Silicate Glass-Ceramic Bonding Layer for Dental Prosthesis
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Solution Overview
Problem
Existing dental prosthesis manufacturing methods face challenges in achieving a strong and aesthetically pleasing metal-ceramic bond, as conventional adhesives cannot withstand firing temperatures, limiting the ability to make adjustments to the ceramic veneer after initial bonding.
Innovation Solution
A method involving a metallic framework with a titanium or titanium alloy content over 80% by weight, a ceramic veneer with zirconium dioxide as the main component, and a joining layer composed of more than 60% silicon dioxide and less than 12% aluminum oxide, allowing for joint firing and subsequent application of additional ceramic layers without detachment, using a silicate glass ceramic joining layer that withstands firing temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional composite adhesives are used to bond the ceramic veneer to the metallic framework, then the bonding process is simple and quick, but the adhesive cannot withstand firing temperatures, preventing subsequent ceramic adjustments
Solution Approach 1:
The bonding layer undergoes a parameter change from organic adhesive to inorganic glass-ceramic material that can withstand high temperatures. The bonding layer is initially applied as a precursor material and then transformed through firing into a temperature-resistant glass-ceramic that maintains bond strength at firing temperatures up to 900°C, enabling subsequent ceramic adjustments.
Solution Approach 2:
The bonding layer experiences a phase transition during the firing process, transforming from an organic adhesive precursor into an inorganic glass-ceramic structure. This phase transition occurs at temperatures between 600-900°C, where the organic components are consumed and an inorganic glass-ceramic matrix forms, providing temperature resistance while maintaining bonding functionality.
2Manufacturing precision
If manual ceramic layering technique is used to create the initial veneer on the metal, then aesthetic quality can be achieved, but the process requires considerable skill and time
Solution Approach 1:
The bonding layer is applied as a precursor material in advance, before the ceramic veneer is attached. This preliminary bonding layer provides a stable foundation that allows the ceramic veneer to be securely attached and subsequently adjusted through multiple firing cycles without compromising the bond, thereby reducing the need for highly skilled manual layering techniques.
Solution Approach 2:
The bonding layer is formulated as a composite material containing glass-forming oxides (SiO2, B2O3, P2O5) and ceramic-forming oxides (Al2O3, ZrO2) that combines the advantages of both organic adhesives (initial bonding capability) and inorganic ceramics (temperature resistance). This composite structure enables simplified manufacturing processes while maintaining high aesthetic quality.
3Adaptability or versatility
If additional ceramic layers are applied after initial bonding, then aesthetic adjustments can be made, but conventional adhesives detach under firing temperatures
Solution Approach 1:
The bonding layer's chemical composition and physical properties change during firing, transforming from an organic adhesive precursor into a temperature-resistant glass-ceramic. This parameter change enables the bonding layer to withstand firing temperatures up to 900°C while maintaining bond strength, allowing multiple ceramic layers to be applied and fired without detachment.
Solution Approach 2:
The bonding layer maintains its bonding function continuously through the entire firing process and subsequent ceramic adjustments. Unlike conventional adhesives that fail at high temperatures, the glass-ceramic bonding layer preserves its cohesive and adhesive properties throughout multiple firing cycles, ensuring continuous bond strength from initial attachment through final aesthetic adjustments.
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 ensures a strong, cohesive connection between the metallic framework and ceramic veneer, enabling multiple firing processes and allowing for aesthetic adjustments without compromising the bond, thereby improving the durability and appearance of dental prostheses.
Implementation Method 1
the bonding layer creates a metallurgical bond between the metallic framework and the ceramic veneer
Implementation Method 2
joint firing of the metallic framework, the bonding layer, and the ceramic veneer
Implementation Method 3
the bonding layer consists of more than 60 wt.% silicon dioxide and less than 12 wt.% aluminum oxide
Implementation Method 4
using a silicate glass ceramic joining layer that withstands firing temperatures
Data Source
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Figure 2i~2vi
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AI summary
Method for manufacturing a dental prosthesis (Z), in particular a crown, bridge or bar, comprising the steps of: - manufacturing a metallic framework (1), - manufacturing a ceramic veneer (3), - applying at least one bonding layer (2) to the metallic framework (1) and/or to the ceramic veneer (3), - applying the ceramic veneer (3) to the metallic framework (1), wherein the bonding layer (2) is arranged between the metallic framework (1) and the ceramic veneer (3), and firing the metallic framework (1), the bonding layer (2) and the ceramic veneer (3) together, whereby the bonding layer (2) connects the metallic framework (1) to the ceramic veneer (3) in a metallurgical bond.