Dental Appliance Curing with Preheating and LED Light Control
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Solution Overview
Problem
Existing methods for curing polymeric dental appliances, such as dentures and dental restorations, are inefficient and unreliable, leading to incomplete curing and potential material instability and cytotoxicity risks due to unreacted monomers.
Innovation Solution
A method involving a curing apparatus with controllable heating and LED light sources is used to convert partially cured photopolymerizable components into a final cured state by preheating to a temperature above the glass transition temperature of the lowest component and then exposing it to UV and visible light for a specified time, ensuring complete curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional light curing units are used for final curing, then the curing process can be initiated, but complete curing is not achieved and material stability is compromised
Solution Approach 1:
The patent applies parameter changes by systematically varying temperature (heating to specific ranges), time (extended curing periods), and light intensity/duration (multiple exposure phases) to achieve complete curing. The method transitions from conventional single-parameter curing to multi-parameter optimization, ensuring full polymerization while maintaining efficiency through controlled parameter progression.
Solution Approach 2:
The patent implements preliminary action through preheating the dental appliance to specific temperature ranges before initiating the final curing process. This preliminary thermal preparation activates the material for more effective and complete photopolymerization, ensuring that subsequent light exposure achieves full curing rather than partial curing.
2Reliability
If extended curing time is used to achieve complete curing, then material stability improves, but production time increases
Solution Approach 1:
The patent optimizes the balance between time and stability by dynamically adjusting curing parameters. Temperature is increased to activate polymerization, light exposure is applied in controlled phases with varying intensity and duration, and the process monitors material response to terminate curing at the optimal moment for complete polymerization without excessive time consumption.
Solution Approach 2:
The patent employs periodic action through multi-phase light exposure cycles. Instead of continuous exposure, the method uses alternating phases of light application and interruption, allowing heat to penetrate and polymerize while preventing overheating. This periodic illumination pattern achieves complete curing efficiently by synchronizing light exposure with thermal activation phases.
3Reliability
If heating is applied during light curing, then curing effectiveness improves, but energy consumption increases
Solution Approach 1:
The patent applies preliminary heating to a controlled temperature range before initiating light curing. This preheating step prepares the material structure to be more receptive to photopolymerization, ensuring that subsequent light exposure is highly effective. By performing the thermal preparation in advance at optimized temperatures, the system achieves maximum curing effectiveness while minimizing redundant energy input during the light exposure phase.
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
This method achieves fully cured polymeric dental appliances with improved mechanical properties and reduced cytotoxicity, ensuring stability and reliability for patient use.
Implementation Method 1
performing a preheating step in the curing chamber, wherein the one or more controllable heating sources heats the polymeric dental appliance in a time period of t1, wherein 1 minute≤t1≤40 minutes, to a temperature T1≥Tg(Lowest)
Implementation Method 2
performing a curing step in the curing chamber, wherein the one or more controllable heating sources maintains the polymeric dental appliance at a temperature T2≥Tg(Lowest) for a time period of t2, wherein 2 minutes≤t2≤120 minutes, while the one or more controllable LED light sources emits light in the ultraviolet and/or visible wavelength range onto the polymeric dental appliance for a time period of t3
Data Source
AI summary
The present invention relates to methods for curing polymeric dental appliances comprised of partially cured photopolymerizable components, especially for additively manufactured denture base and artificial tooth components utilized in the production of full and partial dental prostheses. In particular, the invention relates to methods of utilizing a curing apparatus having one or more controllable heating sources and one or more controllable LED light sources to achieve specific preheating and light curing conditions for more effectively converting partially cured photopolymerizable components from a partially cured state to a final cured state.