JP2016527017A - 酸化物セラミックの焼結動力学の制御 - Google Patents
酸化物セラミックの焼結動力学の制御 Download PDFInfo
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- JP2016527017A JP2016527017A JP2016528477A JP2016528477A JP2016527017A JP 2016527017 A JP2016527017 A JP 2016527017A JP 2016528477 A JP2016528477 A JP 2016528477A JP 2016528477 A JP2016528477 A JP 2016528477A JP 2016527017 A JP2016527017 A JP 2016527017A
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- oxide ceramic
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- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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- A61C13/00—Dental prostheses; Making same
- A61C13/0003—Making bridge-work, inlays, implants or the like
- A61C13/0022—Blanks or green, unfinished dental restoration parts
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
- A61K6/00—Preparations for dentistry
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- B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
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Abstract
Description
HV2.5が、ISO14705:2008に従って2.5kgf(24.517N)の荷重で測定されるビッカース硬さであり;
HVmaxが、HV2.5の測定値の最大値であり;
HVminが、HV2.5の測定値の最小値であり;
予備焼結済み多層酸化物セラミックブランクによって解決される。
本発明によるブランクは、最終的な焼結ステップ中に歪みを示さないか、または本質的に歪みを示さないことが意外にも判明した。特に、これらは、異なる層間の焼結動態または収縮挙動の著しい差異を欠点として持たない。さらに、標準的なISO14705:2008に従ったビッカース硬さの測定値は、予備焼結済み多層ブランク内の異なる位置の焼結挙動を特定および予測するのに適していることが予想外にも判明した。
Y2O3 2.0〜10.0wt.%、特に4.5〜6.0wt.%;
HfO2 最大で5.0wt.%;
Al2O3 最大で0.5wt.%;
SiO2 最大で0.1wt.%;および
Na2O 最大で0.1wt.%。
HV2.5が、ISO14705:2008に従って2.5kgf(24.517N)の荷重で測定されるビッカース硬さであり;
HVmaxが、HV2.5の測定値の最大値であり;
HVminが、HV2.5の測定値の最小値であり;
多層酸化物セラミック未焼結体も提供する。
(a)少なくとも第1の酸化物セラミック材料および第2の酸化物セラミック材料を準備するステップであり、第1の酸化物セラミック材料および第2の酸化物セラミック材料が、焼結挙動の観点において異なる、ステップと、
(b)第1の酸化物セラミック材料の焼結挙動を第2の酸化物セラミック材料の焼結挙動に対して調整するように酸化物セラミック材料の少なくとも1種を適応させるステップと
を含む。
(c)酸化物セラミック材料の層を形成し、互いの上に層を配列するステップ、または第1の酸化物セラミック材料から第2の酸化物セラミック材料への連続的な勾配を含む酸化物セラミック材料の層を形成するステップと;
(d)酸化物セラミック材料を、任意選択で締め固め、特に圧縮して、未焼結体を得るステップと;
(e)酸化物セラミック材料を、任意選択で予備焼結して、予備焼結済みセラミックブランクを得るステップ
を含む。
酸化物粉末上にコーティングされる元素の適当な量の水溶性塩および0.1〜2wt.%(コーティングされる粉末の量と比べて)のポリビニルアルコール(例えば、Zschimmer&Schwarz社製Optapix PAF2またはPAF35)などの水溶性結合剤を含有する水溶液を、約0.5時間撹拌することによって(例えば、磁気撹拌機を使用して)ホモジナイズした。得られた溶液を、流動床造粒機によって酸化物粉末上に完全に塗布した。このステップ中、粉末を、圧縮空気(0.15〜0.30バール、30〜80℃)によって流動床として懸濁液中に維持し、この流動床の上に配列されたノズルを通して2〜6バールの吹き付け圧力で吹き付けることによって、着色液を粉末に塗布した。加熱された圧縮空気は、プロセス中にコーティングされた粉末を同時に乾燥させた。
着色または無着色粉末にドーパント(すなわち、非着色焼結助剤または焼結阻害剤)を添加することによる収縮性の制御:
2)3wt.%のY2O3および0.25wt.%のAl2O3を含む
