US20050040551A1 - Hardenable dental article and method of manufacturing the same - Google Patents

Hardenable dental article and method of manufacturing the same Download PDF

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Publication number
US20050040551A1
US20050040551A1 US10/643,749 US64374903A US2005040551A1 US 20050040551 A1 US20050040551 A1 US 20050040551A1 US 64374903 A US64374903 A US 64374903A US 2005040551 A1 US2005040551 A1 US 2005040551A1
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US
United States
Prior art keywords
hardenable dental
dental article
mold cavity
liner
hardenable
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/643,749
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English (en)
Inventor
Robert Biegler
Kevin Cummings
Lance Gore
Naimul Karim
James Kvitrud
Darin Meyertholen
Robert Peterson
Daniel Scott
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Innovative Properties Co
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US10/643,749 priority Critical patent/US20050040551A1/en
Assigned to 3M INNOVATIVE PROPERTIES COMPANY reassignment 3M INNOVATIVE PROPERTIES COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BIEGLER, ROBERT M., CUMMINGS, KEVIN M., GORE, LANCE C., KARIM, NAIMUL, KVITRUD, JAMES R., MEYERTHOLEN, DARIN J., PETERSON, ROBERT W., SCOTT, DANIEL T.
Priority to PCT/US2004/026634 priority patent/WO2005018483A2/en
Priority to AT04781639T priority patent/ATE519448T1/de
Priority to EP04781639A priority patent/EP1663053B1/en
Priority to US10/921,648 priority patent/US7811486B2/en
Priority to PCT/US2004/026991 priority patent/WO2005018484A2/en
Priority to AU2004266716A priority patent/AU2004266716B2/en
Priority to EP10173717A priority patent/EP2258305A1/en
Priority to EP10182767A priority patent/EP2305165A2/en
Priority to JP2006524058A priority patent/JP4745232B2/ja
Priority to CNA2004800238724A priority patent/CN1838923A/zh
Priority to CA002535928A priority patent/CA2535928A1/en
Publication of US20050040551A1 publication Critical patent/US20050040551A1/en
Priority to AU2010200650A priority patent/AU2010200650B2/en
Priority to JP2010159715A priority patent/JP2010279708A/ja
Priority to US12/877,167 priority patent/US8136657B2/en
Abandoned legal-status Critical Current

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Classifications

    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C5/00Filling or capping teeth
    • A61C5/70Tooth crowns; Making thereof
    • A61C5/77Methods or devices for making crowns
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C13/00Dental prostheses; Making same
    • A61C13/08Artificial teeth; Making same
    • A61C13/081Making teeth by casting or moulding
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C13/00Dental prostheses; Making same
    • A61C13/08Artificial teeth; Making same
    • A61C13/087Artificial resin teeth
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C13/00Dental prostheses; Making same
    • A61C13/20Methods or devices for soldering, casting, moulding or melting
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C5/00Filling or capping teeth
    • A61C5/30Securing inlays, onlays or crowns
    • A61C5/35Pins; Mounting tools or dispensers therefor
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C13/00Dental prostheses; Making same
    • A61C13/0001In-situ dentures; Trial or temporary dentures
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C13/00Dental prostheses; Making same
    • A61C13/08Artificial teeth; Making same
    • A61C13/09Composite teeth, e.g. front and back section; Multilayer teeth
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C2202/00Packaging for dental appliances
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61CDENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
    • A61C2202/00Packaging for dental appliances
    • A61C2202/01Packaging for light-curable material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/56Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • B29C33/68Release sheets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/003Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material

Definitions

  • Restorative dentistry is an important market in today's dental industry.
  • tooth repair with temporary and permanent crowns is a common procedure, typically requiring multiple dental appointments.
  • Conventional technologies use liners, adhesives, pastes, two-part powder/liquid systems, preformed metal temporary crowns, and ceramic or porcelain/metal permanent crowns.
  • the problems associated with the conventional technologies are the need for multiple visits to a dentist if a customized dental article is desired. Conversely, if customization is not desired, the dental article used may have a less than desirable fit and/or appearance, e.g., a metallic finish, larger gaps between proximal teeth, significant color variations from natural teeth, etc.
  • Hardenable dental materials have been developed to address some of these issues. Examples of some of these materials are described in, e.g., International Publication No. WO 03/015720 (Karim et al.) and U.S. application Ser. No. 10/219,398 filed Aug. 15, 2002 (Karim et al.), both titled HARDENABLE SELF-SUPPORTING STRUCTURES AND METHODS.
  • “hardenable dental materials” are materials that are capable of being hardened to form dental articles such as crowns, etc.
  • the techniques used to form the hardenable dental materials into usable dental articles may contribute to or detract from the finished appearance of the dental articles.
  • the hardenable dental material may exhibit an undesirable rough appearance due to less than desirable forming techniques and/or packaging.
  • the exact shape of dental articles manufactured of the hardenable materials before final hardening may be adjusted, significant shaping of the materials may not be possible or desirable depending on the properties of the hardenable dental material being used.
  • the dentist may prefer that the materials be provided in a shape that is close to the final desired shape of the dental article—subject to some minor shaping to provide a more customized fit and/or appearance.
  • the time required for the dentist to complete any given dental procedure in which the dental article is used can be reduced. Such forming, however, may exacerbate the problems identified in the preceding paragraphs.
