SCAN POSTS SYSTEM AND METHOD

Abstract

A scan posts system with scan posts is presented. Each scan post includes a scan post core and a scan post body surrounding the core and resting in the shoulder of the core. At least part of the scan post body is intended to be in contact with healing tissue. Each scan post body belongs to a group of scan post bodies including at least a combination of two different shapes with three different sizes and at least one height. Each scan post body includes at least one scan mark suitable for providing information about the shape, size and height of the scan post to a scanning device, this information being useful for designing a dental implant prosthesis. A method of manufacturing a dental implant prosthesis using such a system is also presented.

Claims

1.-29. (canceled)

30. A scan post suitable for being used in designing a dental implant prosthesis, the scan post comprising: a scan post core comprising: a prosthetic connection defining a connection axis, a pillar defining a pillar axis, a shoulder located between the pillar and the prosthetic connection, and a core mark; and a scan post body configured to be installed around the pillar of the scan post core and resting in the shoulder of the scan post core, the scan post body defining a body axis, wherein at least part of the scan post body is intended to be in contact with healing tissue, wherein: the pillar comprises at least a portion of a cylinder having an outer diameter; the scan post body comprises a central cavity with a first portion having a cylindrical shape with a diameter configured to fit the portion of the cylinder of the pillar, so that when the scan post body is installed around the pillar, the scan post body is allowed to freely rotate around the scan post core with lateral stability; and the scan post further comprises fixing means to fix the scan post body to the scan post core when a desired position of the scan post body with respect to the scan post core is achieved.

31. The scan post according to claim 30, wherein: the scan post core further comprises a protrusion protruding a protrusion length from the pillar, and the scan post body comprises a second portion extending over at least 15° and being configured to allow movement of the protrusion along the second portion.

32. The scan post according to claim 31, wherein the scan post core further comprises a cap, wherein the core mark is located in a position of the cap depending on a position of the protrusion of the scan post core.

33. The scan post according to claim 30, wherein the fixing means comprises: a securing screw configured to securely attach the scan post body to the scan post core and to an implant.

34. The scan post according to claim 30, wherein the fixing means comprises: a securing screw configured to securely attach the scan post body to the scan post core, and an auxiliary securing screw configured to securely attach the scan post core to an implant.

35. The scan post according to claim 34, wherein: the scan post core further comprises a protrusion protruding a protrusion length from the pillar and a cap, wherein the core mark is located in a position of the cap depending on a position of the protrusion of the scan post core; the scan post body comprises a second portion extending over at least 15° and being configured to allow movement of the protrusion along the second portion; and the securing screw is configured to securely attach the cap to the scan post body and to the scan post core.

36. The scan post according to claim 35, wherein the securing screw comprises an opening configured to allow the protrusion of the scan post core to be visible from outside the scan post.

37. The scan post according to claim 30, wherein the fixing means comprises glue or a friction fit connection.

38. The scan post according to claim 30, wherein at least part of the scan post body and the shoulder of the scan post core form a continuous and derivable surface.

39. The scan post according to claim 38, wherein the continuous and derivable surface formed by the shoulder and at least part of the scan post body comprises a convex portion and a concave portion, the concave portion being closer to the prosthetic connection than the convex portion.

40. The scan post according to claim 30, wherein the pillar axis and the connection axis cut each other and form an angle comprised between 1 and 45°.

41. The scan post according to claim 30, wherein the pillar axis is parallel to the body axis and is arranged at a distance between 1 and 20 mm therefrom.

42. The scan post according to claim 30, wherein the scan post body further comprises first retention means and the scan post core comprises second reception means, the second retention means being arranged to abut against the first reception means to reversibly block movement of the scan post body with respect to the scan post core in a direction parallel to the pillar axis, while allowing free rotation of the scan post body with respect to the scan post core.

43. The scan post according to claim 42, wherein: the scan post core further comprises a protrusion protruding a protrusion length from the pillar, and the scan post body comprises a second portion extending over at least 15° and being configured to allow movement of the protrusion along the second portion, and the first retention means comprises a protruding arc extended along a part of the second portion of the scan post body, and the second reception means comprises a recess performed in the protrusion of the scan post core, in such a way that the protruding arc has a height equal to the height of the recess.

44. The scan post according to claim 31, wherein a cross section of the scan post body perpendicular to the body axis cuts both the first portion and the second portion of the scan post body.

