Dental Prosthesis Blank With Wavy Interface for Secure Anchorage
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Solution Overview
Problem
Existing dental prostheses face challenges in providing good biocompatibility, slim design, and secure anchorage while being cost-effective and durable, with conventional methods often requiring complex tools and materials that are expensive or prone to breakage.
Innovation Solution
A dental prosthesis is manufactured from a blank with a wave-like interface connecting tooth and base materials, eliminating an adhesive layer and using a subtractive process like milling, where retention elements are polymerized into recesses for secure anchorage, enhancing stability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional injection molding process is used to insert teeth, then teeth can be securely anchored, but special injection molding tools with slides are required which are expensive to manufacture
Solution Approach 1:
The invention extracts the complex injection molding tooling with slides from the manufacturing process. Instead of using specialized tools, the patent employs a simple injection mold that injects material directly to form teeth with integrated anchoring features, eliminating the need for expensive slide mechanisms while maintaining secure tooth anchorage
Solution Approach 2:
The invention changes the manufacturing approach from mechanical insertion using slides to direct injection molding. By modifying the injection process parameters and mold design, teeth are formed and anchored in a single step, reducing tooling complexity and cost while achieving the required anchorage strength
2Strength
If heat polymerization process is used to provide strong bond between teeth and denture base, then bond strength is improved, but the prosthesis becomes relatively prone to breakage
Solution Approach 1:
The invention uses a composite material system consisting of a denture base material and tooth material that are both polymerized together. This composite approach creates a unified structure where the materials work together to provide both bond strength and fracture resistance, eliminating the brittleness issue associated with heat-polymerized prostheses
Solution Approach 2:
The invention merges the polymerization process of the denture base and teeth into a single simultaneous operation. Both materials are polymerized together in the same mold under controlled conditions, creating a unified structure with optimized mechanical properties that combines bond strength and fracture resistance
3Stability of the object's composition
If metal framework is used to extend along the dental arch, then prosthesis stability is improved, but the prosthesis becomes heavy and thick causing patient discomfort
Solution Approach 1:
The invention changes the material parameter from metal to polymer for the framework structure. By using a polymer-based denture base material with optimized density and mechanical properties, the prosthesis achieves sufficient stability without the weight and thickness associated with metal frameworks, improving patient comfort
Solution Approach 2:
The invention applies local quality optimization by concentrating structural reinforcement only where needed in the denture base, rather than using a continuous metal framework. The polymer base material is formulated and molded to provide localized strength and stability, reducing overall weight and thickness while maintaining necessary structural integrity
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 achieves improved stability, rigidity, and fracture resistance with reduced material stress, allowing for a long service life and cost-effective production, adaptable to various prosthesis types.
Implementation Method 1
both materials are polymerized together under pressure and heat, resulting in a direct chemical bond between them
Data Source
Figure 1~2
Figure 3
Figure 4~4a
AI summary
It describes a method for producing a dental prosthesis from a blank using a CAD/CAM device. The blank consists partly of base material and partly of tooth material, and an interface between these materials is formed in the form of a wave, the crests and troughs of which alternate along the outer circumference of the blank. The apex of each crest has a substantially radial orientation relative to the blank. The CAD/CAM device determines the position of a retention element, in particular an outer telescope, a bar cap, or an abutment, within the prosthesis for attaching the prosthesis to the patient's alveolar ridge, such that the interface is penetrated by this element. The retention element is attached by bonding or polymerization.