Fiber-Reinforced Composite Dental Implant Substructure
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Solution Overview
Problem
Current dental implant prostheses face issues with distortion due to polymerization shrinkage of PMMA denture base materials over glass fiber-reinforced composite substructures, leading to misfit and instability, and denture teeth breakage and debonding, with metal alloys being unaesthetic and costly, and fabrication processes being lengthy.
Innovation Solution
The implementation of a light polymerized resin suprastructure with fibers or fillers, fabricated before the substructure, using resins with low shrinkage to minimize distortion and improve bonding between denture teeth and base, allowing for immediate prosthesis availability post-surgery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal alloy substructure is used, then rigidity and resistance to distortion are improved, but aesthetic appearance and bonding capability to resin are worsened
Solution Approach 1:
The patent employs fiber-reinforced composite materials (such as carbon fiber or glass fiber reinforced polymers) to create a substructure that combines the rigidity of metal alloys with the aesthetic appearance and bonding capability of non-metallic materials. The fiber reinforcement provides structural strength while the polymer matrix enables aesthetic flexibility and chemical bonding to resin denture base materials.
2Ease of manufacture
If FRC material is used for substructure, then aesthetic appearance and bonding capability are improved, but rigidity and resistance to distortion are worsened
Solution Approach 1:
The patent uses fiber-reinforced composite materials where discrete fibers (carbon, glass, or other reinforcements) are embedded in a polymer matrix. This composite structure provides both the aesthetic advantages of non-metallic materials and the rigidity needed to resist distortion during PMMA polymerization, effectively combining the benefits of both material types.
3Reliability
If PMMA denture base is polymerized over FRC substructure, then bonding to substructure is achieved, but prosthesis distortion and misfit occur due to polymerization shrinkage
Solution Approach 1:
The patent incorporates expansion compensators or spacer elements into the FRC substructure before the PMMA polymerization process. These pre-placed components compensate for the expected polymerization shrinkage, maintaining dimensional stability and preventing prosthesis distortion and misfit during and after the bonding process.
4Manufacturing precision
If prosthesis fabrication is delayed until after abutment placement, then proper fit and stability are achieved, but treatment time and patient waiting period are extended
Solution Approach 1:
The patent enables preliminary fabrication of the prosthesis framework using the FRC substructure before final abutment placement. The light-polymerized resin suprastructure can be constructed in advance on a model, allowing for proper fit and stability to be established beforehand, thereby reducing the overall treatment time and allowing immediate or accelerated prosthesis delivery.
5Productivity
If light polymerized resin suprastructure is used, then fabrication time is reduced and immediate prosthesis is possible, but polymerization shrinkage may cause distortion
Solution Approach 1:
The patent uses expansion compensators or spacer elements that are pre-installed in the FRC substructure before the light-polymerized resin suprastructure is applied. These compensators anticipate and offset the polymerization shrinkage, allowing the rapid light-curing process to proceed while maintaining dimensional accuracy and preventing distortion of the final prosthesis.
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 approach reduces prosthesis distortion and enhances bonding between denture teeth and base, eliminating the need for mechanical retention, resulting in a more stable and aesthetically pleasing implant system that can be provided to patients shortly after surgery.
Implementation Method 1
Light polymerized glass fiber-reinforced composites (FRC)s have been developed that have the potential to make an esthetic implant prosthesis substructure utilizing a simple, time-efficient technique
Implementation Method 2
the polymerization of PMMA denture base material with embedded denture teeth over this dimensionally stable FRC substructure results in measurable distortion due to the expected high polymerization shrinkage of the PMMA
Data Source
AI summary
An implant system including a substructure, a suprastructure, abutments and an implant. The suprastructure is preferably fabricated of a light polymerized resin material having reinforcements such as fibers or fillers. The suprastructure is fabricated before the substructure. The use of resin materials that exhibit less shrinkage and the fact that the process begins with the suprastructure fabrication prevents distortion of the prosthesis when the suprastructure is bonded to the substructure and placed in the patient's mouth. Additionally, the method involved in making this implant system provides a prosthesis that is available to the patient almost immediately after surgery.