Dual-Layer Dental Prosthesis Enamel-Dentin Structure

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Solution Overview

Problem

Current dental prostheses lack a dual structure similar to natural teeth, which can lead to issues like wear of adjacent teeth and secondary infections due to differences in physical properties between the prosthesis and natural teeth.

Innovation Solution

A dental prosthesis with a structure and properties similar to natural teeth is achieved by using a cured product with ceramic particles dispersed in a polymer matrix, featuring a first layer with 70-90% ceramic particles of 100 nm to 1,000 nm diameter and a second layer with 40-60% ceramic particles of 10 μm to 500 μm diameter, manufactured using three-dimensional printing to replicate the dense structure of enamel and porous structure of dentin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single-layer prosthesis material is used, then manufacturing is simpler and cost is lower, but the prosthesis cannot replicate the dual structure of natural teeth (enamel and dentin) leading to wear of adjacent teeth and secondary infections

Engineering Contradiction:

Improveprevention of wear and infectionVSAvoidprosthesis structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The prosthesis is divided into two distinct layers: a first layer with ceramic particles of 100-1000 nm mimicking enamel, and a second layer with ceramic particles of 10-500 μm mimicking dentin. This segmentation allows each layer to replicate the specific physical properties and functions of natural tooth structures, preventing wear of adjacent teeth and reducing secondary infections while maintaining the dual structure necessary for biological compatibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the prosthesis are assigned different material compositions and particle sizes to match local requirements. The first layer uses finer ceramic particles (100-1000 nm) to replicate enamel's dense, wear-resistant structure, while the second layer uses coarser particles (10-500 μm) to replicate dentin's porous, shock-absorbing structure. This local differentiation ensures each region performs its specific function, improving overall reliability.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If ceramic particles with specific size distributions are used, then the prosthesis achieves physical properties similar to natural teeth, but material selection and manufacturing precision requirements increase

Engineering Contradiction:

Improveparticle size controlVSAvoidmaterial selection

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention specifies precise parameter ranges for ceramic particle sizes (100-1000 nm for the first layer, 10-500 μm for the second layer) and their corresponding weight percentages (70-90% and 40-60% respectively). By defining these parameters within optimal ranges, the prosthesis achieves physical properties matching natural teeth while providing clear manufacturing guidelines that balance precision requirements with manufacturability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite materials combining ceramic particles with polymer matrices in specific configurations. The first layer combines fine ceramic particles (100-1000 nm) with polymer to replicate enamel, while the second layer combines coarser ceramic particles (10-500 μm) with polymer to replicate dentin. This composite approach enables precise control over physical properties while maintaining ease of manufacture through established composite material processing techniques.

Inventive Principle:

Principle #40Composite materials

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 resulting prosthesis exhibits biaxial flexural strength, elastic modulus, and hardness similar to natural teeth, enhancing esthetics and preventing abrasion and secondary infections by mimicking the properties of enamel and dentin.

Implementation Method 1

a cured product including ceramic particles dispersed in a polymer matrix

Methodology Applied

Scientific EffectDispersion: Dispersion (of waves)

Implementation Method 2

manufactured using three-dimensional printing to replicate the dense structure of enamel and porous structure of dentin

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Implementation Method 3

a curable composition including ceramic particles and a polymerizable organic compound, the curable composition is layered and cured

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS20230021279A1Dental prosthesis having structure similar to that of natural teeth, and manufacturing method therefor

Publication Date: 2023.01.19 HAAS CO LTD

AI summary

Dental prosthesis having a structure similar to that of natural teeth and a method for manufacturing the same. Provided is a dental prosthesis capable of expressing a structure and properties similar to natural teeth in which enamel is a surface layer and dentine is an inner layer underneath the enamel. In addition, a method of manufacturing the same dental prosthesis through three-dimensional printing is provided. The dental prosthesis is a cured product including ceramic particles dispersed in a polymer matrix. The cured product includes a first cured product layer including 70% to 90% by weight of ceramic particles having an average particle diameter of 100 to 1,000 nm and a second cured product layer including 40% to 60% by weight of ceramic particles having an average particle diameter of 10 μm to 500 μm, the second cured product layer being adjacent to the inner surface of the first cured product layer.