such that there is no gap between the first implant member and the second implant member, wherein the first implant member is at least partially formed of a ceramic material, and the second implant member is at least partially formed of a metal. In embodiments where the dental implant device is a crown-abutment piece, the first implant member comprises a crown member and the second implant member comprises an abutment member. In other embodiments, the first implant member comprises a first implant fixture and the second implant member comprises an second implant fixture, leading to the manufacture of a hybrid implant fixture.

[0008] The present disclosure eliminates the root cause of peri-implantitis. Laser welding, joining, or soldering the crown and second implant members eliminates the gaps commonly found in state of the art implants such as in the crown-abutment portion of a dental implant, creating a seamless contact surface, thus minimizing abrasion and bacterial plaque accumulation, aligning with biological desirability.

[0009] Optionally, the affixing of the first implant member and the second implant member comprises melting at least part of the material of both the first implant member and the second implant member at the same time using a two-wavelength laser in order to create a mechanical coupling between the first implant member and the second implant member, wherein a first wavelength of the two-wavelength laser is selected to be a wavelength that is absorbed by a material of the first implantmember, and a second wavelength of the two-wavelength laser is selected to be a wavelength that is absorbed by a material of the second implant member.

[0010] Optionally, the affixing of the first implant member and the second implant member comprises melting the two materials at the same time using an infrared or near-infrared laser in order to create a mechanical coupling between the first implant member and the second implant member.

[0011] Optionally, the affixing of the first implant member and the second implant member comprises depositing a layer of a metal on a region of the first implant member adjacent to the second implant member, or on a region of the second implant member adjacent to the first implant member, and using one or more lasers to weld the first implant member to the second implant member by melting the metal and at least part of the materials of the first implant member and the second implant member. In some embodiments, the metal that is deposited on the crown portion may be the same as the metal that the second implant member is at least partially formed from. The metal may comprises titanium or an alloy thereof. In some embodiments the laser comprises a near-infrared laser.

[0012] Optionally, the affixing of the first implant member and the second implant member comprises positioning a biocompatible soldering material in the vicinity of the first implant member and the second implant member, and using one or more lasers to melt the biocompatible soldering material in order to create a mechanical coupling between the first implant member and the second implant member. The one or more lasers may include an infrared laser and / or a near-infrared laser.

[0013] Optionally, the one or more lasers comprises a three-wavelength laser, wherein each wavelength of the three-wavelength laser is selected to be absorbed by one of the biocompatible soldering material, a material of the first implant member, and amaterial of the second implant member, such that all three materials are melted by the three-wavelength laser at the same time creating a mechanical coupling.

[0014] Optionally, the biocompatible soldering material comprises gold.

[0015] According to a further aspect of the present disclosure, there is provided a method of manufacturing a dental implant device, comprising: affixing a first implant member and an second implant member using a laser welding, joining, or soldering technique such that there is no gap between the first implant member and the second implant member, wherein the first implant member is at least partially formed of a ceramic material, and the second implant member is at least partially formed of a metal; forming, using a 3-D printer, the first implant member from a first powder material; and forming, using the same or a second 3-D printer, the second implant member from the second powder material.

[0016] Optionally, in any of the above methods of the present disclosure, the first implant member comprises a zirconium-based ceramic material.

[0017] Optionally, in any of the above methods of the present disclosure, the second implant member comprises titanium or an alloy thereof.

[0018] Optionally, any of the above methods of the present disclosure may further comprise a step of polishing the dental implant device in the region where the first implant member and the second implant member have been mechanically coupled. The polishing may be accomplished using an infrared or near-infrared laser.

[0019] The methods may optionally further comprise a step of depositing a layer of a biocompatible metal on the polished area. The layer of biocompatible metal may bedeposited by dipping the dental implant device in an ink product comprising the biocompatible metal, or alternatively by Laser Induced Forward Transfer (LIFT).

[0020] Optionally, in any of the above methods of the present disclosure, the laser(s) may be configured with a spot size in the range of 10pm and 100pm. The inventors have found that this range of spot sizes is particularly effective in ensuring that the mechanical joining of the crown and abutment is gap-free.

