Multi-Layer Artificial Teeth Blank Injection Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing artificial teeth blanks with multiple color layers result in unnatural color transitions due to visible separating lines and are time-consuming and costly, with prior processes failing to achieve a homogeneous color gradient.
Innovation Solution
A method using multi-component injection molding where a first thermoplastic layer with a specific pigmentation is molded in an injection mold, followed by a second layer of the same thermoplastic with lighter pigmentation, allowing the layers to combine and mix for a homogeneous color transition, eliminating visible dividing lines and reducing production time by eliminating subsequent processing steps like sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple colored materials are layered into a mold and pressed to create artificial teeth blanks, then the blanks exhibit different color layers, but visible dividing lines appear between layers resulting in unnatural color transitions
Solution Approach 1:
The patent changes the physical state parameter of the material from solid to viscous state during the molding process. By injecting thermoplastic material in a viscous state that has not yet solidified, subsequent layers can intermix at the boundaries, eliminating visible dividing lines and creating homogeneous color transitions while maintaining manufacturing simplicity
Solution Approach 2:
The patent uses composite materials by combining multiple thermoplastic materials with different pigments in a single molding process. The materials are injected in sequence while in viscous state, allowing them to bond and mix at interfaces, creating a composite structure with continuous color gradients without visible layer boundaries
2Manufacturing precision
If pressing and heating processes are used to blend adjacent color layers, then color transitions are attempted to be made continuous, but the transitions remain visible and the process becomes time-consuming
Solution Approach 1:
The patent performs the blending action preliminarily by injecting all layers in viscous state before solidification occurs. The intermixing of colors happens during the injection process itself rather than requiring subsequent heating and blending steps, significantly reducing production time while achieving homogeneous color transitions
Solution Approach 2:
The patent utilizes phase transition by controlling the material to remain in viscous state during injection and layering, then allowing solidification after the layers are in place. This reverse approach—maintaining fluidity during the critical blending phase rather than using heat after solidification—eliminates the need for time-consuming post-processing while achieving continuous color gradients
3Manufacturing precision
If multiple processing steps including sintering are used to create multicolored blanks, then color layers can be formed, but the process becomes expensive and time-consuming
Solution Approach 1:
The patent merges multiple processing steps into a single injection molding operation. By injecting thermoplastic material in viscous state and allowing layers to intermix during the injection process itself, the patent combines what would otherwise require separate sintering, heating, and blending steps into one efficient process, dramatically improving productivity while maintaining color layer quality
Solution Approach 2:
The patent replaces complex mechanical processing steps (sintering, heating, blending) with a simplified injection molding process. By utilizing the viscous flow properties of thermoplastic material during injection, the system achieves color layer formation and blending through fluid dynamics rather than requiring subsequent thermal and mechanical processing steps
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 method produces artificial teeth blanks with a natural appearance and simplified manufacturing, achieving a homogeneous color transition without visible dividing lines and reducing production time and costs.
Implementation Method 1
a first plastic layer with a first pigmentation is injected into a first cavity of an injection mold
Implementation Method 2
the adjacent layers of material bond and mix, resulting in a homogeneous color transition
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a method for producing a blank for artificial teeth consisting of plastic, said blank comprising a plurality of different coloured layers and being introduced into a mould under pressure. The blank consists of a thermoplastic material and is produced in a multi-component injection-moulding method. A first plastic layer with a first pigmentation is introduced into a first cavity in an injection mould, and at least one further plastic layer consisting of the same plastic but having a lighter pigmentation than the first plastic layer is introduced into at least one second cavity in said injection mould. Such a blank comprises a first plastic layer with a first pigmentation, and a further plastic layer consisting of the same plastic but with a lighter pigmentation than that of the first plastic layer.