  • the present invention provides methods of manufacturing hardenable dental articles, packaged hardenable dental articles, and methods of packaging hardenable dental articles.
  • the manufacturing may involve molding a hardenable dental material in a mold cavity that may be lined with a mold liner.
  • the mold body may also form the package of the hardenable dental article formed within the mold cavity.
  • the hardenable dental articles may be provided in mold cavities located in sacrificial mold bodies that may be torn, stretched, softened, dissolved, etc. to release the hardenable dental articles in the mold cavities.
  • the use of a mold liner during manufacturing of hardenable dental articles from hardenable dental materials may provide a number of potential advantages such as assisting with release of the hardenable dental article from the mold cavity; protecting the hardenable dental article from contamination, enhancing the finish of the hardenable dental article by providing a smooth finish on the article during the forming process (if the liner itself is smooth), and enhancing the finish of the dental article after hardening (if the smooth inside surface of the mold liner is retained in intimate contact with the outer surfaces of the hardenable dental article during hardening).
  • a mold liner is used in connection with the manufacturing of a hardenable dental article, it may be preferred that the mold liner be in intimate contact with the outer surfaces of the hardenable dental article after release of the hardenable dental article from the mold cavity. Alternatively, the hardenable dental article may release from the mold liner after or during its removal from the mold cavity.
  • the mold liner may function as an actinic light barrier to retard the passage of actinic radiation that could otherwise prematurely harden the photocurable hardenable dental material.
  • the liner is malleable, the dentist may be able to customize or adjust the shape of the dental crown with the liner in place. Alternatively, the dentist may remove the liner before customizing.
  • the liner may also function as a protective barrier for the outer surfaces of the hardenable dental article. If the liner is maintained in place on the outer surfaces of the hardenable dental article during hardening, it may protect the outer surfaces from, e.g., exposure to oxygen before and during the hardening process. If the liner is to be retained in place during hardening, the liner may be flexible to allow the dentist to customize or shape the hardenable dental article before hardening (if desired).
  • the liner may also function as a portion of the packaging of the hardenable dental articles manufactured of hardenable dental materials in accordance with the present invention.
  • the liner in intimate contact with the outer surfaces of the hardenable dental article
  • the liner may function as a package cover while a package base is attached to contain the hardenable dental article therein (in a manner similar to a “blister pack”).
  • mold cavities formed in reusable mold bodies made of conventional materials such as metals, etc. may be used in connection with manufacturing of hardenable dental articles of the present invention
  • the present invention may also include the use of mold cavities located in sacrificial mold bodies that include, e.g., lines of weakness formed therein, such that after molding or forming of the hardenable dental material into the shape of the selected hardenable dental article, the sacrificial mold body can be separated along the lines of weakness to remove the hardenable dental article from the mold cavity.
  • Other sacrificial mold bodies may be manufactured of materials that can either be stretched or torn to remove the hardenable dental article in the absence of defined lines of weakness.
  • sacrificial mold bodies may be manufactured of materials that can be softened or dissolved by contact with a solvent (such as, e.g., water) that does not significantly adversely affect the hardenable dental article.
  • a solvent such as, e.g., water
  • sacrificial mold bodies could be manufactured of water-soluble materials such that exposure to water (by, e.g., sprays, baths, etc.) softens or dissolves the sacrificial mold body such that the hardenable dental article can be removed—preferably without distorting the shape of the hardenable dental article. All of such mold bodies are described as “sacrificial” because they cannot be reused due to their destruction during the removal process.
  • Removal of a hardenable dental article from a sacrificial mold body may be performed as part of the manufacturing process, with the shaped hardenable dental article being packaged for delivery to a customer after the hardenable dental article has been removed from the sacrificial mold cavity.
  • the sacrificial mold body itself may form a part of the packaging of the hardenable dental article located therein, with removal of the hardenable dental article from the sacrificial mold cavity being performed by, e.g., the dentist or an assistant, at the point of use of the hardenable dental articles.
  • Such sacrificial mold bodies may be used in connection with mold liners as well.
  • the term “dental article” includes, but is not limited to, dental restoratives and dental prostheses, including, e.g., temporary, intermediate, and permanent crowns and bridges, inlays, onlays, implants, dentures, and artificial teeth, etc., as well as orthodontic appliances (e.g., retainers, night guards, etc.), tooth facsimiles or splints, maxillofacial prostheses, and other customized structures.
  • dental restoratives and dental prostheses including, e.g., temporary, intermediate, and permanent crowns and bridges, inlays, onlays, implants, dentures, and artificial teeth, etc., as well as orthodontic appliances (e.g., retainers, night guards, etc.), tooth facsimiles or splints, maxillofacial prostheses, and other customized structures.
  • a “hardenable dental article” may optionally be defined as a self-supporting structure of a hardenable dental material that is dimensionally stable and will maintain its shape (e.g., the preformed shape of a dental crown) without significant deformation at room temperature (i.e., about 20° C. to about 25° C.) for at least two weeks when free-standing (i.e., without any external support).
  • the hardenable dental articles of the present invention are dimensionally stable at room temperature for at least about one month, and, more preferably, for at least about six months.
  • the hardenable dental articles of the present invention are dimensionally stable at temperatures above room temperature, more preferably up to about 40° C., even more preferably up to about 50° C., and even more preferably up to about 60° C. This definition applies in the absence of conditions or materials that would otherwise act to harden the hardenable dental article and in the absence of an external force other than gravity.
