Shade-coordinated, veneering porcelain system for dental prostheses

Abstract

The invention is related to a shaded porcelain system that contains two types of veneering porcelains: natural enamel/dentin body and opal enamel, as well as stain & glaze porcelain, with CTE that are compatible to and which can be used for veneering a dental prosthesis made of 1) lithium disilicate-based glass-ceramic substructure that is formed by hot pressing or CAD/CAM machined process or 2) YTZP zirconia-based ceramic substructure that is formed by CAD/CAM machined process in order to improve overall esthetics of final prosthesis.

Claims

1. A shade-coordinated porcelain system for a lithium disilicate-based glass-ceramic and/or YTZP zirconia-based ceramic substructure, comprising: (i) a natural enamel/dentin body having a composition that includes: TABLE-US-00007 Natural Enamel/ Oxide Body White (wt %) SiO.sub.2 60-65 Al.sub.2O.sub.3 10-13 Na.sub.2O 5-7 K.sub.2O 6-9 Li.sub.2O 1-3 CaO 0-2 BaO 2-4 MgO 0.5-1   CeO.sub.2 0.5-1   Sb.sub.2O.sub.3 0.5-1   Tb.sub.2O.sub.3 0.5-1   TiO.sub.2 0-1 SnO.sub.2 0 B.sub.2O.sub.3 3-5 ZrO.sub.2 0.5-1   P.sub.2O.sub.5 0.5-1   F 0.5-1   Total 100 (ii) an opal enamel having a composition that includes: TABLE-US-00008 Oxide Opal Enamel (wt %) SiO.sub.2 58-63 Al.sub.2O.sub.3 10-13 Na.sub.2O 5-8 K.sub.2O 6-9 Li.sub.2O 1-3 CaO 1-3 BaO 1-3 MgO 0.05-1   CeO.sub.2 0.05-1   Sb.sub.2O.sub.3 0.05-1   Tb.sub.2O.sub.3 0.05-2   TiO.sub.2 0-1 SnO.sub.2 0.05-1   B.sub.2O.sub.3 3-6 ZrO.sub.2 0.05-1   P.sub.2O.sub.5 0.05-1   F 0.05-1   Total 100 and (iii) a stain and/or glaze porcelain having a composition that includes: TABLE-US-00009 Oxide Stain and/or Glaze (wt %) SiO.sub.2 58-63 Al.sub.2O.sub.3 10-13 Na.sub.2O 5-8 K.sub.2O  4-10 Li.sub.2O 1-3 CaO 1-3 BaO 2-6 CeO.sub.2 0.05-1   Sb.sub.2O.sub.3 0.005-1    Tb.sub.2O.sub.3 0-2 TiO.sub.2 0-1 B.sub.2O.sub.3  5-12 Total 100 wherein the natural enamel/dentin body, the opal enamel, and the stain and/or glaze porcelain are thermally compatible to the substructure and have a CTE in the range between 8.8 ppm/° C. and 9.5 ppm/° C. @ 500° C. and wherein the CTE of the natural enamel/dentin body and the opal enamel is achieved after firing the shade-coordinated porcelain system at a temperature in the range between 680° C. and 800° C.

2. The shade-coordinated porcelain system of claim 1, wherein the lithium disilicate-based glass-ceramic substructure has a CTE in the range of 9.5 ppm/° C. and 10.5 ppm/° C. @ 500° C.

3. The shade-coordinated porcelain system of claim 1, wherein the YTZP zirconia-based ceramic substructure has a CTE in the range of 10.0-11.0 ppm/° C. @ 500° C.

4. The shade-coordinated porcelain system of claim 1, wherein the CTE of the natural enamel/dentin body, the opal enamel, and the stain and/or glaze porcelain is achieved after firing the shade-coordinated porcelain system at a temperature in the range between 720° C. and 800° C.

5. The shade-coordinated porcelain system of claim 4, wherein the CTE is achieved after the firing the shade-coordinated porcelain system at a temperature 50° C. lower than the firing temperature of natural enamel/dentin body.

6. The shade-coordinated porcelain system of claim 4, wherein the CTE is achieved after firing the shade-coordinated porcelain system at a temperature 50° C. lower than the firing temperature of the opal enamel porcelain.

7. The shade-coordinated porcelain system of claim 4, wherein the CTEs of the natural enamel/dentin body or the opal enamel porcelain and stain and/or glaze porcelain are in the range between 9.0 ppm/° C. and 9.5 ppm/° C. @ 500° C. and the porcelain firing temperatures are in the range between 750° C. and 770° C.

8. The shade-coordinated porcelain system of claim 1, wherein the CTE of the natural enamel/dentin body, the opal enamel, and the stain and/or glaze porcelain is achieved after firing the shade-coordinated porcelain system at a temperature in the range between 740° C. and 780° C.

