Dental Composite Blank Pressurization for Filler Dispersion
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Solution Overview
Problem
Dental composite blanks face challenges in dispersing non-dispersed fillers and removing bubbles, leading to inadequate mechanical properties, particularly in posterior teeth repairs due to the low mechanical strength of existing hybrid ceramics and the rigidity of zirconia or glass ceramics.
Innovation Solution
A method involving repeated pressurization at different pressures before curing a dental composite paste, using a composite paste with unsaturated-double-bond compounds, fillers, and a polymerization initiator, to disperse fillers and remove bubbles, resulting in improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If zirconia or glass ceramics are used for dental prostheses, then mechanical strength is improved, but post-processing complexity increases and opposing teeth may be damaged due to rigidity
Solution Approach 1:
The invention changes the material parameters by using hybrid ceramics with optimized composition (40-60 wt% inorganic filler, 40-60 wt% organic binder) instead of traditional zirconia or glass ceramics, achieving a balance between mechanical strength and processing ease that eliminates the need for complex post-processing
Solution Approach 2:
The invention employs composite materials by combining inorganic filler particles (such as silica, alumina, or zirconia) with an organic binder in specific proportions to create hybrid ceramics that exhibit both high mechanical strength and improved processability, avoiding the rigidity issues of pure zirconia
2Ease of manufacture
If hybrid ceramics are used for dental prostheses, then processing simplicity and aesthetics are improved, but mechanical strength decreases making them unsuitable for posterior teeth repair
Solution Approach 1:
The invention optimizes the compositional parameters of hybrid ceramics by precisely controlling the weight ratios of inorganic filler (40-60 wt%) and organic binder (40-60 wt%), and adjusting particle size distributions, to achieve a critical threshold of mechanical strength suitable for posterior teeth while maintaining processing simplicity
3Ease of manufacture
If dental composite paste is cured without repeated pressurization, then manufacturing process is simplified, but filler dispersion is inadequate and bubbles remain reducing mechanical properties
Solution Approach 1:
The invention applies periodic pressurization cycles during the curing process, where the paste is subjected to repeated pressure applications and releases, which progressively improves filler dispersion and eliminates bubbles without requiring overly complex continuous pressurization systems
4Ease of manufacture
If non-dispersed filler is used in dental composite, then manufacturing is easier, but mechanical properties are inadequate particularly for posterior teeth repair
Solution Approach 1:
The invention performs preliminary dispersion of filler particles in the organic binder phase before the final curing process, ensuring uniform distribution that enhances mechanical properties while maintaining manufacturing simplicity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively disperses fillers and removes bubbles, enhancing the flexural strength of the dental composite blank to 200-300 MPa, addressing the limitations of existing materials by improving mechanical properties and wear resistance.
Implementation Method 1
pressurizing the composite paste placed in the mold at a first pressure P1, pressurizing the composite paste placed in the mold at a second pressure P2
Implementation Method 2
curing the pressurized composite paste
Data Source
AI summary
The present invention relates to a method of manufacturing a dental composite blank, including (a) placing a composite paste in a mold, (b) pressurizing the composite paste placed in the mold at a first pressure (P1), (c) pressurizing the composite paste placed in the mold at a second pressure (P2), and (d) curing the pressurized composite paste, in which each of steps (b) and (c) is performed once or multiple times, and the first pressure (P1) is less than or greater than the second pressure (P2). The dental composite blank and the method of manufacturing the same are effective at dispersing a non-dispersed filler and removing bubbles, thus improving mechanical properties, through repeated pressurization at different pressures before curing the composite paste.