Adhesion Promoter for Oxide Ceramic Veneer Bonding
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Solution Overview
Problem
Current methods for improving the bond between oxide ceramic and veneering materials in dental applications are limited by requiring complex and expensive equipment, and fail to achieve a significant increase in bond strength, leading to issues like 'chipping' due to inadequate mechanical and chemical bonding.
Innovation Solution
An adhesion promoter consisting of a mixture of feldspar and quartz particles with a dispersant is applied to a pre-sintered oxide ceramic surface, allowing it to penetrate and diffuse up to 10 μm before final sintering, creating both mechanical and chemical bonds between the oxide ceramic and veneering materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a silicate layer is applied to the oxide ceramic surface to increase bond strength, then the bond strength between oxide ceramic and veneering material is improved, but the complexity of the manufacturing process and equipment requirements increase
Solution Approach 1:
The patent replaces complex, expensive equipment (magnetron sputtering devices, flame hydrolysis systems) with a simple, inexpensive sol-gel coating process that can be applied using basic spray or dip methods. The adhesion promoter layer is applied as a simple liquid sol that cures to form the bonding layer, eliminating the need for sophisticated deposition equipment.
Solution Approach 2:
The patent replaces complex mechanical deposition systems (magnetron sputtering, corundum blasting) with a chemical sol-gel process. Instead of physically depositing silicate layers through mechanical or physical means, the invention uses chemical reactions of metal alkoxides in a sol-gel system to form the adhesion promoter layer, simplifying the manufacturing process.
2Strength
If conventional methods are used to apply silicate layers, then the bond strength is marginally improved, but the veneering material still chips under extreme oral conditions due to insufficient bonding
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesion promoter layer by using specific metal alkoxides (silane, titanate, zirconate, aluminum alkoxide) in controlled ratios. This chemical parameter optimization creates a layer with enhanced chemical bonding capability that maintains durability under extreme oral conditions, going beyond marginal improvements to achieve reliable long-term performance.
Solution Approach 2:
The patent creates a composite adhesion promoter layer containing multiple metal oxides and alkoxides (silane, titanate, zirconate, aluminum alkoxide) that work synergistically. This composite chemical system provides both mechanical interlocking and chemical bonding, resulting in a bond that is both strong and durable under the extreme moisture, temperature, and mechanical stress conditions of the oral environment.
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 enhances the bond strength and durability, reducing the risk of 'chipping' by establishing a strong mechanical and chemical bond, ensuring the veneering material adheres firmly to the oxide ceramic, even under extreme oral conditions.
Implementation Method 1
The bonding agent penetrates the surface of the not yet densely sintered base body (to a depth of up to 10 μm, depending on the application).
Implementation Method 2
A bonding agent is then applied as a sol (slurry) to the surface of this prefabricated base body to be veneered.
Implementation Method 3
Only then is the base body densely sintered at temperatures of 1250 °C to 1600 °C, whereby the oxide ceramic ultimately achieves its full mechanical strength and robustness.
Data Source
AI summary
The aim of the invention is to improve the bond between the oxide ceramic and the veneer material and to increase the durability of said bond. According to the invention, an adhesion promoter (mixture of silicate ceramic and quartz) is applied as a sol to a main body that is to be veneered and that has not yet been densely sintered, the main body being made of oxide ceramic or starting materials thereof. The main body is then sintered to a final state together with the worked-in adhesion promoter, and afterwards the veneer material is applied. The invention is used, for example, to produce dental crowns and bridges having a high load-bearing capacity.