  • the present invention provides a method of manufacturing a hardenable dental article by providing a mold cavity in a shape of a hardenable dental article, wherein the mold cavity has an opening; forcing a hardenable dental material into the mold cavity through the opening; providing a liner between the hardenable dental material and the mold cavity; and removing the hardenable dental material and the liner from the mold cavity, wherein the hardenable dental material has the shape of the hardenable dental article.
  • the present invention provides a packaged hardenable dental article including a mass of hardenable dental material in the shape of a hardenable dental article, wherein the hardenable dental article has a base and outer surfaces extending from the base; a package cover conforming to and in intimate contact with the outer surfaces of the hardenable dental article, wherein the package cover includes a polymeric film plastically deformed by the mass of hardenable dental material; and a package base facing the base of the hardenable dental article; wherein the package cover and the package base are attached together about a periphery of the base of the hardenable dental article such that the hardenable dental article is contained within the package base and the package cover.
  • the present invention provides a dental article that includes a sacrificial mold body with a sacrificial mold cavity in the shape of a hardenable dental article, wherein the sacrificial mold body includes at least one line of weakness formed therein, the at least one line of weakness defining at least two mold sections in the sacrificial mold body; and a mass of hardenable dental material located within the volume of the sacrificial mold cavity such that the hardenable dental material is in the shape of the hardenable dental article.
  • the present invention provides a packaged hardenable dental article that includes a mass of hardenable dental material in the shape of a hardenable dental article, wherein the hardenable dental article has a base and outer surfaces extending from the base; a package cover conforming to and in intimate contact with the outer surfaces of the hardenable dental article, wherein the package cover includes a sacrificial mold body with a sacrificial mold cavity in the shape of the hardenable dental article, and wherein the sacrificial mold body includes at least one line of weakness formed therein, the at least one line of weakness defining at least two mold sections in the sacrificial mold body; and a package base facing the base of the hardenable dental article; wherein the package cover and the package base are attached together about a periphery of the base of the hardenable dental article such that the hardenable dental article is contained within the package base and the package cover.
  • the present invention provides a dental article that includes a sacrificial mold body with a sacrificial mold cavity in a shape of a hardenable dental article, wherein the sacrificial mold cavity conforms to and is in intimate contact with outer surfaces of the hardenable dental article; and a mass of hardenable dental material located within the volume of the sacrificial mold cavity such that the hardenable dental material is in the shape of the hardenable dental article.
  • the present invention provides a method of manufacturing a hardenable dental article by providing a sacrificial mold body with a sacrificial mold cavity in a shape of a hardenable dental article, wherein the sacrificial mold body includes a water soluble polymer; and forcing a hardenable dental material into the sacrificial mold cavity through the opening, wherein the hardenable dental material takes the shape of the hardenable dental article.
  • the present invention provides a method of manufacturing a hardenable dental article by providing a sacrificial mold body with a sacrificial mold cavity in a shape of the hardenable dental article, wherein the sacrificial mold cavity has an opening, and wherein the sacrificial mold body includes at least one line of weakness formed therein, the at least one line of weakness defining at least two mold cavity sections in the sacrificial mold body; and forcing a hardenable dental material into the sacrificial mold cavity through the opening, wherein the hardenable dental material takes the shape of the hardenable dental article.
  • FIG. 1 is an exploded schematic diagram of one illustrative manufacturing process according to the present invention.
  • FIG. 2 is a cross-sectional view of one illustrative hardenable dental article in a package according to the present invention.
  • FIG. 3 is a schematic diagram of one illustrative variation in a manufacturing process according to the present invention.
  • FIG. 4 is a schematic diagram of another illustrative variation in a manufacturing process according to the present invention.
  • FIG. 5 is a schematic diagram of an alternative illustrative manufacturing process according to the present invention.
  • FIG. 6 is a schematic diagram of the manufacturing process of FIG. 5 , with the hardenable dental material located within the mold cavity.
  • FIG. 7 is a schematic diagram of still another alternative illustrative manufacturing process according to the present invention.
  • FIG. 8 is a plan view of the base of one illustrative hardenable dental article in a package in accordance with the present invention.
  • FIG. 9 is a cross-sectional view of the hardenable dental article of FIG. 8 taken along line 9 — 9 in FIG. 8 .
  • FIG. 10 is a perspective view of the outer surface of one illustrative sacrificial mold cavity/body used in connection with the present invention.
  • FIG. 11 is a perspective view of the opposite side of the sacrificial mold of FIG. 10 depicting the mold cavity formed therein.
  • FIG. 12 is a side elevational view of an illustrative hardenable dental article on a base of the sacrificial mold body of FIG. 10 after removal of the mold sections.
  • FIG. 13 is a cross-sectional view of another illustrative sacrificial mold cavity according to the present invention.
  • FIG. 1 is an exploded diagram illustrating one process of forming a hardenable dental article according to the present invention.
  • the illustrated process includes a mold cavity 10 formed in a body 12 .
  • the mold cavity 10 includes an opening 14 leading to the volume of the mold cavity itself, which is depicted in cross-section in FIG. 1 .
  • the mold cavity 10 is in the shape of a dental crown. It should, however, be understood that the hardenable dental articles of the present invention may include a wide variety of articles as discussed above.
