Sintering Support With Stabilized Zirconia Surface
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Solution Overview
Problem
Existing sintering processes for indirect dental ceramic restorations often result in poor fit and discoloration due to adhesion and contamination issues with conventional sintering supports, such as aluminum oxide pegs and zirconia beads.
Innovation Solution
A sintering support with a fully stabilized zirconia outer surface is developed by coating a zirconia base with a precursor stabilizing element, such as calcium, magnesium, or rare earth oxides, and sintering at high temperatures to create a surface that does not adhere to or contaminate ceramic parts during the sintering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sintering supports (aluminum oxide pegs, platinum alloy hangers, ceramic beads) are used, then the ceramic restoration can be supported during sintering, but adhesion and contamination occur causing poor fit and discoloration
Solution Approach 1:
The patent changes the chemical composition parameters of the sintering support by incorporating specific stabilizing elements (yttria, alumina, silica) in controlled amounts. This chemical parameter modification transforms the support material to have non-adhesive properties while maintaining structural stability during sintering, thereby preventing contamination of the ceramic restoration.
Solution Approach 2:
The invention uses composite material structure combining zirconia base with stabilizing elements (yttria, alumina, silica). This composite approach creates a multi-phase material where the stabilizing elements prevent adhesion to the ceramic restoration while the zirconia matrix provides structural support, resolving the contradiction between support stability and contamination prevention.
2Object-affected harmful factors
If the sintering support is made of fully stabilized zirconia with stabilizing elements, then adhesion and contamination are prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-coating the zirconia base with stabilizing element precursors before sintering. This preliminary surface treatment ensures that the stabilizing elements are readily available to form the non-adhesive surface layer during sintering, simplifying the overall process compared to requiring complex multi-step manufacturing.
Solution Approach 2:
The invention applies local quality by concentrating the stabilizing elements specifically on the outer surface of the zirconia base where adhesion prevention is most critical, rather than uniformly throughout the entire material. This localized approach reduces manufacturing complexity while achieving the desired non-adhesive property.
3Object-affected harmful factors
If the outer surface is coated with precursor of stabilizing element and sintered at high temperature, then a fully stabilized zirconia surface is formed that does not adhere to ceramic parts, but energy consumption increases
Solution Approach 1:
The patent modifies the chemical composition parameters by adding stabilizing elements that enable the zirconia to be sintered at optimized temperatures. These stabilizing elements facilitate phase transformation and stabilization at lower temperatures compared to pure zirconia, reducing the energy input required while achieving the desired non-adhesive surface.
Solution Approach 2:
The stabilizing element precursors are applied as thin surface coatings rather than bulk materials, representing a minimal investment of material and energy. The precursor layer is consumed during sintering to form the stabilized surface, providing a cost-effective solution that prevents adhesion without requiring excessive energy input.
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 solution prevents adhesion and contamination, allowing for accurate fit and preventing discoloration of ceramic restorations, enabling the production of dental restorations with improved fit and appearance.
Implementation Method 1
evaporating the solvent to provide the zirconia base having the outer surface coated with the precursor of the at least one stabilizing element
Implementation Method 2
sintering the zirconia base having the outer surface coated with the precursor of the at least one stabilizing element at a temperature of at least 1200 °C to provide a sintering support having a fully stabilized zirconia outer surface
Implementation Method 3
sintering the zirconia base... at a temperature of at least 1200 °C
Data Source
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AI summary
A sintering support comprising a fully stabilized zirconia outer surface; wherein the sintering support withstands sintering a ceramic part in contact with the outer surface without adhesion between the outer surface and the ceramic part, and methods of making and using the sintering support are disclosed.