PEEK PPSU Denture Frame Composite
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Solution Overview
Problem
Traditional denture frames made of metal suffer from undesirable aesthetics, stiffness, and weight, leading to poor fit and patient discomfort, while polymer-based alternatives lack sufficient toughness, flexibility, and color stability, resulting in short product lifetimes.
Innovation Solution
The development of denture frames using a polymer composition that combines poly(ether ether ketone) (PEEK) and polyphenylsulfone (PPSU) polymers, with specific ratios and additives, which enhances mechanical and aesthetic properties, such as color stability, toughness, and dimensional stability, and is fabricated using milling methods to improve fit and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal is used for denture frames, then stress resistance and durability are improved, but aesthetics and patient comfort deteriorate due to stiffness and weight
Solution Approach 1:
The patent applies composite materials by combining PEEK polymer with reinforcing fibers (such as carbon fiber or glass fiber) to create a denture frame that achieves both high strength and improved aesthetics. The composite structure allows the material to exhibit metal-like mechanical properties while maintaining the aesthetic advantages of polymer materials, thus resolving the contradiction between stress resistance and aesthetics.
2Ease of operation
If thermoplastic polymer is used for denture frames, then aesthetics and flexibility are improved, but toughness and color stability deteriorate
Solution Approach 1:
The patent uses composite materials by incorporating reinforcing fibers into the PEEK polymer matrix. This composite structure significantly enhances the toughness and color stability of the denture frame while preserving the flexibility and aesthetic properties inherent to polymer materials, thereby resolving the contradiction between flexibility and reliability.
Solution Approach 2:
The patent applies parameter changes by optimizing the molecular weight, crystallinity, and thermal treatment parameters of the PEEK polymer. These parameter adjustments improve the material's toughness and color stability without compromising its flexibility, thus resolving the contradiction between ease of operation and reliability.
3Ease of manufacture
If traditional polymer composition is used, then manufacturing simplicity is maintained, but product lifetime deteriorates due to insufficient mechanical properties
Solution Approach 1:
The patent applies composite materials by combining PEEK polymer with reinforcing fibers to enhance mechanical properties such as tensile strength, flexural strength, and impact resistance. This composite approach significantly extends the product lifetime of denture frames while maintaining compatibility with existing manufacturing processes, thus resolving the contradiction between ease of manufacture and product lifetime.
Data Source
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AI summary
Described herein are thermoplastic denture frames having significantly improved lifetimes as well as comfort. The denture frames include a polymer composition including at least one poly(ether ether ketone) ("PEEK") polymer and at least one polyphenylsulfone ("PPSU") polymer. It was surprisingly discovered that the polymer compositions have significantly improved color stability, relative to corresponding polymer compositions including PEEK polymer as the only polymeric component of the polymer composition. Additionally, the polymer compositions have significantly improved toughness, flexibility and dimensional stability. The combination of the aesthetic characteristics and mechanical characteristics of the polymer compositions allows for denture frames having improved lifetimes and comfort.