Description

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(1) The present invention provides for a shade-coordinated, veneering porcelain system for a dental prosthesis. Generally, the shade-coordinated, veneering porcelain system for a dental prosthesis may be made of hot-pressed or CAD/CAM machined lithium silicate-based material (e.g., lithium disilicate and/or monosilicate, preferably lithium disilicate) or CAD/CAM machined YTZP zirconia-based material. More particularly, the invention comprises a shade coordinated porcelain system, which contains two, type of veneering porcelain: natural enamel/dentin body and opal enamel porcelain, as well as glaze and stain porcelain, that are thermally compatible with both lithium disilicate-based glass-ceramic and YTZP zirconia-based ceramic substructure. With its well-designed shade scheme, shade coordination can be obtained between these two types of dental prosthesis.

(2) The composition of the natural enamel/body white porcelain in powder form (see Table 1) is formulated such that after first dentin porcelain firing, it is refractory and is resistant to drifting during subsequent second dentin or enamel porcelain firing for making either lithium disilicate-based glass-ceramic or YTZP zirconia-based ceramic restorations. In addition, it is also thermally compatible with the above two types of glass ceramic/ceramic. The firing temperature of the natural enamel/dentin body porcelain in powder form is preferably between 680° C. and 840° C., more preferably between 720° C. and 800° C., and most preferably between 740° C. and 780° C.

(3) TABLE-US-00001 TABLE 1 CHEMICAL COMPOSITION OF NATURAL ENAMEL/BODY WHITE PORCELAIN (WT %) Oxide Natural Enamel/Body White SiO.sub.2 55-70 (60-65) Al.sub.2O.sub.3 5-18 (10-13) Na.sub.2O 0.5-13 (5-7) K.sub.2O 1-14 (6-9) Li.sub.2O 0.05-8 (1-3) CaO 0-7 (0-2) (0.05-1) BaO 0.5-9 (2-4) MgO 0-3 (0.5-1) (0.005-0.05) CeO2 0-3 (0.5-1) (0.05-1) Sb.sub.2O.sub.3 0-3 (0.5-1) (0.05-1) Tb.sub.2O.sub.3 0-3 (0.5-1) (0.05-1) TiO.sub.2 0.14 (0-1) SnO.sub.2 — B.sub.2O.sub.3 0.5-10 (3-5) ZrO.sub.2 0-3 (0.5-1) (0.05-1) P.sub.2O.sub.5 0-3 (0.5-1) F 0-3 (0.5-1) (0.05-1) Total 100

(4) The composition of the opal enamel porcelain (see Table 2) is formulated such that it is thermally compatible with the above the two types of glass ceramic/ceramic as well as natural enamel/dentin body porcelain. The firing temperature of the opal enamel porcelain is preferably between 680° C. and 840° C., more preferably between 720° C. and 800° C., and most preferably between 740° C. and 780° C.

(5) TABLE-US-00002 TABLE 2 CHEMICAL COMPOSITION OF OPAL ENAMEL WHITE PORCELAIN (WT %) Oxide Opal Enamel White (Range) SiO.sub.2 53-68 (58-63) Al.sub.2O.sub.3 5-18 (10-13) Na.sub.2O 0.5-13 (5-8) K.sub.2O 1-14 (6-9) Li.sub.2O 0.05-8 (1-3) CaO 0.05-8 (1-3) BaO 0.05-8 (1-3) MgO 0-2 (0.05-1) CeO.sub.2 0-2 (0.05-1) Sb.sub.2O.sub.3 0-2 (0.05-1) Tb.sub.2O.sub.3 0-5 (0.05-2) TiO.sub.2 0.14 (0-1) SnO.sub.2 0-2 (0.05-1) B.sub.2O.sub.3 1-11 (3-6) ZrO.sub.2 0-2 (0.05-1) P.sub.2O.sub.5 0-2 (0.05-1) F 0-2 (0.05-1) Total 100

(6) Furthermore, the present invention may include an add-on (e.g. correction porcelain, formulation resulting in the composition in Table 3. The firing temperature of the add-on porcelain is preferably similar to that of the Natural Enamel/Body White composition, the Opal composition as described above.

(7) TABLE-US-00003 TABLE 3 CHEMICAL COMPOSITION OF ADD-ON ENAMEL (WT %) Oxide Add-On Enamel (Range) SiO.sub.2 51-71 (56-66) Al.sub.2O.sub.3 1-20 (15-25) Na.sub.2O 1-20 (2-15) K.sub.2O 1-20 (2-12) Li.sub.2O 0.05-8 (1-4) CaO 0.05-8 (1-4) BaO 0.5-10 (1-6) MgO 0-2 (0.05-1) CeO.sub.2 0-2 (0.05-1) Sb.sub.2O.sub.3 0-2 (0.05-1) Tb.sub.2O.sub.3 0-5 (0.5-4) TiO.sub.2 0.14 (0-1) SnO.sub.2 0-2 (0.05-1) B.sub.2O.sub.3 1-12 (3-9) ZrO.sub.2 0-2 (0.05-1) P.sub.2O.sub.5 0-2 (0.05-1) F 0-2 (0.05-1) Total 100

(8) It is appreciated that the Natural Enamel/Body White composition, the Opal composition and/or the add-on composition of TABLES 1-3 may be formed from the combination of at least two different granulated frit materials. Generally, a frit material may be a ceramic composition that has been fused in a heating apparatus (furnace, fusing oven, etc. . . . ), quenched to form a glass, and then granulated. Various exemplary chemical compositions of the granulated frit materials of the present invention are shown in TABLE 4A.

