WO2017106335A1

WO2017106335A1 - Dental prosthetic

Info

Publication number: WO2017106335A1
Application number: PCT/US2016/066642
Authority: WO
Inventors: Mark Durham; Andy LARSON; Alesha SNELL
Original assignee: University Of Utah Research Foundaton
Priority date: 2015-12-14
Filing date: 2016-12-14
Publication date: 2017-06-22

Abstract

A dental prosthetic system (100) can include a dental implant (104) for coupling with a jaw bone of a user. The dental prosthetic system (100) can also include a dental prosthetic (102a) having an artificial tooth portion (107), and a support member (106) coupled to and supporting the artificial tooth portion (107). The support member (106) can be removably coupleable to the dental implants (104) by the patient user. The coupling interface (110) can also be fabricated indirectly without the presence of the patient user.

Description

DENTAL PROSTHETIC

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/267, 149, filed on December 14, 2015, which is incorporated herein by reference.

BACKGROUND

Repair or replacement of teeth is a common medical need, though the employed solution may vary greatly depending upon a particular individual and the state of their dentition. For individuals who are partially or completely edentulous the standard solution involves a prescription of a pair of dentures which act as prosthetic teeth for the patient. However, due to the need for replacement every five years, coupled with poor fit and occasional impediments to taste, some patients opt for dental implant-type prosthetics over dentures.

Dental implant-type prosthetics are secured to the patient's jaw through direct connections to the bone. Sometimes such prosthetics are created by a piecewise assembly of an implant bar by a skilled technician or surgeon. Once a bar is fabricated and a preliminary fit has been achieved the bar is sent to a lab to create the prosthetics. A second fitting is then undertaken to ensure that the device meets the patient's needs before implantation. Screws and various attachments are typically used to couple the prosthetic to the patient by threading or mechanically locking to implants in the patient's jaw bone.

A typical dental implant-type prosthetic has several drawbacks. The screws used to secure the prosthetic to the patient do not facilitate removal of the prosthetic by the patient for cleaning, thus leading to poor hygiene and odor. Some implant prosthetics are removable using a coupling system to allow for cleansability, but their resilient coupler lends itself to movement of the prosthetic. Typically bar-based prosthetics require removal of such screws, which involves a visit to a professional since the screws are not user removable. The prosthetic also has a lower than optimal strength due to the screw holes. Some implant prosthetics (e.g. those without internal rigid support members) do not have enough material strengthening to withstand long usages and effect the prosthetic itself and the implants. Some implant with removable coupling systems can provide cleansibility, but are fabricated with the limitations of being made directly in the mouth of the patient. In addition, the multiple steps of the fitting process can be time consuming and can involve multiple visits.

SUMMARY

Accordingly, a dental prosthetic system is disclosed herein that can facilitate coupling and removal of a dental prosthetic by a user of the prosthetic, wherein the bar is retained within the removed prosthetic. The dental prosthetic system can include a dental implant for coupling with a jaw bone of a user. The dental prosthetic system can also include a dental prosthetic having an artificial tooth portion, and a support member (and/or bar) coupled to and supporting the artificial tooth portion. The support member can be removably coupleable to the dental implant by the patient user. The removable coupling can also provide exceptionally small movement tolerances of the prosthetic relative to the implants. The small movement provides psychological value to the patient as well as biomechanical value to the patients' implant success.

In another aspect, a method of making a dental prosthetic is disclosed. The method utilizes a plurality of dental implants set into a jaw bone of a patient user. The method can also comprise determining positions of the plurality of dental implants. Additionally, the method can comprise forming a plurality of coupling interfaces about a support member of a dental prosthetic. The coupling interfaces can be located about the support member based on the positions of the dental implants to facilitate coupling the support member to the dental implants. The coupling interfaces can be fabricated so that the joining of the interfaces is made indirectly outside of the user's mouth.