  • the mold body 12 may be formed in any suitable material or combination of materials, e.g., metals, polymeric materials, etc. that provide sufficient structural integrity to withstand the forming process as described herein. In some instances, the mold body 12 may be formed in separable sections to facilitate removal of a hardenable dental article formed therein. Also, the mold body 12 may be made of or coated with a material adapted to aid release of a hardenable dental article from the interior surfaces of the mold cavity 10 .
  • the interior surfaces of the mold cavity 10 may be coated with, e.g., fluorinated polymers (e.g., PTFE, etc.), boron carbide, chrome, thin dense chrome, chromium nitride, electroless nickel infused with fluorinated polymers, modified tungsten disulfide (e.g., DICRONITE), etc.
  • fluorinated polymers e.g., PTFE, etc.
  • boron carbide e.g., chrome, thin dense chrome, chromium nitride, electroless nickel infused with fluorinated polymers, modified tungsten disulfide (e.g., DICRONITE), etc.
  • the mold cavity 10 may be temperature controlled to assist in the molding process by, e.g., heating and/or cooling the temperature of the interior surfaces of the mold cavity 10 .
  • the mold cavity 10 may be vented or evacuated during the molding process to enhance molding. Ultrasonic or other vibrational energy may also be used to enhance filling of the mold cavity 10 and/or assist with release the article from the mold cavity 10 .
  • a mold liner 20 is depicted in FIG. 1 as positioned in between a mass of hardenable dental material 30 and the opening 14 into the mold cavity 10 .
  • a pin liner 40 is positioned between the mass of hardenable dental material 30 and a core pin 50 .
  • the core pin 50 is preferably used to force the mass of hardenable dental material 30 into the mold cavity 10 through the opening 14 therein. As a result, the core pin 50 , a portion of the pin liner 40 , the hardenable dental material 30 , and a portion of the mold liner 20 are all advanced in the direction of arrow 52 as depicted in FIG. 1 .
  • the mass of hardenable dental material 30 may be pre-formed into a shape suitable for molding into the desired finished dental article.
  • the hardenable dental material 30 may be provided in the shape of, e.g., a circular cylinder, circular cone, rectangular prism, spherical pellet, etc.
  • the shape of the core pin 50 may be selected such that it enhances molding of the hardenable dental material 30 within the mold cavity 10 .
  • the shape of the core pin 50 may also be selected to impart a desired shape to the interior profile of the finished hardenable dental article.
  • the process illustrated in FIG. 1 may be described as a compression molding process. It should, however, be understood that the hardenable dental material 30 may be formed into the shape of the hardenable dental article by any suitable process. Some suitable processes may include, but are not limited to, e.g., injection molding, forging, casting, vacuum forming, extrusion molding, thermoforming, transfer molding, blow molding, etc.
  • the mold liner 20 may be stretched to conform to the shape of the mold cavity 10 .
  • the mass of hardenable dental material 30 is also molded to conform to the shape of the mold cavity 10 .
  • the hardenable dental material 30 will, however, be slightly smaller than the mold cavity 10 because the mold liner 20 is interposed between the hardenable dental material 30 and the interior surfaces of the mold cavity 10 .
  • Stretching of the mold liner 20 may reduce the chances of unwanted voids in the molded hardenable dental article (due to, e.g., wrinkling of the mold liner 20 ). Furthermore, stretching of the mold liner 20 during the molding process may also enhance intimate contact between the mold liner 20 and the outer surfaces of the molded hardenable dental article.
  • the mold liner 20 is an optional component in the molding process. In other words, it may be possible to force the hardenable dental material 30 into the mold cavity 10 and remove it therefrom after molding.
  • the mold liner 20 may, however, provide some potential advantages as discussed herein with respect to removal of the hardenable dental material from the mold cavity 10 , packaging of the hardenable dental article, etc.
  • the mold liner 20 may be constructed of a variety of different materials.
  • the mold liner 20 may be manufactured of a deformable material that may be provided in sheet form over the opening 14 of the mold cavity 10 and deformed under the molding conditions (e.g., temperature, pressure, etc.) used to form the hardenable dental material 30 into the desired shape.
  • Examples of some suitable materials for the mold liner 20 may include, but are not limited to, e.g., polypropylenes, polyethylenes, polyurethanes, vinyls, thermoplastic elastomers, elastomeric films (e.g., rubber, latex, etc.), fluorinated polymers (e.g., FEP, PFA, THV, ECTFE, etc.), plasticized PVC, elastic-plastic films (e.g., blends of KRATON and polypropylene), copolymers, water soluble polymers (e.g., selected from the group consisting of polyvinylpyrrolidones, polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohols, polyethylene oxides, polyacrylamides, polyacrylic acids, polysaccharides and synthetically modified polysaccharides (e.g., cellulose ether polymers), alginates (e.g., sodium alginate), polyethyl o
  • the mold liner 20 is depicted as a unitary layer, it should be understood that it could be provided as a multilayer or other non-homogeneous structure to, e.g., provide different properties for the surface facing the hardenable dental material 30 as compared to the surface facing the interior surfaces of the mold cavity 10 .
  • examples of some different properties that may be achieved by a multilayer structure, coating, etc. may include, but are not limited to the tensile strength of the mold liner 20 , formability, durability, etc.
  • the mold liner 20 itself may be treated or processed to improve its molding properties during forming of the hardenable dental material 30 in the mold cavity 10 .
  • the pin liner 40 is also optional, i.e., it may or may not be provided.
