Zirconia Denture Teeth Wear Resistance via Sintering
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Solution Overview
Problem
Conventional denture manufacturing methods face challenges in achieving a natural bite feel due to inconsistent sizing and rapid wear of plastic teeth, leading to discomfort and potential fracture, while metal occlusal inserts compromise aesthetics.
Innovation Solution
The method involves creating a first denture with a wax or acrylic base and polymer teeth, electronically storing its shape and size, discarding the polymer teeth, and replacing them with custom-sized and shaped zirconia teeth to form a second denture that approximates the desired parameters, ensuring a natural bite feel and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic teeth are used in conventional dentures, then ease of manufacture and aesthetics are improved, but wear resistance and durability deteriorate
Solution Approach 1:
The patent changes the material parameter from plastic to zirconia, transforming the teeth from a molded, wear-prone material to a sintered, highly durable ceramic material that maintains aesthetic properties while dramatically improving wear resistance and durability
Solution Approach 2:
The patent uses zirconia, a ceramic composite material, to create denture teeth that combine the aesthetic qualities needed for natural appearance with superior mechanical properties including extreme hardness and wear resistance, resolving the contradiction between ease of manufacture and reliability
2Ease of manufacture
If plastic teeth are used in conventional dentures, then manufacturing simplicity is improved, but dimensional consistency and precision deteriorate
Solution Approach 1:
The patent replaces the mechanical molding process with a sintering process, where zirconia teeth are formed through controlled sintering of zirconia powder in a mold, allowing for precise dimensional control and consistency that cannot be achieved through conventional plastic molding
Solution Approach 2:
The patent changes the manufacturing parameter from room-temperature molding to high-temperature sintering, which enables precise dimensional control and eliminates the wear and dimensional inconsistency problems associated with repeated use of plastic molds
3Reliability
If metal occlusal inserts are used to improve wear resistance, then durability is improved, but aesthetics deteriorate
Solution Approach 1:
The patent uses zirconia, a white ceramic material, that can be aesthetically matched to natural teeth while providing metal-level durability and wear resistance, eliminating the need for visible metal inserts and resolving the contradiction between durability and aesthetics
Solution Approach 2:
The patent applies zirconia material properties locally to the occlusal surfaces of the teeth, providing enhanced wear resistance exactly where needed for chewing functions while maintaining the aesthetic appearance of the visible tooth surfaces
Data Source
AI summary
The present invention to a method of denture manufacture that incorporates CAM-formed zirconia teeth or zirconia tooth segment members, resulting in a natural fit, feel, and wear essentially equivalent to the wear properties of natural teeth, with wear and durability properties superior to dentures known in the art.