There has thus been outlined, rather broadly, the more important features of the invention so that the detailed description thereof that follows may be better understood, and so that the present contribution to the art may be better appreciated. Other features of the present invention will become clearer from the following detailed description of the invention, taken with the accompanying drawings and claims, or may be learned by the practice of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 A illustrates a dental prosthetic system for upper dentures in accordance with an example of the present disclosure.

FIG. IB illustrates a dental prosthetic system for lower dentures in accordance with an example of the present disclosure.

FIG. 2 illustrates a cross-section view of an example coupling member as part of a dental prosthetic system in accordance with an example of the present disclosure.

FIG. 3 illustrates a schematic of a dental prosthetic system in accordance with an example of the present disclosure.

FIG. 4 illustrates a schematic of a support member and abutment of a dental prosthetic system in accordance with an example of the present disclosure.

FIG. 5 illustrates a schematic of a support member and abutment of a dental prosthetic system in accordance with another example of the present disclosure.

These drawings are provided to illustrate various aspects of the invention and are not intended to be limiting of the scope in terms of dimensions, materials, configurations, arrangements or proportions unless otherwise limited by the claims.

DETAILED DESCRIPTION

While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that various changes to the invention may be made without departing from the spirit and scope of the present invention. Thus, the following more detailed description of the embodiments of the present invention is not intended to limit the scope of the invention, as claimed, but is presented for purposes of illustration only and not limitation to describe the features and characteristics of the present invention, to set forth the best mode of operation of the invention, and to sufficiently enable one skilled in the art to practice the invention. Accordingly, the scope of the present invention is to be defined solely by the appended claims.

Definitions

In describing and claiming the present invention, the following terminology will be used.

The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a dental implant" includes reference to one or more of such features and reference to "forming" refers to one or more such steps.

As used herein with respect to an identified property or circumstance,

"substantially" refers to a degree of deviation that is sufficiently small so as to not measurably detract from the identified property or circumstance. The exact degree of deviation allowable may in some cases depend on the specific context.

As used herein, "adjacent" refers to the proximity of two structures or elements. Particularly, elements that are identified as being "adjacent" may be either abutting or connected. Such elements may also be near or close to each other without necessarily contacting each other. The exact degree of proximity may in some cases depend on the specific context.

As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.

As used herein, the term "at least one of is intended to be synonymous with "one or more of." For example, "at least one of A, B and C" explicitly includes only A, only B, only C, or combinations of each.

Numerical data may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a numerical range of about 1 to about 4.5 should be interpreted to include not only the explicitly recited limits of 1 to about 4.5, but also to include individual numerals such as 2, 3, 4, and sub-ranges such as 1 to 3, 2 to 4, etc. The same principle applies to ranges reciting only one numerical value, such as "less than about 4.5," which should be interpreted to include all of the above-recited values and ranges. Further, such an interpretation should apply regardless of the breadth of the range or the characteristic being described.

Any steps recited in any method or process claims may be executed in any order and are not limited to the order presented in the claims. Means-plus-function or step-plus- function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) "means for" or "step for" is expressly recited; and b) a corresponding function is expressly recited. The structure, material or acts that support the means-plus function are expressly recited in the description herein. Accordingly, the scope of the invention should be determined solely by the appended claims and their legal equivalents, rather than by the descriptions and examples given herein.

Dental Prosthetic

With reference to FIGs. 1A and IB, dental prosthetic systems 100 are illustrated in accordance with an example of the present disclosure, showing an upper dental prosthetic 102a and a lower dental prosthetic 102b. Each prosthetic 102a and 102b can include a plurality of dental implants 104. Each dental implant 104 can be configured to couple with bone structure of a mouth of a patient (upper or lower, as the case may be). Dental implants are typically permanent and may be referred to as dental fixtures or posts. These permanent dental implants are often made of titanium, which is more acceptable by the body's biological processes and which are locked into position by bone growth. However, dental implants can be formed of any suitable material such as, but not limited to, titanium (e.g. commercially pure), titanium alloys (e.g. at least 85 wt% Ti), titania, zirconia, tantalum, alumina, polymers, alloys thereof, composites thereof, and the like. The dental implants can also optionally include surface texturing to increase coupling with bone. For example, creating a roughened or porous surface such as by sand blasting, etching or the like intergrowth of bone with the implant can be improved. Surfaces can be roughened with either uniform or non-uniform patterns. Typically an implant surface roughness of at least 10 μπι can be useful. Referring to FIG. 1A and IB, by utilization of the permanently installed implants 104 in the mouth of the individual, the dental prosthetics 102a and 102b can be removably coupled or secured in place, as described further below.