  • One potential advantage of providing a pin liner 40 between the core pin 50 and the hardenable dental material 30 is that adhesion between the core pin 50 and the hardenable dental material 30 may be prevented.
  • Another potential advantage is that the pin liner 40 may be incorporated into a package for the hardenable dental material 30 after it has been molded into the shape of the mold cavity 10 .
  • the core pin 50 may be coated with, e.g., fluorinated polymers (e.g., PTFE, etc.), boron carbide, chrome, thin dense chrome, chromium nitride, electroless nickel infused with fluorinated polymers, modified tungsten disulfide (e.g., DICRONITE), etc.
  • fluorinated polymers e.g., PTFE, etc.
  • boron carbide chrome
  • chrome thin dense chrome
  • chromium nitride chromium nitride
  • electroless nickel infused with fluorinated polymers e.g., modified tungsten disulfide (e.g., DICRONITE), etc.
  • the core pin 50 may be temperature controlled to assist in the molding process by, e.g., heating and/or cooling the temperature of the core pin 50 .
  • the core pin 50 may be vented or include vacuum orifices to assist in forming the hardenable dental material 30 .
  • ultrasonic or other vibrational energy may be supplied to the core pin 50 during the forming process.
  • the core pin 50 may be provided as a separate piece part attached to a driver such that the core pin 50 can remain attached to the molded hardenable dental material 30 after it is removed from the mold cavity 10 to assist in handling and/or packaging of the hardenable dental article.
  • the pin liner 40 may be constructed of a variety of different materials.
  • the pin liner 40 may be manufactured of a stretchable material that may be provided in sheet form between the core pin 50 and the hardenable dental material 30 and deformed under the molding conditions (e.g., temperature, pressure, etc.) used to form the hardenable dental material 30 into the shape of the mold cavity 10 .
  • suitable materials for the pin liner 40 may include, but are not limited to the same materials described herein for the mold liner 20 .
  • Stretching of the pin liner 40 may reduce the chances of unwanted voids in the molded hardenable dental article (due to, e.g., wrinkling of the pin liner 40 ). Furthermore, stretching of the pin liner 40 during the molding process may also enhance intimate contact between the pin liner 40 and the molded hardenable dental article.
  • the pin liner 40 is depicted as a unitary layer, it should be understood that it could be provided as a multilayer or other non-homogeneous structure to, e.g., provide different properties for the surface facing the hardenable dental material 30 as compared to the surface facing the outer surfaces of the core pin 50 .
  • Examples of some different properties that may be achieved by a multilayer structure, coating, etc. may include, but are not limited to the tensile strength of the pin liner 40 , formability, durability, control over surface energy, control over release properties, etc.
  • the pin liner 40 itself may be treated or processed to improve its molding properties during forming of the hardenable dental material 30 .
  • At least a portion of the liner 20 may be retained in intimate contact with the outer surfaces of the hardenable dental article formed of the hardenable dental material 30 .
  • FIG. 2 One example of such a construction is depicted in FIG. 2 .
  • FIG. 2 one embodiment of a packaged, shaped hardenable dental article 160 manufactured in accordance with the present invention is depicted in a cross-sectional view.
  • the hardenable dental article 160 includes outer surfaces 162 that are in intimate contact with package cover 120 .
  • the hardenable dental article 160 also includes a base 164 and a package base 140 located over the base 164 .
  • the package cover 120 may include a flange 124 extending away from the hardenable dental article 160 proximate the base 164 .
  • the flange 124 may provide a convenient location at which the package base 140 may be attached to the flange 124 such that the hardenable dental article 160 is sealed within the package cover 120 and the package base 140 .
  • the seal 128 between the package cover 120 and the package base 140 may be accomplished by any suitable technique or combination of techniques, e.g., heat sealing, adhesives, cold sealing, chemical welding, ultrasonically, etc.
  • the seal 128 may be a peelable seal, i.e., separation of the package cover 120 and the package base 140 be accomplished without significant deformation of the hardenable dental article 160 located therein.
  • the area of the flange 124 may also provide a convenient location for indicia that may be useful to identify the hardenable dental article, the hardenable dental material, a date by which the hardenable dental article should be used, etc.
  • the package cover 120 may be formed from the mold liner 20 and the package base 140 may be formed from the pin liner 40 . If the hardenable dental article 160 is to be a hollowed out dental crown, then a void 154 may be formed in the base 164 of the hardenable dental article 160 as seen in FIG. 2 .
  • package cover 120 and the package base 140 are each depicted as unitary layers, it should be understood that one or both could be provided as a multilayer or other non-homogeneous structure to, e.g., provide different properties for the surface facing the hardenable dental article 160 as compared to the surface facing away from the hardenable dental article, to provide vapor barrier properties, to provide moisture barrier properties, to provide sealing layers (e.g., heat sealable thermoplastic layers, adhesive layers, etc.).
  • sealing layers e.g., heat sealable thermoplastic layers, adhesive layers, etc.
  • the package base 140 may not be deformed as part of the process of forming the hardenable dental material. Rather, the package base 140 may be provided as a pre-formed piece having the shape seen in FIG. 2 that is inserted into the mass of hardenable dental material ( 30 in FIG. 1 ).
  • the package base 140 may include a void 154 as depicted in FIG. 2 that may receive a core pin shaped driver (see, e.g., core pin driver 50 in FIG. 1 ) during the manufacturing process.