[0021] Optionally, in any of the above methods of the present disclosure, the first implant member and the second implant member are located on a rotating surface configured to rotate at a speed selected based on the speed of welding or soldering. Advantageously, this may facilitate a steady, uniform welding, soldering, or joining process around the circumference of the crown and second implant members.

[0022] According to a further aspect of the present disclosure, there is provided a dental implant device manufactured according to any of the methods disclosed herein.

[0023] In some embodiments, the first implant member is at least partially formed of a ceramic material, and the second implant member at least partially formed of a metal. The first implant member and the second implant member are affixed as a result of a laser welding, joining, or soldering process such that there is no gap between the first implant member and the second implant member.

[0024] Optionally, the first implant member comprises a zirconium-based ceramic material. Different zirconium-based ceramic materials are envisaged by the inventors, such as but not limited to ZrO2. Zirconium-based ceramics have the advantage of providing a colour that more closely resembles the white colour of clean, real teeth.

[0025] Optionally, the second implant member comprises titanium or an alloy thereof.Titanium and its alloys provide the benefit of osseointegration and durability.

[0026] Optionally, the second implant member comprises a first portion at least partially formed of the metal and a second portion joined to the first portion and at least partially formed of a ceramic material.

[0027] According to another aspect of the present disclosure there is provided a dental implant device, comprising: a first implant member at least partially formed of a ceramic material and selected to at least be in contact with a patient’s gum, and a second implant member at least partially formed of a metal and selected to be in contact with the jawbone of the patient, wherein the first implant member and the second implant member are affixed to each other using a laser welding, joining, or soldering technique, such that there is no gap between the first implant member and the second implant member and no cement is used for the affixment.

[0028] Optionally, when the dental implant device is a hybrid implant, the first implant member is further selected to be in contact with a patient’s jawbone so that it is contact with both the patient’s gum and the patient’s jawbone. When the dental implant device is a crown abutment piece, the first implant member is selected to be in contact with the patient’s gum but not the jawbone. The dental implant device is manufactured according to any of the newly disclosed techniques 1 -6.BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 illustrates a typical prior art dental implant devices joined using a cement.

[0030] Figure 2 illustrates a dental implant device comprising a crown-abutment piece manufactured according to the methods of the present disclosure.

[0031] Figure 3 illustrates a schematic of a dental implant device according to embodiments of the present disclosure.

[0032] Figure 4 illustrates a schematic of a dental implant device comprising a hybrid implant fixture manufactured according to embodiments of the present disclosure.DETAILED DESCRIPTION

[0033] Reference to the accompany Figures will now be made in order to describe the exemplary methods and dental implant devices of the present disclosure, which include dental implant devices manufactured using a laser source or multiple laser sources. In various embodiments, the laser sources can have a wide spectrum of wavelengths including UV, near-infrared (NIR), and infrared (IR). The present disclosure facilitates the manufacture of a gap free, cement free, abrasion free, novel category of dental implant devices.

[0034] Generally speaking, the term “dental implant device” used in the present disclosure can refer to either the crown-abutment portion of a dental implant, or the complete implant fixture piece to be located in the jawbone of a patient.

[0035] Figure 1 demonstrates a prior art dental implant device 100 comprising a crown member 110 cemented to an abutment member 120 which is itself screwed in to a single piece implant fixture 130 to be located in the jawbone of a patient. The crown member 110 is typically formed of ZrCh, whilst the abutment member 120 and the implant fixture 130 are typically formed of Ti.

[0036] As depicted in Figure 1 , with the conventional cementing process for coupling the crown member 110 and the abutment member 120 a small gap greater than or equal to about 50 microns in size remains between the two members 110, 120. Due to the relatively small size of this gap it cannot readily be removed by further cementing. At the same time, the gap represents an infection risk since bacterial colonies can develop in this gap region, whilst also acting as source of micro-abrasions to the patient’s gums.