(9) TABLE-US-00004 TABLE 4A CHEMICAL COMPOSITION OF FRITS (WT %) Oxide/wt % Frit A Frit B Frit C Frit D Frit E Frit F SiO.sub.2 62-68   62-66 58-62 66-70 63-67 57-61 Al.sub.2O.sub.3 12-16   14-18  8-12 12-16 5-9  9-13 K.sub.2O  7-11   12-16 3-7 5-9 10-14  6-10 Na.sub.2O 3-7   2-6 4-8 5-9  8-12  8-12 Li.sub.2O 1-5  0.5-3 1-5 0.05-0.5  0.05-1   0.05-1   CaO 0.05-1   0.05-1 0.05-1   1-3 9.05-1   1-5 BaO 0.5-3.sup.  2-6 0.05-1   1.98 MgO 0.05-1 CeO.sub.2 0.5-3.sup.  0.05-1 0.05-1   0.5-1.sup.  Sb.sub.2O.sub.3 0.005-1    0.01-0.5  1-3 2.25 Tb.sub.2O.sub.3 0.05-1 1-4 1-4 TiO.sub.2 0.05-1   SnO.sub.2 0.5-3.sup.  B.sub.2O.sub.3  8-12 2-6 ZrO.sub.2 1-3 P.sub.2O.sub.5 0.5-4.sup.  F.sup.− 0.5-1.sup.  0.5-3.sup.  Total 100.0 100.0 100.0 100.00 100.00 100.00

(10) Preferably, the Natural Enamel/Body White composition, the Opal composition and/or the add-on composition of TABLES 1-3 may be formed from the combination of at least three different granulated frit materials and most preferably at least four different granulated frit materials (e.g., from three to six different granulated frit materials) as shown in TABLE 4B.

(11) TABLE-US-00005 TABLE 4B CHEMICAL COMPOSITION OF RESULTANT PORCELAINS (WT %) Natural Enamel/ Component Body White Opal Add-on frits Wt % Wt % Wt % Frit A 20-40 (25-35) 0-60 (30-50) 0-60 (30-50) Frit C 25-45 (30-40) 20-40 (25-35) 45-65 (50-60) Frit D 5-25 (10-20) 15-35 (20-30) 1-20 (5-15) Frit B 0-5 (1-3) 0-5 (1-3) 0-4 (0.05-2) Frit E 10-30 (15-25) 0-30 (10-20) 1-15 (2-8) Frit F 0-60 (30-50) 30-50 (35-45) 15-35 (20-30)

(12) The composition of the glaze and stain white porcelain (see Table 5) is formulated such that it can be applied and fired either directly over either full-contour or veneered lithium disilicate-based glass-ceramic and YTZP zirconia-based ceramic substructure to form dental restorations at a lower temperature than both natural enamel/dentin body and opal enamel porcelain. The firing temperature of the stain and glaze porcelain is preferably 50° C., more preferably 30° C., and most preferably 10-20° C. lower than the firing temperature of natural enamel/dentin body and opal enamel porcelain.

(13) TABLE-US-00006 TABLE 5 CHEMICAL COMPOSITION OF GLAZE & STAIN PORCELAIN (WT %) Oxide Glaze & Stain White SiO.sub.2 53-68 (58-63) Al.sub.2O.sub.3 5-18 (10-13) Na.sub.2O 0.5-13 (5-8) K.sub.2O 1-14 (4-10), (6-9) Li.sub.2O 0.05-8 (1-3) CaO 0.05-2 (1-3) BaO 0.05-9 (2-6), (1-3) CeO.sub.2 0-2 (0.05-1) Sb.sub.2O.sub.3 0-2 (0.005-1) Tb.sub.2O.sub.3 0.5-5 (0-2) TiO.sub.2 0.42 (0-1) B.sub.2O.sub.3 1-15 (5-12), (3-6) Total 100

(14) The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the invention. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes.

REFERENCE

(15) U.S. Pat. No. 5,482,732 “Dental Porcelain Shading Method” by Carolyn Kramer Jun. 9, 1994. U.S. Pat. No. 5,685,717 “Dental Porcelain Shading Kit, System and Method” by Carolyn Kramer May 31, 1995.