  • the package base 140 may be formed with a solid mass of material in the volume of the void 154 , with that solid mass of material having sufficient strength to deform the hardenable dental material during manufacturing of the hardenable dental article 160 .
  • the package cover 120 and/or package base 140 may function as an actinic light barrier to provide protection from actinic radiation that may otherwise prematurely harden the hardenable dental material forming the hardenable dental article 160 .
  • the package cover 120 and/or the package base 140 may transmit less than 1% of actinic radiation incident thereon.
  • Methods and materials of providing such light barrier properties are known to those skilled in the art. Examples may be described in U.S. Pat. No. 5,538,129 (Chester et al.); U.S. Pat. No. 5,552,177 (Jacobs et al.); U.S. Pat. No. 5,636,736 (Jacobs et al.); and U.S. Pat. No. 5,785,178 (Kvitrud et al.), etc.
  • the package cover 120 and/or package base 140 materials and/or construction may be selected to provide a desired level of oxygen permeability to control exposure of the hardenable dental article 160 located therein to oxygen during, e.g., storage.
  • FIG. 3 illustrates another variation in the manufacturing process in which a mold liner 220 is located over the opening 214 of a mold cavity 210 .
  • the depicted mold liner 220 is partially deformed before the hardenable dental material 230 is introduced into the mold cavity 210 .
  • the preforming may be accomplished by forcing the liner 220 into the mold cavity 210 .
  • preforming of the mold liner 220 may occur outside of the mold cavity 210 .
  • Preforming of the mold liner 220 in this manner may be accomplished with a tool (not shown) or by any other suitable technique such as fluid pressure, vacuum within the mold cavity 210 , etc. It may be helpful if the mold liner 220 is heated or otherwise processed to improve its formability.
  • FIG. 4 also illustrates another variation in the manufacturing process in which the mold liner 320 is deformed such that it replicates the shape of the mold cavity 310 before hardenable dental material 330 is introduced into the mold cavity 310 .
  • preforming of the mold liner 320 in this manner may be accomplished with a tool (not shown) or by any other suitable technique such as, e.g., fluid pressure, vacuum within the mold cavity 310 , etc. It may be helpful if the mold liner 320 is heated or otherwise processed to improve its formability.
  • FIGS. 5 & 6 depict another manufacturing process in which the hardenable dental material 430 is located within a pocket 421 formed in mold liner 420 before the mold liner 420 and hardenable dental material 430 are introduced into the mold cavity 410 .
  • the process includes an optional pin liner 440 located between the hardenable dental material 430 and the core pin 450 .
  • FIG. 6 depicts the hardenable dental material formed into the shape of a hardenable dental article 460 within cavity 410 , including a void 454 formed by the core pin 450 .
  • the pocket 421 in mold liner 420 may be formed under conditions of pressure, temperature, etc. using the hardenable dental material 430 itself.
  • the hardenable dental material 430 may be forced against the mold liner 420 under conditions of temperature, pressure, etc. such that the portion of the mold liner 420 forming the pocket 421 is permanently or plastically deformed.
  • the mold liner 420 itself may be deformed by, e.g., vacuum forming, blow molding, cold forming/embossing, thermoforming, injection molding, compression molding, etc., such that the pocket 421 is formed before the hardenable dental material 430 is placed therein.
  • the mold liner 420 and pin liner 440 may be retained in intimate contact with the hardenable dental article 460 and attached together to form a package containing the hardenable dental article 460 after removal from the mold cavity 410 if so desired (and as described with respect to other embodiments elsewhere herein).
  • FIG. 7 depicts still another alternative manufacturing process according to the present invention in which the hardenable dental material 530 is located within a volume defined by a mold liner 520 and a pin liner 540 before the hardenable dental material 530 and the mold liner 520 are introduced into the mold cavity 510 .
  • the mass of hardenable dental material 530 may also be sealed within the mold liner 520 and pin liner 540 before forming.
  • the mold liner 520 and pin liner 540 may be adhered together, heat sealed, cold sealed, chemically welded, ultrasonically welded, etc. to enclose the hardenable dental material.
  • the hardenable dental material 530 may be located within a pocket 521 formed in the mold liner 520 .
  • the pin liner 540 may be used to form a pocket in addition to or in place of the pocket 521 formed in the mold liner.
  • FIG. 8 is a plan view of the base 664 of a hardenable dental article 660 located within a liner 620 and FIG. 9 is a cross-sectional view of the hardenable dental article 660 and liner 620 taken along line 9 - 9 in FIG. 8 .
  • the liner 620 is preferably in intimate contact with the outer surfaces 662 of the hardenable dental article 660 .
  • the hardenable dental article 660 and liner 620 depicted in FIGS. 8 & 9 may be manufactured using the methods described above.
  • the liner 620 includes a flange portion 628 extending away from the hardenable dental article 660 .
  • the liner 620 may be a stretchable film or other structure such that deforming (e.g., stretching, tearing, etc.) the liner 620 causes it to release from the outer surfaces 662 of the hardenable dental article 660 with little or no deformation of the shape of the hardenable dental article 660 .
  • the liner 620 is made of a water soluble polymer, removal of the hardenable dental article 660 may be facilitated by contacting the liner 620 with water (by, e.g., spraying, immersion in a water bath, etc.).
  • FIGS. 10 & 11 are perspective views, respectively, of the outer and base surfaces of one exemplary embodiment of a sacrificial mold cavity that may be used to manufacture and, potentially, package a hardenable dental article according to the present invention.