[0037] The present disclosure addresses this issue by providing different methods directed to solving the same problem, namely the removal of the gap between the crown and abutment portions 110, 120 of a dental implant device whilst at the same timeproviding stable mechanical coupling of the two members 110, 120. In particular, the present disclosure provides dental implant devices 200, 400 best presented in Figures 2-4, in which a first implant member 210 and a second implant member 220 are affixed as a result of a laser welding, joining, or soldering process such that there is no gap between the first implant member 210 and the second implant member 220. In the embodiment of Figure 2, the first implant member 210 is a crown member 210 and the second implant member 220 is an abutment member 220, leading to the manufacture of a crown-abutment piece 200 using any of Techniques 1-6 disclosed herein.

[0038] In the embodiment of Figure 4, the first implant member 210 is a first implant fixture 420a and the second implant member 220 is a second implant fixture 420b, leading to the manufacture of a hybrid implant fixture 420 using any of Techniques 1- 6 disclosed herein. It will be appreciated that the first implant fixture 420a is distinct from the dental restoration component (crown) resembling the tooth. A dental restoration is mounted on the first implant fixture 420a, using any known method. The present disclosure newly provides for a single piece dental implant device formed partly of ceramic material, in a region corresponding to the first implant member 420a, and partly of metal material, in a region corresponding to the second implant member 420b. Using any of the techniques 1-6 disclosed herein, a single-piece implant device 420 is formed.

[0039] Depending on the combination of material systems of ceramics and metals, a single or multiple wavelengths of lasers can be used for joining or welding of the first implant member 210 to the second implant member 220. For example, as can be seen in Figure 3, crowns 210 are typically made of ceramics such as Zirconia or Zirconia compounds including ZrCh, and abutments 220 are typically made of Titanium or Ti- alloys.

[0040] Conventional, single piece implant fixtures 410 illustrated in Figure 4 are typically made of titanium or zirconia materials. The present disclosure provides for a hybrid implant fixture 420 comprising a first portion of the implant fixture 420a whichwill at least be in contact with the patient’s gum and is formed at least partially of a ceramic material, joined, welded, or soldered to a second portion of the implant fixture 420b which will be in contact with the jawbone and is formed at least partially of a metal material. For example, the first implant fixture 420a may be formed of zirconia material, and the second implant fixture 420b may be formed of titanium. In some embodiments, the first portion of the implant fixture 420a is selected to be positioned at the interface between the patient’s gum and jawbone, meaning it is selected to be in contact with both the gum and the jawbone.

[0041] Each wavelength can be fine-tuned for a specific material, facilitating the melting of ceramics and metals at the same time. This can enable mechanical-interlocking, welding or soldering of the crown to the abutment, or first and second implant fixture portions to each other.

[0042] In order to optimize the welding or soldering quality, the implant members may be placed on a rotary table and the speed of rotation may be adjusted to the speed of welding or soldering while the laser source and laser spot is stationary.

[0043] In some embodiments, in order to remove artifacts caused by the laser processing step from the implant device 200, it is possible to polish the joint or weld line 230 using a laser polishing step.

[0044] If the final surface roughness of certain material systems after joining, welding and polishing requires improved biocompatibility, it is possible to deposit a layer of Ti on the affected area with the typical thickness of 100 pm-200pm.

[0045] The following Techniques 1-6 all address the same problem, namely the need to provide a gap free, cement free, abrasion free, novel category of dental implant devices 200.Technique No. 1

[0046] Using a 2-wavelength laser, where one wavelength is selected to be absorbed by the material of the first implant member 210 with a predefined desired % absorption, and one wavelength is selected to be absorbed by the material of thesecond implant member 220 with a predefined desired % absorption, melting the two materials at the same time and creating a mechanical-interlocking between the two materials.Technique No. 2

[0047] Using an IR laser melting the material of the first implant member 210 and the second implant member 220 at the same time and creating a mechanicalinterlocking between the two materials.Technique No. 3

[0048] A layer of Ti is deposited on the target area of the first implant member 210 and it is welded to the second implant member 220 using a Near-Infrared (NIR) laser 220210.Technique No. 4

[0049] A biocompatible metal, such as but not limited to gold (Au), can be used as a soldering material to create a mechanical coupling between the first implant member 210 and the second implant member 220. An IR or NIR laser can be used to melt the material of the first implant member 210, the material of the second implant member 220, and the solder material at the same time, creating a mechanical-interlocking.Technique No. 5