Each dental prosthetic 102a and 102b can have an artificial tooth portion 107, as shown. The artificial tooth portion is typically made of an acrylic material, although any suitable material can be used, and integrally fitted with a plurality of artificial teeth mimicking the individual's natural teeth as far as shape, size, color, etc. In one aspect, the plurality of artificial teeth comprises at least three artificial teeth. In another aspect, the plurality of artificial teeth can comprise at least half a number of teeth associated with the upper or lower jaw bone (e.g., 8 for a typical adult having 32 total teeth). The artificial tooth portion can also have a gum mimicking portion, the color and texture of which mimic the natural appearance of the individual's gum. The gum mimicking portion can simulate and complete the gingival area and can offer an aesthetic appearance to conceal any artificial structure and cover any gaps which may exist. Although a variety of materials can be used the gum mimicking portion can be any material which is biocompatible and has sufficient structural integrity to retain the artificial teeth during use. Non-limiting examples of suitable material can include acrylic, porcelain, and the like.

Each dental prosthetic 102a and 102b can also have a bar 106 coupled to and supporting the artificial tooth portion 107. As such, the dental prosthetics 102a and 102b can be a removable hybrid bar. The bars 106 can be constructed of any suitable structural material having a sufficiently low bending modulus which is typically rigid. As a general rule structural material used for a rigid bar can have a Young's modulus greater than about 190 GPa, and in some cases greater than 280 GPa. Non-limiting examples of suitable structural material can include titanium, tungsten, zirconium oxide, alumina, silicon nitride, zirconia, carbides thereof (e.g. WC, etc), alloys thereof, rigid polymers, or other rigid materials.

In one optional aspect, a plurality of abutments 110 can be secured to the dental prosthetics 102a and 102b through apertures 108 in the respective bar 106 (e.g., see also the abutment receiver 128 attached to bar 126 of FIG. 2). The abutments 110 can typically be permanently secured to the bar 106. For example, the abutments can be secured by welding, simultaneous molding with the bar, additive processing such as 3D printing, interference fit, rivets, pin locks, threaded, or the like. Further, abutments may be inserted through an underside of the bar followed by formation of the tooth portion 107 about a portion of the abutment remaining on the underside. Alternatively, the abutments 1 10 can be removable for adjustment or cleaning. In such cases, the abutments 110 and bar 106 can include corresponding coupling features such as, but not limited to, threaded portions (e.g. see FIG. 2), cam locks, and the like. The plurality of abutments 110 can be removably attached to the plurality of apertures 108.

As further discussed below, each abutment 110 are also removably coupleable to complimentary dental implants 104. Such removability of each dental prosthetic 102a and 102b is also configured to be removably coupleable to the dental implant 104 (including a complimentary coupling member) by the patient user. More specifically, threaded couplings would not be considered removable by the patient user. The dental implants 104 can be permanently secured to a jaw bone of a patient in the conventional manner. However, specific coupling systems can be used to removably secure dental prosthetics 102a and 102b.

In one example, a dental prosthetic can have one or two teeth, for example, which can be removably coupled to a bone structure by a patient user. In this way, one dental implant 104, support structure 106, and abutment 110 could be used, for instance. In other examples, the dental prosthetic 102a/102b can include at least three prosthetic teeth coupled to the bar 106 in the tooth portion 107.

