Green Compact Ceramic Denture Shaping
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Solution Overview
Problem
Current methods for producing ceramic dental prostheses using semi-finished products are hindered by their brittle nature, leading to difficult and time-consuming processing, high risk of cracking, and the need for specialized systems, which result in long processing times and increased costs.
Innovation Solution
A method involving the use of a green compact ceramic shell that can be plastically adapted and processed using a viscous ceramic filler compound, allowing for easier shaping and infiltration before a firing step below 1050°C, enabling flexible processing and correction of design errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If densely sintered ceramic semi-finished products are used for production, then manufacturing precision and structural stability are improved, but processing difficulty increases and processing time extends
Solution Approach 1:
The patent changes the sintering temperature parameter to produce a green compact at lower temperature (below 1050°C) rather than dense sintering, transforming the material state from brittle and hard-to-process to plastic and easily processable, thereby resolving the contradiction between precision and processing speed
Solution Approach 2:
The patent performs preliminary shaping and adaptation of the ceramic shell before final sintering, allowing design errors to be corrected in the plastic green compact state, which eliminates the need for time-consuming post-sintering adjustments and accelerates overall production
2Stability of the object's composition
If densely sintered ceramic semi-finished products are used, then structural stability is improved, but the risk of cracking during processing increases
Solution Approach 1:
The patent uses a green compact produced at lower sintering temperature, which maintains structural integrity while exhibiting plastic deformability that prevents crack propagation during processing, thereby simultaneously achieving structural stability and crack resistance
3Manufacturing precision
If specialized processing systems are used for densely sintered material, then manufacturing precision is improved, but device complexity and costs increase
Solution Approach 1:
The patent changes the material state from densely sintered to green compact, which can be processed using simpler, conventional tools and methods without requiring specialized cooling systems or complex equipment, thereby reducing device complexity while maintaining processing precision
4Productivity
If green compact ceramic shell is used instead of densely sintered material, then processing time is reduced, but manufacturing precision may deteriorate
Solution Approach 1:
The patent performs all necessary shaping, adaptation, and correction operations as preliminary actions while the ceramic shell is in the plastic green compact state, before final sintering locks the dimensions, thereby achieving both fast processing and high precision
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 processing times, minimizes the risk of fractures, and allows for more efficient chip-removing processing with faster parameters, while also enabling color adaptation and improved mechanical stability through infiltration, resulting in a more reliable and cost-effective production method.
Implementation Method 1
a green compact that can be shaped and therefore can be plastically adapted to the framework contour
Implementation Method 2
affixing the ceramic shell to a framework or to a carrier by means of a viscous ceramic filler compound as an equalization compound
Implementation Method 3
carrying out at least one firing step below a temperature of 1050° C
Data Source
AI summary
A method for producing dentures uses a green compact containing a mixture of ceramic powder and a binder system. A ceramic shell for dentures can be produced from the green compact and can be shaped and can be adapted to a carrier prior to a firing step below a temperature of 1050° C.