  • the sacrificial mold cavity 710 is formed in a sacrificial mold body 712 that may include one or more lines of weakness 716 formed therein, wherein the lines of weakness define sections 717 in the sacrificial mold body 712 .
  • the interior surfaces 711 of the sacrificial mold cavity 710 are in the shape of the desired hardenable dental article such that when hardenable dental material is forced into the sacrificial mold cavity 710 , it takes the shape of the desired hardenable dental article in the sacrificial mold cavity 710 itself.
  • the lines of weakness 716 may define lines along which the sacrificial mold body 712 may separate when tension is applied across the line of weakness 716 or when a shearing force is generated on opposite sides of the line of weakness 716 .
  • the lines of weakness 716 may take a variety of forms, e.g., thinned lines in which the wall thickness of the mold body 712 is reduced relative to the surrounding wall thickness, score lines formed after the mold body 712 is manufactured, etc.
  • each line of weakness 716 may be defined by a filament molded in the body 712 such that the body preferentially separates along the filament.
  • Other variations of providing a means of separation for a sacrificial mold cavity may be envisioned by those skilled in the art.
  • Lines of weakness may be provided in any desired orientation on the sacrificial mold body 712 (i.e., the depicted lines of weakness 716 are not to be construed as limiting the orientation of lines of weakness used in connection with the invention).
  • lines of weakness that extend around the sacrificial mold body 712 in helical spirals from the portion of the mold cavity 712 forming the margin to the incisal/occlusal surfaces of the dental crown may alternatively be provided.
  • Other variations in the orientation or paths of lines of weakness used in connection with sacrificial mold cavities of the present invention may also be provided.
  • the mold body 712 may also include a flange or tab 718 associated with one or more of the mold sections 717 .
  • the tabs 718 may be used to facilitate handling of the mold body 712 , to provide a location on which a package base may be attached to seal the sacrificial mold cavity 710 after locating the hardenable dental material therein, and/or to provide a location at which the mold body 712 may be grasped to apply the force required to separate the one or more lines of weakness 716 in the mold body 712 .
  • the flanges 718 may also provide a convenient location for indicia that may be useful to identify the hardenable dental article, the hardenable dental material, a date by which the hardenable dental article should be used, etc.
  • notches 715 may be provided at the ends of the lines of weakness 716 .
  • the notches 715 may act as stress concentrators to initiate separation along the lines of weakness 716 .
  • the notches 715 are formed in between adjacent tabs 718 , with the notches 715 transitioning into thinned lines of weakness 716 .
  • a base line of weakness that extends about the periphery of the mold body 712 proximate, e.g., the incisal/occlusal surfaces formed by the mold cavity 710 .
  • the sections may be separated completely from the mold body 712 along base line of weakness.
  • the base line of weakness may preferably define a base 772 that may remain attached to the hardenable dental article 760 as seen in FIG. 12 .
  • a post or stud 774 attached to the base 772 as depicted may facilitate handling of the hardenable dental article 760 .
  • the mold body 712 may be manufactured of any suitable material or materials that may be provided in the desired shape and that will function to form or shape the hardenable dental material used to form the hardenable dental article 760 .
  • suitable materials for the mold body 712 may include, but are not limited to, thermoplastic polymers, thermoplastic elastomers, polyethylenes, polypropylenes, polystyrenes, polyesters (e.g., poly(ethylene terephthalate)), etc.
  • a number of approaches may be employed to facilitate release of the interior surface 711 of the sacrificial mold cavity 710 from the hardenable dental material used to form the hardenable dental article 760 .
  • additives may be provided in the material used to form the mold body. Examples of some suitable additives may include, but are not limited to, fluoropolymers, graphite, fatty acids, low molecular weight polyethylene, silicone, hydrocarbon waxes, metallic stearates, etc.
  • the interior surfaces 711 of the sacrificial mold cavity 710 may include a coating formed thereon to enhance release from the hardenable dental material, e.g., silicone, fluorinated polymers, etc.
  • a mold liner (as described above with respect to FIGS. 1 and 3 - 7 ) may be used in connection with the sacrificial mold cavity 710 . If a mold liner is used, it may be retained in intimate contact with the outer surfaces of the hardenable dental article after removal of the mold body 712 .
  • the lines of weakness 716 do not include any voids, perforations, or other structures that could fill with the hardenable dental material during the molding process because such features would change the shape of the hardenable dental article 760 thus formed.
  • the lines of weakness 716 it may be preferred that, on the interior surfaces 711 of the sacrificial mold cavity 710 , the lines of weakness 716 be indistinguishable from the remainder of the interior surfaces 711 of the sacrificial mold cavity 710 .
  • the lines of weakness 716 may include voids (e.g., lines of perforations formed in the mold body 712 ) because such perforations could be sealed by the mold liner. Furthermore, such perforations may act to vent the sacrificial mold cavity 710 .
  • a sacrificial mold cavity of FIGS. 10-12 includes lines of weakness formed therein
  • other sacrificial mold cavities used in connection with hardenable dental articles of the present invention may not include lines of weakness to assist in removal of the hardenable dental articles.
  • another sacrificial mold cavity may be made of, e.g., an elastomeric material (e.g., rubber, thermoplastic elastomers, etc.) or a material exhibiting a low tear strength.