[0050] A 3-wavelength laser can be used for soldering of the first implant member 210 and second implant member 220 using a biocompatible material such as but not limited to Au as solder. Each of the three wavelengths of the laser is selected to be absorbed by the materials of one of the first implant member 210, the secondimplant member 220, and the biocompatible solder material, melting all 3 materials at the same time creating a mechanical-interlocking.Technique No. 6

[0051] Using a single wavelength or multiple wavelength laser in a 3D printing process and using first and second powder compounds to manufacture the dental implant device 200 using one or more 3-D printers. In particular, the first implant member 210 may be formed from a Zi powder material using a 3-D printer, and the second implant member 220 may be formed from a Ti powder material using the same or a second 3-D printer.

[0052] Each of Techniques 1-6 address the same need for gap-free, cement-free, abrasion- free dental implant devices, both with regard to crown-abutment pieces and implant fixtures.

[0053] In any of Techniques 1-6, if needed, a near-infrared (NIR) or infrared (IR) laser can optionally be used to polish the outer surface of the welded line 230, creating a smooth surface.

[0054] In certain embodiments, where an NIR laser is used in any of Techniques 1-6, the NIR laser may be configured to emit light at a wavelength of about 1064mm, resulting in absorption in the range of about 30% and about 40% for a Ti-based second implant member 220 and absorption of about 10% for a zirconia-based first implant member 210.

[0055] In embodiments of Techniques 1-6 where an absorption % greater than 10% is required for the zirconia first implant member 210, a CO2 laser may be used either in conjunction with the NIR laser. The wavelength of the CO2 may be about 10.6 pm, but not limited to this value, resulting in absorption in the range of about 80-90% for a zirconia-based first implant member 210.

[0056] In other embodiments involving Techniques 1-6, the laser(s) used may comprise ultraviolet (UV) lasers configured to emit light of wavelength about 355nm, but not limited to this value, resulting in absorption of about 70% for both Ti-based and Zirconia-based members.

[0057] It will be appreciated that the preceding wavelengths and spot sizes are provided by way of example only and are not intended to be limiting in scope.

[0058] If required, a layer of Ti or another biocompatible metal can be deposited on the final polished area. In order to deposit the biocompatible metal on the final polished area, any of the known techniques may be utilized such as but not limited to chemical deposition including dipping techniques, or alternatively physical deposition techniques such as but not limited to Laser Induced Forward Transfer (LIFT). For example, in order to deposit a layer of Ti on the final polished area by chemical deposition, a Ti ink may be used.

[0059] The post-processing steps of laser polishing and Ti deposition on the joined, welded or soldered area creates an abrasion-free surface.

[0060] Whilst gold is listed as a biocompatible metal in the foregoing embodiments, it will be appreciated that other biocompatible metals are envisaged by the inventors. For example, titanium, stainless steel, cobalt-chromium alloys, platinum, palladium, tantalum, or zirconium, or an alloy thereof, may be used in addition to or in the place of gold.

[0061] In an example embodiment, a manufacturing system (not presented) for implementing any of the Techniques 1-6 may comprise 2 incoming trays or magazines, one for each of the first and second implant members, for example one for the prosthesis piece such as the crown and one for the implant or abutment. A material handling robotmay pick-up the second implant member and place it on a rotary table. Optionally, the second implant member may be placed on a holder on the rotary table to enhance stability of the second implant member on the table during manufacture. Next, the material handling robot may pick-up the first implant member, align it with the second implant member, and place it on the second implant member. A machine vision system of the manufacturing system may be configured to detect the gap between the crown and the abutment in the case of Figures 2-3, or between the first and second implant fixture portions 420a, 420b in the case of Figure 4. Next, a motion system aligns the optical path of the laser with the detected gap. The continuous welding starts and proceeds by controlling the speed of rotation of the implant. Depending on the materials and sizes of the implant device members, the rotational speed can be selectively adjusted to optimize the welding quality. After the welding is completed, the handling robot picks the Unified Crown Abutment, or Unified Implant, and places it on an outgoing tray. This process may repeat until the incoming try materials are empty. It will be appreciated that this is provided as an example configuration of a system for implementing Techniques 1-6 and is not intended to be limiting.

