Zirconia Block Color Gradient via Layered Powder Mixing
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Solution Overview
Problem
Current methods for manufacturing zirconia blocks for artificial teeth require complex processes like pigment treatment and surface treatment to achieve color gradients similar to natural teeth, often using porcelain powder or liquid color sets, which are time-consuming and prone to color changes.
Innovation Solution
A method involving the preparation of colored and white zirconia-based powders mixed in varying ratios, sequentially injected into a mold with pressure application and calcination, allowing for a color gradient within the zirconia block without external colorants, utilizing organic binders and a de-binding process to achieve a uniform density and desired color gradient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If several complex processes such as pigment treatment and surface treatment are used after zirconia block processing to express natural tooth colors, then the aesthetic function is improved, but the manufacturing time increases and productivity decreases
Solution Approach 1:
The color gradient is incorporated into the zirconia block during the initial mixing and molding stages, before the actual tooth fabrication process. By preparing multiple raw materials with different colored zirconia powder concentrations in advance and stacking them sequentially, the patent eliminates the need for subsequent pigment treatment and surface treatment processes, thereby reducing manufacturing time while achieving natural tooth aesthetics
Solution Approach 2:
The patent combines the coloration process with the zirconia block formation process itself. Instead of treating color application as a separate subsequent step, the colored and white zirconia powders are mixed in varying ratios and molded together to form a single integrated block with inherent color gradient, merging two previously separate operations into one
2Shape
If several complex processes such as pigment treatment and surface treatment are used after zirconia block processing to express natural tooth colors, then the aesthetic function is improved, but the process complexity increases
Solution Approach 1:
The color gradient structure is established in advance during raw material preparation by mixing colored and white zirconia powders in different ratios. This preliminary configuration of color layers within the raw materials eliminates the need for complex subsequent pigment application and surface treatment processes, simplifying the overall manufacturing workflow
Solution Approach 2:
The zirconia block is divided into multiple raw materials with different color concentrations (colored zirconia-based powder mixed with white zirconia-based powder in varying ratios). These segmented raw materials are then stacked in a specific sequence during molding to create the final color gradient, breaking down the complex coloration task into manageable discrete components
3Shape
If porcelain powder or liquid color set is used to express natural tooth colors, then the aesthetic function is improved, but the reliability decreases due to color changes
Solution Approach 1:
The patent changes the fundamental parameter of color application from external coating (porcelain powder or liquid color set) to internal composition (colored zirconia powder mixed with white zirconia powder). By varying the concentration ratio of colored to white powder within the zirconia matrix itself, the color gradient is inherently built into the material structure, ensuring color consistency without the reliability issues of external colorants
Solution Approach 2:
The patent creates a composite zirconia material system combining colored zirconia-based powder and white zirconia-based powder in different ratios. This composite approach allows the color gradient to be an intrinsic property of the material composition rather than a surface treatment, improving color stability and eliminating the need for separate porcelain or liquid color applications
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 enables the creation of zirconia blocks with a natural tooth color gradient, reducing manufacturing time by 30% and ensuring consistent color, enhancing patient satisfaction by eliminating the need for additional treatments and minimizing color change concerns.
Implementation Method 1
applying a pressure to the compression mold into which the plurality of raw materials are injected to mold
Implementation Method 2
performing a cold isostatic pressing (CIP) process in order to maintain a uniform internal density distribution of the molding result before the calcining
Implementation Method 3
calcining a molding result
Data Source
AI summary
There is provided a method of manufacturing a zirconia block for an artificial tooth having a color gradient. The method includes: preparing colored zirconia-based powder and white zirconia-based powder; preparing a plurality of raw materials in which the colored zirconia-based powder and the white zirconia-based powder are mixed in different weight ratios by mixing the colored zirconia-based powder and the white zirconia-based powder while changing a mixing ratio in order to express a desired color gradient; sequentially injecting the plurality of raw materials into a compression mold or a mold frame to mold in increasing or decreasing order of content of the colored zirconia-based powder of the raw material; and calcining a molding result. According to the present invention, it is possible to express aesthetics of a natural tooth by implementing a color gradient of the natural tooth in the zirconia block itself without using porcelain powder or a liquid color set.