  • the internal surfaces of a sacrificial mold cavity may have the shape of the hardenable dental article while the external surfaces of the sacrificial mold body in which the mold cavity is located may conform to the shape of the hardenable dental article located within the cavity.
  • a sacrificial mold body and cavity is depicted in, e.g., FIG. 2 in the form of the package cover 120 .
  • the exterior shape of a sacrificial mold cavity may not conform to the shape of the hardenable dental article located within the mold cavity.
  • the exterior shape of the sacrificial mold cavity may be a generic shape such as, for example, a block, cylinder, etc.
  • any sacrificial mold body used in connection with the present invention does not, itself, possess sufficient strength to mold or form the hardenable dental material, then the sacrificial mold body (and the mold cavity it contains) may be supported by a support structure during the molding process.
  • a suitable support structure may be, e.g., the mold cavity 10 depicted in connection with FIG. 1 and described as one example of a structure used to form the package cover 120 of FIG. 2 .
  • the support structure will preferably conform to the exterior shape of the sacrificial mold body in which the sacrificial mold cavity is located.
  • the support structure used to support the mold body will include interior surfaces that also conform to the exterior shape of the sacrificial mold body.
  • the exterior shape of the sacrificial mold body is generic, i.e., in the shape of a cylinder, block, etc., then the support structure used to support the mold body will typically include interior surfaces that conform to the generic shape of the sacrificial mold body.
  • FIG. 13 One illustrative example of a sacrificial mold cavity having a generic outer shape and an inner cavity in the shape of a desired hardenable dental article is depicted in FIG. 13 , where mold body 812 defines a mold cavity with inner surfaces 810 .
  • a hardenable dental article 860 is formed within the mold cavity defined by inner surfaces 810 .
  • the hardenable dental article 860 may include an inner cavity 854 .
  • the mold body 812 may be formed of, e.g., elastomeric materials and/or materials exhibiting low tear strength to facilitate removal of the hardenable dental article 860 as discussed above.
  • the mold body may be formed of soluble polymers (e.g., water soluble polymers selected from the group consisting of polyvinylpyrrolidones, polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohols, polyethylene oxides, polyacrylamides, polyacrylic acids, polysaccharides and synthetically modified polysaccharides (e.g., cellulose ether polymers), alginates (e.g., sodium alginate), polyethyl oxazolines, esters of polyethylene oxide, esters of polyethylene oxide and polypropylene oxide copolymers, urethanes of polyethylene oxide, urethanes of polyethylene oxide and polypropylene oxide copolymers, etc.).
  • soluble polymers e.g., water
  • the hardenable dental article 860 could be removed from the sacrificial mold body 812 at some point after the forming operation either by softening and/or dissolving the soluble mold body 812 through contact with an appropriate solvent (e.g., a water bath or spray for water soluble polymers).
  • an appropriate solvent e.g., a water bath or spray for water soluble polymers.

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  • Veterinary Medicine (AREA)
  • Epidemiology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Public Health (AREA)
  • Dentistry (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Dental Preparations (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Dental Tools And Instruments Or Auxiliary Dental Instruments (AREA)
US10/643,749 2003-08-19 2003-08-19 Hardenable dental article and method of manufacturing the same Abandoned US20050040551A1 (en)

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US10/643,749 US20050040551A1 (en) 2003-08-19 2003-08-19 Hardenable dental article and method of manufacturing the same
PCT/US2004/026634 WO2005018483A2 (en) 2003-08-19 2004-08-17 Hardenable dental article and method of manufacturing the same
CA002535928A CA2535928A1 (en) 2003-08-19 2004-08-19 Hardenable dental article and method of manufacturing the same
AU2004266716A AU2004266716B2 (en) 2003-08-19 2004-08-19 Hardenable dental article and method of manufacturing the same
JP2006524058A JP4745232B2 (ja) 2003-08-19 2004-08-19 硬化性歯科物品およびその製造方法
US10/921,648 US7811486B2 (en) 2003-08-19 2004-08-19 Method of manufacturing a hardenable dental article
PCT/US2004/026991 WO2005018484A2 (en) 2003-08-19 2004-08-19 Hardenable dental article and method of manufacturing the same
AT04781639T ATE519448T1 (de) 2003-08-19 2004-08-19 Herstellungsverfahren eines härtbaren dentalartikels und verpackter härtbarer dentalartikel
EP10173717A EP2258305A1 (en) 2003-08-19 2004-08-19 Hardenable dental article and sacrificial mold body
EP10182767A EP2305165A2 (en) 2003-08-19 2004-08-19 Hardenable dental article and method of manufacturing the same
EP04781639A EP1663053B1 (en) 2003-08-19 2004-08-19 Method of manufacturing a hardenable dental article and packaged hardenable dental article
CNA2004800238724A CN1838923A (zh) 2003-08-19 2004-08-19 可硬化牙科用制品及其制造方法
AU2010200650A AU2010200650B2 (en) 2003-08-19 2010-02-22 Hardenable dental article and method of manufacturing the same
JP2010159715A JP2010279708A (ja) 2003-08-19 2010-07-14 硬化性歯科物品およびその製造方法
US12/877,167 US8136657B2 (en) 2003-08-19 2010-09-08 Packaged hardenable dental article

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AT (1) ATE519448T1 (enrdf_load_stackoverflow)
AU (2) AU2004266716B2 (enrdf_load_stackoverflow)
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