Dental Restoration Molding with Segmented Ceramic Ingot

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Solution Overview

Problem

Existing methods for preparing dental restorations from ceramic or polymeric materials are limited to single-color productions, requiring laborious and expensive subsequent surface treatments to achieve color and opacity gradients simulating natural dentition.

Innovation Solution

A method and system that utilize an ingot with distinct volume regions of different colors or opacities, directed through a press mold's system of channels to achieve color and opacity gradients without subsequent coating, by controlling the flow paths and timing of material injection into the mold cavity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single-color ceramic material is used in the molding process, then the manufacturing process is simple, but the dental restoration lacks natural appearance requiring subsequent surface treatment

Engineering Contradiction:

Improvemolding process simplicityVSAvoidcolor gradient accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The ceramic ingot is segmented into multiple regions with different colors and opacities. The ingot comprises a first region with a first color and opacity, and a second region with a second color and opacity. This segmentation allows different color zones to be positioned at different locations in the ingot, which are then distributed to specific areas of the dental restoration through the channel system during molding, eliminating the need for post-manufacturing surface treatment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The color and opacity gradients are prepared in advance within the ceramic ingot structure itself, rather than being applied afterward. The ingot is pre-configured with multiple regions of different colors and opacities in specific spatial arrangements. During the molding process, these pre-positioned color regions are automatically distributed to the corresponding areas of the dental restoration through the channel system, achieving the color gradient effect before the restoration is even formed.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If subsequent surface treatment is applied to achieve color gradients, then natural appearance is achieved, but labor and cost increase significantly

Engineering Contradiction:

Improvecolor gradient accuracyVSAvoidmanual work efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The coloring step is merged with the molding step into a single integrated process. Instead of separately manufacturing a single-color restoration and then applying surface treatment, the invention combines both operations by incorporating multiple color regions within the ceramic ingot itself. When the ingot is molded, the different color regions are simultaneously distributed to form the complete colored restoration in one operation, eliminating the need for separate surface treatment operations and significantly improving productivity.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If material is forced through channels into mold cavity, then the molding process is efficient, but controlling color distribution timing is complex

Engineering Contradiction:

Improvemolding process speedVSAvoidchannel system configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Different regions of the ceramic ingot are assigned different local qualities in terms of color and opacity. The ingot is structured with a first region having a first color and opacity, and a second region having a second color and opacity. The channel system is configured to exploit these local differences by directing material from different regions of the ingot through different channels to specific locations in the mold cavity, achieving controlled color distribution through the inherent properties of the material regions rather than complex active control mechanisms.

Inventive Principle:

Principle #3Local quality

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

Enables the creation of dental restorations with natural appearance color and opacity gradients directly during the molding process, reducing manual labor and costs associated with surface treatments.

Implementation Method 1

an ingot of ceramic or polymeric material is entirely or partially forced through a system of channels in a press mold into a mold cavity in the press mold

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS7845924B2System for preparing dental restorations

Publication Date: 2010.12.07 IVOCLAR VIVADENT AG

AI summary

The present invention relates to a method and a system for preparing dental restorations from ceramic or polymeric material to achieve color and opacity gradients simulating natural dentition, wherein an ingot of ceramic or polymeric material is entirely or partially forced through a system of channels in a press mold into a mold cavity in the press mold, wherein the mold cavity corresponds to a dental restoration.