ドープされた酸化物セラミック粉末を使用する予備焼結済み多層酸化物セラミックブロック
最大で300℃まで0.25K/分、維持時間60分
最大で500℃まで0.25K/分
最大で1120℃まで1K/分、維持時間120分。
歪みの係数の決定
実施例2Aおよび2Bで得られたタイプAおよびBの予備焼結済みブロックの複数の測定点で、ビッカース硬さHV2.5(0.5〜1.0GPa)を測定した。測定点の位置を図3に概略的に示す。図中、zは、異なる層が配列されている次元である。結果を以下の表に示す。
ドープされた酸化物セラミック粉末を使用する完全に焼結された多層酸化物セラミックブロック
(比較)
二重層ブロック(29mm×4.6mm×5.8mm)を、一方が以下の表に示した一般的な手順を使用して着色元素でコーティングされた、2種の異なる原料ジルコニア粉末に由来する酸化物粉末から調製した。
2)0.05wt.%のAl2O3を含む、比表面積 約13m2/g
3)0.25wt.%のAl2O3を含む;比表面積 約7m2/g
最大で300℃まで0.25K/分、維持時間120分
最大で500℃まで0.25K/分
最大で700℃まで0.5K/分、維持時間120分
最大で1050℃まで1K/分、維持時間120分
二つの層を含み、白色の、濃淡を付けられた4ユニットモノリシックブリッジをシミュレートする四つの細長い矩形ブロック(46mm×7.5mm×5.8mm)を、以下の表のように配合されたY−TZPジルコニア粉末から製作した。粉末の二つの層を、層間の適度に平らな界面を保証するための振動台上の単純な鋼チャネル金型中に順次注ぎ、約18MPaの圧力を使用して一軸性に締め固めた。得られた一軸性に予備加圧成形された未焼結コンパクトを、ラテックスバッグ中に真空密封し、約345MPaでさらに冷間等方圧加圧成形し、1500℃で2時間最終的に焼結した。歪み/湾曲の非存在または存在についての目視観察を以下の表に要約する。
2)0wt.%のFe2O3を含む;比表面積 約7m2/g
3)0.14wt.%のFe2O3を含む;比表面積 約13m2/g
4)0.19wt.%のFe2O3を含む;比表面積 約7m2/g
異なる予備緻密化がなされた粉末の焼結挙動
ジルコニアセラミック粉末のサンプル(KCM KZ−3YF(SD)AC)を、100、150、200、および250MPaの圧力で冷間一軸加圧成形し、500℃で脱結合させた。得られた緻密化された粉末を、950〜1150℃の温度範囲にわたって、最大で900℃まで5K/分および最大で1150℃まで1K/分の加熱速度で熱処理に付した。温度の関数としての相対的な収縮のプロットを図7に示す。この図から分かるように、酸化物セラミック粉末の焼結挙動を、前記粉末を異なる程度の部分的な緻密化に付すことによって適応させることができる。異なる層中で使用される粉末を異なる程度の部分的な緻密化に付すことによって、所与の焼結温度でのこれらの線収縮を等しくすることができ、その結果、これらの粉末から作製される多層ブロックは、予備焼結状態または高密度焼結状態で歪みを示さない。
Claims (26)
- 歯科修復物を製造するための予備焼結済み多層酸化物セラミックブランクであって、
前記ブランクは少なくとも二つの異なる層を含み、歪みの係数
式中、HV2.5が、ISO14705:2008に従って2.5kgf(24.517N)の荷重で測定されるビッカース硬さであり;
HVmaxが、HV2.5の測定値の最大値であり;
HVminが、HV2.5の測定値の最小値であり;
ブランク。 - マルチユニット歯科修復物、好ましくは二つまたはそれより多くのユニットに及ぶ歯科修復物、特に、二つまたはそれより多くのユニットに及ぶブリッジの製造に適している、請求項1に記載のブランク。
- 前記少なくとも二つの異なる層が、化学組成の観点において異なり、好ましくは異なる色を有する、請求項1または2に記載のブランク。
- 前記酸化物セラミックが、ジルコニア、好ましくは安定化正方晶ジルコニア多結晶に基づく、請求項1から3のいずれか一項に記載のブランク。
- 前記歪みの係数が、前記ブランクの外表面上の前記異なる層を横切る第1の線に沿って一定の間隔で分布している測定点、および、好ましくは、前記ブランクを切断することによってアクセス可能にされた前記ブランクの中心における表面上の前記第1の線に平行な第2の線に沿って一定の間隔で分布している追加の測定点での、HV2.5の測定に基づいて計算される、請求項1から4のいずれか一項に記載のブランク。
- 前記第1および第2の線に沿った前記測定点間の前記一定の間隔が、5mm以下である、請求項5に記載のブランク。
- 歯科修復物を製造するための多層酸化物セラミック未焼結体であって、前記多層酸化物セラミック未焼結体は、少なくとも二つの異なる層を含み、歪みの係数
式中、HV2.5が、ISO14705:2008に従って2.5kgf(24.517N)の荷重で測定されるビッカース硬さであり;
HVmaxが、HV2.5の測定値の最大値であり;
HVminが、HV2.5の測定値の最小値であり;
多層酸化物セラミック未焼結体。 - 少なくとも二つの異なる層を含む、歯科修復物を製造するための多層酸化物セラミック体であって、前記少なくとも二つの異なる層の焼結挙動が、前記セラミック体が歪みを伴うことなく焼結されることを可能にするように調整されている、多層酸化物セラミック体。
- 歪みを伴うことなく焼結され得る、少なくとも二つの異なる層を有する多層酸化物セラミック体を製造するためのプロセスであって、前記異なる層の焼結挙動を調整するステップを含む、プロセス。
- 前記体が、マルチユニット歯科修復物、好ましくは二つまたはそれより多くのユニットに及ぶ歯科修復物、特に、二つまたはそれより多くのユニットに及ぶブリッジの製造に適している、請求項9に記載のプロセス。
