Layered Denture Blocks With Shape-Memory Fit Adaptation
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Solution Overview
Problem
Existing denture fabrication methods are labor-intensive, time-consuming, and result in fit issues due to polymerization shrinkage, requiring additional adjustments and visits, while traditional materials are brittle and lack adjustability for optimal comfort and esthetics.
Innovation Solution
A multiple layered dental block or disk is fabricated using polymerizable materials, allowing for precise CAD/CAM milling with adjustable layers for improved fit and esthetics, incorporating shape memory polymers for oral cavity adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional polymerization methods are used to fabricate dentures, then the denture base material can be formed, but polymerization shrinkage and thermal shrinkage occur which adversely affect the fit of the denture
Solution Approach 1:
The denture base is divided into multiple layers with different materials: a rigid layer for structural support and a resilient layer for comfort and fit adaptation. This segmentation allows each layer to perform its specific function without the negative effects of polymerization shrinkage compromising the overall fit.
Solution Approach 2:
The invention uses composite materials consisting of a resilient polymer layer and a rigid polymer layer. The resilient layer (e.g., polyether block amide or polyurethane) provides comfort and adaptability to oral tissues, while the rigid layer (e.g., poly methyl methacrylate) provides structural support. This composite structure eliminates fit issues caused by shrinkage in traditional single-material dentures.
2Adaptability or versatility
If homogeneous denture base material is used, then the manufacturing process is simplified, but the denture lacks adjustability for optimal comfort and fit
Solution Approach 1:
The denture base is segmented into multiple functional layers: a resilient layer for comfort and tissue adaptation, and a rigid layer for structural support and tooth positioning. This segmentation enables localized adjustability in different regions of the denture base without complicating the overall manufacturing process.
Solution Approach 2:
Different regions of the denture base have different material properties: the resilient layer provides local adaptability and comfort where it contacts oral tissues, while the rigid layer provides local structural support where teeth are positioned. This local quality differentiation enhances overall denture performance without requiring complex manufacturing.
3Manufacturing precision
If traditional multi-visit fabrication process is used, then adjustments can be made for optimal fit, but the process is labor-intensive and time-consuming
Solution Approach 1:
The denture base is pre-fabricated with both rigid and resilient layers in a single manufacturing process, providing preliminary fit and comfort characteristics before the patient receives the final denture. This preliminary action reduces the need for multiple adjustment visits, as the resilient layer inherently adapts to oral tissues upon insertion.
Solution Approach 2:
The invention changes the material parameters of the denture base by incorporating a resilient layer with specific elastic properties that allow the denture to adapt to oral tissues through parameter changes in the material itself, rather than requiring multiple visits for mechanical adjustments.
4Strength
If rigid denture base material is used, then the denture provides structural support for artificial teeth, but the denture lacks comfort and adaptability to oral tissues
Solution Approach 1:
The denture base is segmented into a rigid layer for structural support and a resilient layer for comfort. The rigid layer (e.g., poly methyl methacrylate) provides the necessary strength to support artificial teeth, while the resilient layer (e.g., polyether block amide) provides comfort and adaptability to oral tissues through its elastic properties.
Solution Approach 2:
The invention uses composite materials where a rigid polymer layer provides structural support for teeth positioning, and a resilient polymer layer provides comfort and tissue adaptation. This composite structure simultaneously achieves both structural strength and comfort without compromise.
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 enables efficient, adjustable denture production with reduced labor and visits, providing enhanced comfort and esthetics through adjustable layers and improved material properties.
Implementation Method 1
placing first layer of polymerizable denture base material and curing to form first cured layer, placing second layer of polymerizable denture base material and curing to form second cured layer
Implementation Method 2
incorporating shape memory polymers for oral cavity adaptation
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 2E~2H
AI summary
This invention designs and builds multiple layers (two layers or more) of millable dental blocks or disks for milling of various dental devices, specifically denture base blocks or disks of denture base material, where milled teeth cavities to receive artificial denture tooth materials to form final dental devices, such as partial and full dentures. This invention also designs and builds multiple layers (two layers or more) of millable denture base or denture blocks or disks comprised of denture base or/and denture tooth materials to form final dental devices, such as partial and full dentures. A method for manufacturing a layered denture is provided. The invention provides a multiple layered denture base block (or disk) for milling a denture base. The invention also provides a multiple layered denture block (or disk) for milling a denture. Highly shape adjustable or shape memory polymer layer(s) may be used in these multiple layered forms. Different layer of material has different mechanical and physical properties to meet different need, which provide added benefits to the patients, dental professional and dental laboratory.