Polyurethane Dimethacrylate Dental Composites for Toughness
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Solution Overview
Problem
Current dental restorative materials, such as PMMA and Bis-acrylic resins, face issues like cytotoxicity, exothermic reactions, shrinkage, brittleness, and poor marginal fit, which affect the durability and aesthetic quality of provisional restorations.
Innovation Solution
A radically curable polyurethane dimethacrylate composite is developed, incorporating flexible units like hydrogenated polybutadiene diol and polyether diol within a polyurethane dimethacrylate backbone, along with dimethacrylate monomers and a photoinitiator system, to enhance toughness, flexibility, and aesthetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional dental resins (PMMA, Bis-acrylic) are used, then ease of manufacture and cost-effectiveness are maintained, but brittleness and poor marginal fit occur
Solution Approach 1:
The patent applies composite materials by combining polyurethane dimethacrylate prepolymers with flexible units (hydrogenated polybutadiene diol, polyether diol) and dimethacrylate monomers in a multi-component resin system. This composite approach integrates the high toughness and flexibility of polyurethane chains with the curing characteristics of dimethacrylate monomers, achieving superior mechanical properties while maintaining manufacturability through a systematic formulation process.
Solution Approach 2:
The patent employs parameter changes by modifying the chemical composition parameters of the resin system - specifically incorporating flexible units at defined concentrations (5-45% by weight) and adjusting the ratio of prepolymer to monomer. These parameter adjustments transform the material from conventional brittle resins to tough, flexible composites that maintain ease of manufacture through controlled formulation.
2Strength
If high filler loading is used, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses parameter changes to optimize the filler loading range (50-85% by weight) and control the viscosity-moisture relationship through adjusted prepolymer-to-monomer ratios. This allows high filler content that enhances strength while maintaining manageable formulation complexity through systematic parameter control.
3Reliability
If conventional resins are used, then ease of operation is maintained, but shrinkage and exothermic reactions occur
Solution Approach 1:
The patent converts the potential harm of exothermic reactions into a benefit by controlling the polymerization kinetics through the specific combination of prepolymer and monomer. The flexible units and controlled curing sequence allow heat generation to be managed, reducing polymerization shrinkage and exothermic effects while maintaining ease of operation through predictable setting behavior.
4Strength
If flexible units are incorporated, then toughness and flexibility are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by establishing specific concentration ranges for flexible units (5-45% by weight) and prepolymer-to-monomer ratios. These controlled parameters enable the achievement of superior flexural strength and toughness while maintaining manufacturing precision through standardized formulation protocols.
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 composite material exhibits superior hardness, toughness, and flexural strength while maintaining aesthetic appeal, reducing shrinkage and exothermic reactions, and providing improved marginal fit and durability compared to conventional dental resins.
Implementation Method 1
radically curable polyurethane dimethacrylate prepolymers... incorporating flexible units... along with dimethacrylate monomers and a photoinitiator system
Data Source
AI summary
A radically curable polyurethane composite for dental restorations, including provisional restorations, includes polyurethane dimethacrylate prepolymers that have at least one flexible unit within a polyurethane dimethacrylate backbone, and one or more dimethacrylate monomers. Composite materials made with polyurethane dimethacrylate prepolymers of the invention exhibit superior and optimal properties of flexural strength and deflection-at-break relative to conventional dental resin composites. Composite materials of the invention also provide improved melt-resistance in response to the heat of grinding or finishing, thereby improving the fit of restorations made from the composite and preserving the finishing instruments. Methods of treating a tooth using the radically curable polyurethane composite and methods of making the polyurethane dimethacrylate prepolymers with flexible units is also provided. A kit including the radically curable polyurethane composite is also described.