Any number of coupling systems can be used for the implant and abutment coupling mechanism. Typically, the abutment coupling can include a two-part mechanism which includes an implant interface portion and an abutment bar interface portion. The implant interface portion can be secured to the implant (e.g. using permanent or semipermanent mechanisms). The abutment bar interface portion can be secured to the bar and is removably coupleable to the complimentary implant interface portion. As a general rule, any coupling system can be used which provides the movement tolerances described herein. Non-limiting examples of such mechanisms can include stud attachments, radicular (e.g. Allegro OD, Dalla Bona System, Direct ORS (O-Ring System), Locator, Magnedisc, Mini-Clic, Moser Post, Neomagnet, ORS-OD (O-Ring System), OT Cap, Rothermann, SwissAnchor OD, and Uni-Anchor), intra-radicular (Logic, ZAAG, and Zest), resilient (Locator, Ball, ERA, etc), and non-resilient (Locator F-Tx, Syncone, Conus), and the like.

In one non-limiting example, FIG. 2 shows an example of a coupling system 120 for removably coupling a bar 126 of a dental prosthetic 122 (tooth/teeth) to a jaw bone 124 of a patient. One commercial example of this mechanism is available from Zest Anchors as LOCATOR F-Tx. In this example, the bar 126 can support the dental prosthetic 122, as also shown generally on FIG. 1. Referring though to FIG. 2, the coupling system 120 can comprise a dental implant 104a which is secured within a cavity of the bone 124. A complimentary implant interface portion 132 of the coupling system 120 can be secured within the dental implant 104a. For purposes of illustration clarity, a single dental implant 104a and coupling system 120 are shown in cross-sectional views. FIG. 3 shows (schematically) a plurality of such coupling systems 120 that removably couple the prosthetic 122 to the patient's jaw bone 124 at particular locations and orientations specific to the patient.

More specifically regarding FIG. 2, the implant interface portion 132 can be removably coupled (e.g., threaded) to the dental implant 104a. Accordingly, the dental implant 104a can be permanently secured to the jaw bone 124 of the patient (i.e., the bone grows around protrusions and surfaces of the implant 104a). A pair of horizontal lines is drawn on FIG. 2 to illustrate a general separation between the jaw bone 124 and the bar 126 of the prosthetic 122, but it will be appreciated that the dental implant 104a can be secured at various heights in the jaw bone, and that the implant interface portion 132 can be secured at various heights relative to the bone 124.

In one example, the abutment portion 130 comprises a head 134 that can be friction- fit (e.g., snap-fit) to the complimentary implant interface portion 132, collectively forming a support member coupling interface. The abutment portion 130 can further comprise an attachment portion 136 that is removably secured (e.g., threaded) to a threaded cavity 138 of the abutment receiver 128 as the abutment bar interface portion. In another example, the attachment portion 136 can be adhered to the cavity 138.

The head 134 can have a particular head diameter, and the implant interface portion

132 can have a cavity 140 that has an opening that receives the head 134 of the abutment portion 130. Thus, the cavity 140 can have an inner diameter that is slightly smaller than the diameter of the head 134 at the interface between the head 134 and the implant interface portion 132. This forms an abutment coupling interface that is a friction- fit such that the patient can "un-snap" or "snap" the dental prosthetic without having to visit a professional. This friction-fit can require less than a pound of force to be un-snapped by the patient using only hands or simple tools for leverage.

To provide proper alignment and a secure fit between the implant interface portion 132 and the abutment receiver 128, a side wall 142 of the implant interface portion 132 is seated against a corresponding side wall 144 of the abutment receiver 128, forming a Morse-taper interface. In this example, said side walls have corresponding rounded (i.e., non-linear) surfaces, but they can be linear surfaces in other examples. This Morse-taper interface cooperates with the rounded head 134 of the abutment portion 130 to ensure proper alignment and to restrict all six degrees of freedom between the dental prosthetic 122 and the jaw bone 124. This configuration is much like a ball-and-socket interface, but that restricts all movement when locked in place.

