Dental Crown Coating Retention Layer to Prevent Delamination
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Solution Overview
Problem
Stainless-steel dental crowns, while durable, have an unattractive appearance and suffer from coating delamination when subjected to occlusal forces and food contact.
Innovation Solution
A dental crown design featuring a continuous, nonporous metal shell with a coating retention metal layer of elongated metal strands, where the interface between the layers includes interstitial regions for a polymeric composition to bond effectively, ensuring the coating remains intact under mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a coating is applied to a stainless-steel dental crown to improve appearance, then aesthetic appearance is improved, but coating delamination occurs under occlusal forces
Solution Approach 1:
The patent applies a porous anodized oxide layer to the stainless-steel crown surface. This porous structure provides increased surface area and mechanical interlocking capability for the coating, allowing the coating to penetrate into the pores and form strong bonds that resist delamination under occlusal forces while maintaining aesthetic appearance
Solution Approach 2:
The patent creates a composite structure consisting of the stainless-steel base layer, the porous anodized oxide intermediate layer, and the aesthetic coating layer. This multi-layer composite design combines the strength and durability of stainless steel with the aesthetic properties of the coating, while the oxide layer serves as a bonding interface that prevents delamination
2Reliability
If a coating retention layer with large apertures is used to improve coating bonding, then coating retention is improved, but structural strength is reduced
Solution Approach 1:
The patent creates different regions with different properties: the anodized oxide layer provides a porous structure for coating retention in specific areas, while the underlying stainless-steel matrix maintains continuous structural integrity. The porous regions are localized to the oxide layer rather than compromising the entire crown structure
Solution Approach 2:
The patent employs a nested structure where the porous anodized oxide layer is formed within and supported by the solid stainless-steel matrix. The coating penetrates and bonds within the porous oxide layer, which itself is supported by the stronger metal substrate, creating a hierarchical structure that provides both retention and strength
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 solution provides a durable and aesthetically pleasing dental crown with a strong bond between the metal shell and the coating, preventing delamination and ensuring long-lasting performance.
Implementation Method 1
a coating retention metal layer diffusion bonded to the metal shell
Data Source
Figure 1~2
Figure 3~5A
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AI summary
Dental crowns and methods of making the same. The dental crown may include a metal shell shaped to cover a portion of a tooth of a patient; a coating retention metal layer diffusion bonded to the metal shell, wherein an interface between the coating retention layer and the metal shell comprises a plurality of interstitial regions; and a composition on the coating retention layer and within the plurality of the interstitial regions to bond the coating composition to the metal shell.