- 前記少なくとも二つの異なる層が、化学組成の観点において異なり、好ましくは異なる色を有する、請求項9または10に記載のプロセス。
- (a)少なくとも第1の酸化物セラミック材料および第2の酸化物セラミック材料を準備するステップであって、前記第1の酸化物セラミック材料および前記第2の酸化物セラミック材料が、焼結挙動の観点において異なる、ステップと;
(b)前記第1の酸化物セラミック材料の焼結挙動を前記第2の酸化物セラミック材料の焼結挙動に対して調整するように前記酸化物セラミック材料の少なくとも1種を適応させるステップと
を含む、請求項9から11のいずれか一項に記載のプロセス。 - 前記焼結挙動が、850〜1350℃、特に900〜1200℃、好ましくは950〜1150℃、より好ましくは1000〜1100℃の範囲内の温度、最も好ましくは約1100℃の温度での焼結の際の相対的な線収縮である、請求項12に記載のプロセス。
- ステップ(a)において、前記第1の酸化物セラミック材料の焼結挙動および前記第2の酸化物セラミック材料の焼結挙動が、少なくとも0.15%、特に少なくとも0.25%、好ましくは少なくとも0.5%、より好ましくは1.0%超異なる、請求項12または13に記載のプロセス。
- ステップ(b)において、前記適応させるステップが、0.15%未満、特に0.10%未満、好ましくは0.05%未満異なる、前記第1の酸化物セラミック材料の焼結挙動および前記第2の酸化物セラミック材料の焼結挙動をもたらす、請求項12から14のいずれか一項に記載のプロセス。
- (c)前記酸化物セラミック材料の層を形成し、互いの上に前記層を配列するステップ、または前記第1の酸化物セラミック材料から前記第2の酸化物セラミック材料への連続的な勾配を含む前記酸化物セラミック材料の層を形成するステップと;
(d)前記酸化物セラミック材料を、任意選択で締め固め、特に圧縮して、未焼結体を得るステップと;
(e)前記酸化物セラミック材料を、任意選択で予備焼結して、予備焼結済みセラミックブランクを得るステップと
をさらに含む、請求項12から15のいずれか一項に記載のプロセス。 - 前記酸化物セラミック材料の少なくとも1種を適応させるステップが、前記酸化物セラミック材料中にドーパントを組み込むことを含む、請求項12から16のいずれか一項に記載のプロセス。
- 前記ドーパントが、焼結助剤、特にAl2O3、および焼結阻害剤、特にY2O3から選択される、請求項17に記載のプロセス。
- 前記酸化物セラミック材料の少なくとも1種を適応させるステップが、前記酸化物セラミック材料の少なくとも一部の一次および/もしくは二次粒子サイズならびに/または比表面積を変更することを含む、請求項12から18のいずれか一項に記載のプロセス。
- 前記酸化物セラミック材料の少なくとも1種を適応させるステップが、前記酸化物セラミック材料を異なる程度の部分的な緻密化に付すことを含む、請求項12から19のいずれか一項に記載のプロセス。
- 請求項9から20のいずれか一項に記載のプロセスによって得ることが可能な多層酸化物セラミック体。
- 請求項1から6のいずれか一項に記載のブランク、請求項7に記載の未焼結体、または請求項8もしくは21に記載のセラミック体を使用するステップを含む、歯科修復物を製造するためのプロセス。
- 成形セラミック製品を得るために前記ブランクまたは体を所望の幾何形状に成形するステップを含む、請求項22に記載のプロセス。
- 前記成形ステップが、機械加工によって、好ましくはCAD/CAMプロセスを使用して実施される、請求項22または23に記載のプロセス。
- 前記成形セラミック製品が、歯科用フレームワーク、アバットメント、またはモノリシック全輪郭歯科修復物、特に、マルチユニット歯科修復物の形状を有する、請求項23または24に記載のプロセス。
- 前記成形セラミック製品を高密度に焼結するステップをさらに含む、請求項22から25のいずれか一項に記載のプロセス。
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US11413122B2 (en) | 2022-08-16 |
CA3084630A1 (en) | 2015-01-29 |
CA2917378C (en) | 2017-07-11 |
CA3084630C (en) | 2022-11-22 |
US20190099245A1 (en) | 2019-04-04 |
CA2952770C (en) | 2020-07-21 |
KR20160033141A (ko) | 2016-03-25 |
CA2952770A1 (en) | 2015-01-29 |
EP2829251A1 (en) | 2015-01-28 |
KR101851881B1 (ko) | 2018-04-26 |
CN107573035A (zh) | 2018-01-12 |
US20160157971A1 (en) | 2016-06-09 |
JP6393328B2 (ja) | 2018-09-19 |
WO2015011079A1 (en) | 2015-01-29 |
CA2917378A1 (en) | 2015-01-29 |
CN105392444A (zh) | 2016-03-09 |
CN105392444B (zh) | 2017-10-31 |
CN107573035B (zh) | 2020-12-01 |
EP2829251B1 (en) | 2019-04-10 |
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