To ensure proper vertical alignment, the abutment portion 130 can comprise a flange 146 seated against a stop portion of the abutment receiver 128 to properly position the abutment portion 130 relative to the abutment receiver 128 so that the head 134 properly snaps in place with the bar 126. This flange/stop interface also accounts for undesirable tolerances that may exist when machining the abutment portion 130 and the abutment receiver 128, for instance. Likewise, the cavity 140 can be formed at a certain depth in the implant interface portion 132 that form a void between an end of the cavity 140 and an end of the head 134, which also assists to account for undesirable tolerance issues due to machining the components of the coupling system 120.

With continued reference to FIG. 3, a patient-removable dental prosthetic is further illustrated, showing a front schematic view of a plurality of dental couplings 120 that removably couple the dental prosthetic 122 to corresponding dental implants 104a which are each secured in the jaw bone 124. This is an example of the lower dental prosthetic of FIG. 1. Here, a professional (e.g., a periodontist) can implant a plurality of dental implants 104a into the jaw bone 124 of the patient. Once the positions of the dental implants are determined and installed, a mold or cast can be formed of the implants within the jaw bone region, which then provides a mold having the particular locations and orientations of the dental implants relative to the jawbone. The mold can then be digitally scanned to create a virtual model of the implanted jaw bone region. Then, the bar and complimentary coupling abutments can then be custom manufactured (e.g., CAD machined) to align with the dental implants that are in the patient.

Each coupling system 120 can have a particular orientation relative to the jaw bone. This is illustrated by the longitudinal axes of the coupling systems 120 of FIG. 3 being at an angle relative to each other (although slightly exaggerated for illustration purposes). Thus, the bar support structure 106 and coupling segments (e.g. implant interface and abutment receiver) of each coupling system 120 are oriented based on their respective longitudinal axis of the plurality of dental implants 104a, which are typically different relative to each other and for each patient.

In one aspect, the bar support member and the abutment can be formed or manufactured using CAD/CAM tools and techniques, such as computer aided milling or machining. Utilizing CAD/CAM to make the various features of the dental prosthetic system, such as the coupling interfaces, can achieve tight tolerances on such features, which can facilitate removable coupling of the support member and the dental implants by the user, unlike relying on screws or other such fasteners that are typically utilized by a dentist to couple a support member to dental implants. User removability of the dental prosthetic can enable the user to remove the dental prosthetic for cleaning whenever desired, instead of depending on a dentist for such care, which can improve hygiene and reduce odor.

FIG. 4 schematically shows an example of a dental implant 200 and an abutment 202 that can be removably coupled to a support structure (as alternatives to 132 of FIG. 2) as a Morse taper. Here, the abutment 202 can be attached to the dental implant 200. In one example, the abutment 202 can be a permanent magnet that has an opposite polarity of a receiving permanent magnet secured on the dental implant. As with FIG. 1 and Fig. 2, the abutment can be secured to a support member of a dental prosthetic, for instance (not shown here).

In yet another example, the abutment 202 and complimentary implant 200 can facilitate a thermally induced interlock interface. In this example, upon transferring heat from the abutment 202 (e.g., using cold water or air), the metal abutment 202 can contract, which can release the mechanical interface between the abutment and the support structure. Thus, such mechanical interface would necessarily be designed to expand at (or near) body temperature so that the dental prosthetic can be locked in place when coupled to the patient. In other examples, the coupling interface can be a Swiss lock.

FIG. 5 schematically shows an example of a dental implant 210 and an abutment 212 that can be removably coupled to a support structure (like 132 of FIG. 2) as a thermal coupler. Here, the abutment 212 can have a plurality of flange members 214 that engage upon exposure to body temperatures.