Claims

CLAIMS1. A dental implant device, comprising: a first implant member at least partially formed of a ceramic material and selected to at least be in contact with a patient’s gum, and a second implant member at least partially formed of a metal and selected to be in contact with the jawbone of the patient, wherein the first implant member and the second implant member are affixed to each other using a laser welding, joining, or soldering technique, such that there is no gap between the first implant member and the second implant member and no cement is used for the affixment.

2. The dental implant device of claim 1 , wherein the first implant member is further selected to be in contact with a patient’s jawbone.

3. The dental implant device of claim 1, wherein the first implant member and the second implant member have been affixed by melting at least part of the material of both the first implant member and the second implant member at the same time using a two-wavelength laser in order to create a mechanical coupling between the first implant member and the second implant member, wherein a first wavelength of the two-wavelength laser is selected to be a wavelength that is absorbed by a material of the first implant member, and a second wavelength of the two-wavelength laser is selected to be a wavelength that is absorbed by a material of the second implant member.

4. The dental implant device of claim 1 , wherein the first implant member and the second implant member have been affixed by melting the two materials at the same time using an infrared or near-infrared laser in order to create a mechanical coupling between the first implant member and the second implant member.

5. The dental implant device of claim 1, wherein the first implant member and the second implant member have been affixed by deposition of a layer of a metal on a region of the first implant member adjacent to the second implant member, or on a region of the second implant member adjacent to the first implant member, and one or more lasers are used to weld the first implant member to the second implant member by melting the metal and at least part of the materials of the first implant member and the second implant member.

6. The dental implant device of claim 5, wherein the metal that is deposited on the first implant portion is the same as the metal that the second implant member is at least partially formed from.

7. The dental implant device of claim 5 or claim 6, wherein the metal comprises titanium or an alloy thereof.

8. The dental implant device of claims 5-7, wherein the laser comprises a nearinfrared laser.

9. The dental implant device of claim 1 , wherein the first implant member and the second implant member have been affixed by positioning a biocompatible soldering material in the vicinity of the first implant member and the second implant member, and one or more lasers are used to melt the biocompatible soldering material in order to create a mechanical coupling between the first implant member and the second implant member.

10. The dental implant device of claim 9, wherein the one or more lasers include an infrared laser and / or a near-infrared laser.

11. The dental implant device of claim 9, wherein the one or more lasers comprises a three-wavelength laser, wherein each wavelength of the three-wavelength laser isselected to be absorbed by one of the biocompatible soldering material, a material of the first implant member, and a material of the second implant member, such that all three materials are melted by the three-wavelength laser at the same time creating a mechanical coupling.

12. The dental implant device of claims 9-11, wherein the biocompatible soldering material comprises gold.

13. The dental implant device of claim 1 , wherein the first implant member is formed by 3-D printing using a first powder material, and the second implant member is formed by 3-D printing using a second powder material.

14. The dental implant device of claims 1-13, wherein the first implant member comprises a zirconium-based ceramic material.

15. The dental implant device of claims 1-14, wherein the second implant member comprises titanium or an alloy thereof.

16. The dental implant device of claims 1-15, wherein the dental implant device is polished in the region where the first implant member and the second implant member have been mechanically coupled.

17. The dental implant device of claim 16, wherein the polishing has been accomplished using an infrared or near-infrared laser.

18. The dental implant device of claims 16-17, wherein a layer of a biocompatible metal is deposited on the polished area.

19. The dental implant device of claim 18, wherein the layer of biocompatible metal has been deposited by dipping the dental implant device in an ink product16comprising the biocompatible metal, or by Laser Induced Forward Transfer (LIFT).

20. The dental implant device of claims 1-19, wherein the laser(s) are configured with a spot size in the range of 10pm and 200pm.

21. The dental implant device of any previous claim, where the first implant member comprises a crown member, and the second implant member comprises an abutment member.

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