Photocurable Composition for Dental Prostheses
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Solution Overview
Problem
Current methods for producing dental prostheses using stereolithography lack photocurable compositions with sufficient flexural strength, flexural modulus, and fracture toughness, which are essential for practical applications.
Innovation Solution
A photocurable composition comprising specific combinations of (meth)acrylic monomers and a photopolymerization initiator, with a functional group value within a defined range, is developed to enhance flexural strength, flexural modulus, and fracture toughness, suitable for stereolithography of dental prostheses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional curable resins are used in stereolithography, then the production process can be implemented, but the flexural strength, flexural modulus, and fracture toughness of the resulting dental prosthesis are insufficient
Solution Approach 1:
The patent employs a composite resin composition containing multiple specific components: a polyfunctional monomer with high molecular weight (400-580) providing structural framework, a polyfunctional monomer with moderate molecular weight (200-400) enhancing crosslinking density, and a monofunctional monomer (50-200) ensuring complete photopolymerization. This multi-component composite system achieves superior flexural strength, flexural modulus, and fracture toughness compared to conventional single-resin systems, making the dental prosthesis reliable for practical use
Solution Approach 2:
The patent systematically optimizes critical parameters including the molecular weight range of each monomer component (400-580, 200-400, and 50-200 respectively), the functional group value (a) within specific ranges (0.50×10^-3 to 2.00×10^-3), and the content ratios of each monomer type. These parameter changes enable precise control over the polymer network structure, achieving the desired balance of flexural strength, flexural modulus, and fracture toughness for clinical application
2Strength
If conventional curable resins are used in stereolithography, then production can proceed, but the flexural modulus is insufficient for practical applications
Solution Approach 1:
The patent utilizes a composite resin system where the polyfunctional monomer with high molecular weight (400-580) serves as the primary structural component contributing to flexural modulus, while the polyfunctional monomer with moderate molecular weight (200-400) provides additional crosslinking that reinforces the polymer network. This composite approach achieves the high flexural modulus required for dental prosthesis reliability
Solution Approach 2:
The patent specifies precise molecular weight ranges for each monomer component, with the first polyfunctional monomer having molecular weight of 400-580 and the second having 200-400. These parameter specifications directly influence the polymer chain length and crosslinking density, thereby controlling the flexural modulus to meet practical usability requirements
3Strength
If conventional curable resins are used in stereolithography, then the denture base can be produced, but the fracture toughness is insufficient for practical use
Solution Approach 1:
The patent employs a composite monomer system where the monofunctional monomer (content: 5-50 parts by mass) ensures complete photopolymerization by reacting with remaining functional groups, eliminating unpolymerized segments that would act as fracture initiation sites. This composite approach significantly improves fracture toughness and makes the dental prosthesis reliable for practical use
Solution Approach 2:
The patent optimizes the content of the monofunctional monomer within the range of 5-50 parts by mass relative to 100 parts by mass of the polyfunctional monomer. This parameter control ensures sufficient monofunctional monomer is present to complete photopolymerization and eliminate weak points, thereby achieving the fracture toughness required for practical usability
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 composition achieves excellent flexural strength, flexural modulus, and fracture toughness in stereolithographically produced dental prostheses, making them suitable for practical use and improving the production process.
Implementation Method 1
a photocurable composition comprising: a (meth)acrylic monomer component comprising: a (meth)acrylic monomer (X) that is at least one selected from di(meth)acrylic monomers not containing, within one molecule, a hydroxyl group or a carboxy group and containing, within one molecule, two aromatic rings and two (meth)acryloyloxy groups
Data Source
AI summary
The present invention provides: a photocurable composition including a monomer component that includes: a monomer (X) containing, within one molecule, two aromatic rings and two (meth)acryloyloxy groups, and having an Mw of from 400 to 580, and a monomer (H) containing, within one molecule, at least one of a hydroxyl group or a carboxy group, and a (meth)acryloyloxy group, and having an Mw of from 100 to 700; as well as a photopolymerization initiator. The above described photocurable composition has a functional group value (a), as defined below, of from 0.5 × 10-3 to 2.0 × 10-3 mol/g. functional group value a=nH/MH×PH In the above Formula, nH represents the total number of hydroxyl groups and carboxy groups contained in one molecule of the (meth)acrylic monomer (H); MH represents the MW of the (meth)acrylic monomer (H); and PH represents the mass ratio of the (meth)acrylic monomer (H) with respect to the total amount of the (meth)acrylic monomer component.