In one aspect, the abutment coupling interface of the support member and the support member coupling interface of the abutment can be constructed to tolerances sufficient to minimize relative movement of the support member, the abutment and the implant when coupled, while facilitating removal of the prosthetic from the implant by the user. Although tolerances can vary, typically tolerances can be less than about 0.1 mm, less than 0.05 mm, and most often less than about 0.01 mm. In one aspect, the tolerances can be configured to minimize or eliminate degrees of freedom for relative movement between the support member and the dental implants. In another aspect, the configuration of the abutment coupling interface and the support member coupling interface can provide an angle of extraction of from about 0 degrees to about 12 degrees. It should be recognized that any suitable coupling feature or structure can be utilized to facilitate removable coupling of the support member and the dental implants.

Without fasteners, such as screws, which are typically used to couple a support member of a dental prosthetic to dental implants, the strength of the support member can be increased due to the lack of through holes in the support member, therefore reducing the need for replacement or repair.

Furthermore, the dental prosthetic can be substantially free of a spacer or other member oriented between the tissue and the support member (e.g. which may include integrated cosmetic or structural layers).

The foregoing detailed description describes the invention with reference to specific exemplary embodiments. However, it will be appreciated that various modifications and changes can be made without departing from the scope of the present invention as set forth in the appended claims. The detailed description and accompanying drawings are to be regarded as merely illustrative, rather than as restrictive, and all such modifications or changes, if any, are intended to fall within the scope of the present invention as described and set forth herein.

Claims

CLAIMS What is claimed is:

1. A dental prosthetic, comprising:

an artificial tooth portion, and a support member coupled to and supporting the artificial tooth portion, wherein the support member is removably coupleable to a plurality of dental implants by the patient user, wherein the plurality of dental implants are coupleable to a jaw bone of a patient user.

2. The dental prosthetic of claim 1, wherein the support member comprises a bar.

3. The dental prosthetic of claim 2, wherein the bar is made of a rigid material.

4. The dental prosthetic of claim 1, further comprising an abutment secured but removably coupleable to the support member.

5. The dental prosthetic of claim 4, wherein the abutment is securable to the dental implant and having an abutment coupling interface.

6. The dental prosthetic system of claim 5, wherein the abutment coupling interface is constructed to tolerances sufficient to minimize relative movement of the support member and the dental implant when coupled while facilitating removal of the support member from the dental implant by the user.

7. The dental prosthetic system of claim 6, wherein the tolerances are less than 0.01 mm.

8. The dental prosthetic system of claim 4, wherein the abutment coupling interface form at least one of a Swiss block, a thermally induced interlock, or a magnetic interlock..

9. The dental prosthetic system of claim 4, wherein the abutment coupling interface forms a Morse taper interface.

10. The dental prosthetic system of claim 1, wherein the artificial tooth portion comprises a plurality of artificial teeth.

11. The dental prosthetic system of claim 10, wherein the plurality of artificial teeth comprises at least three artificial teeth.

12. The dental prosthetic system of claim 10, wherein the plurality of artificial teeth comprises at least half a number of teeth associated with the jaw bone.

13. The dental prosthetic system of claim 1, further comprising an abutment, wherein the dental implant comprises a Morse taper cup permanently securable with the jaw bone of the patient, wherein the abutment forms an abutment coupling interface between the dental implant and the support member.

14. A method of making a dental prosthetic, comprising:

indirectly determining positions of the plurality of dental implants;

indirectly forming a plurality of coupling interfaces about the support member of a dental prosthetic of claim 1, wherein the coupling interfaces are located about the support member based on the positions of the dental implants to facilitate coupling the support member to the dental implants.

15. The method of claim 14, wherein determining positions of the plurality of dental implants comprises determining orientations of longitudinal axes of the plurality of dental implants, and wherein the coupling interfaces are oriented based on the orientations of the longitudinal axes.

16. The method of claim 14, wherein the coupling interfaces of the support member are constructed to tolerances sufficient to minimize relative movement of the support member and the dental implants when coupled.

17. The method of claim 14, wherein the tolerances are less than 0.01 mm.

18. The method of claim 14, further comprising implanting the plurality of dental implants into the jaw bone of the patient user prior to indirectly determining positions.