45. The scan post according to claim 31, wherein the central cavity of the scan post body comprises a beveled wall connecting the first portion and the second portion, preventing presence of cross sections perpendicular to the body axis which cuts both the first portion and the second portion, in view of the first portion and the second portion being separated by the beveled wall.

46. The scan post according to claim 30, wherein the scan post body comprises two different parts attached to each other by mechanical and/or chemical retention means.

47. A scan post system suitable for being used in designing a dental implant prosthesis, the scans post system comprising a plurality of scan posts according to claim 30, wherein the system comprises at least four different scan post bodies with at least two different shapes with two different sizes and at least one height.

48. The scan post system according to claim 47, wherein the system comprises at least eighteen different scan post bodies with at least three different shapes with three different sizes and more than one height; and wherein each scan post body comprises at least one scan mark suitable for providing information about shape, size and height of the scan post body to a scanning device, for designing a dental implant prosthesis.

49. The scan post system according to claim 47, wherein a scan body shape of each scan post is defined by a cross section in a plane perpendicular to the pillar axis crossing the scan post at its maximum equivalent diameter, wherein the equivalent diameter is a maximum distance between two points belonging to said cross section, and wherein said cross section is, for each scan post, one of a triangle with rounded edges, a square with rounded edges, a parallelogram with rounded edges or an ovoid.

50. The scan post system according to claim 47, wherein a scan body height of each scan post is defined by a distance between a plane comprising a cross section of the scan post with minimum equivalent diameter and a plane comprising the cross section of the scan post with maximum equivalent diameter, wherein the equivalent diameter is the maximum distance between two points belonging to said cross section.

51. The scan post system according to claim 47, wherein a scan body size of each scan post is defined by an equivalent diameter of a cross section of the scan body in a plane perpendicular to the pillar axis crossing the scan post at its maximum equivalent diameter, wherein the equivalent diameter is a maximum distance between two points belonging to said cross section, this size being classified into at least three categories, comprising a small category, a medium category and a large category.

52. The scan post system according to claim 47, wherein at least some scan post bodies have different shapes at different cross sections perpendicular to the pillar axis, and wherein the scan marks comprise information about the different shapes and a distance of perpendicular planes from a top of the scan post body.

53. The scan post system according to claim 47, wherein at least some scan post bodies have a circular cross section in a plane perpendicular to the pillar axis crossing the scan post body at its minimum equivalent diameter, wherein the equivalent diameter is a maximum distance between two points belonging to said cross section; and wherein the scan mark is configured to provide information about size and height of the circular cross section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0129] To complete the description and in order to provide for a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate an embodiment of the invention, which should not be interpreted as restricting the scope of the invention, but just as an example of how the invention can be carried out. The drawings comprise the following figures:

[0130] FIG. 1 shows a generic view of a scan posts system according to the invention.

[0131] FIG. 2 shows a vertical section view of a particular embodiment of a scan post according to the invention.

[0132] FIG. 3 shows the same scan post as shown in FIG. 2, but to show different features.

[0133] FIG. 4 shows a perspective view of a particular embodiment of a scan post according to the invention.

[0134] FIG. 5 shows a perspective view of a particular embodiment of a scan post according to the invention.

[0135] FIG. 6 shows a particular feature which may be comprised in any of the scan posts according to the invention.

[0136] FIG. 7 shows an alternative of the feature illustrated in FIG. 6.

[0137] FIGS. 8a and 8b show different cross sections of a scan body of a scan post of a scan post system according to the invention.

[0138] FIGS. 9a and 9b show the feature of a cap to be installed in a scan post according to the invention.

[0139] FIGS. 10 and 11 shows a perspective view and a cross section of a particular embodiment of a scan post according to the invention, where the scan post body is divided into two parts.

[0140] FIGS. 12 and 13 show steps of a method according to the invention.

[0141] FIG. 14 shows another step of an alternative method according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0142] The example embodiments are described in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. It is important to understand that embodiments can be provided in many alternate forms and should not be construed as limited to the examples set forth herein.

[0143] Accordingly, while embodiment can be modified in various ways and take on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.

[0144] FIG. 1 shows a generic view of a scan posts system 100 according to the invention. This scan post system is suitable for being used in designing a dental implant prosthesis.

[0145] As will be shown below, each scan post belonging to the scan posts system comprises a scan post core and a scan post body. The scan post body is different for each scan post, while the scan post core is substantially the same for each scan post.

[0146] This system 100 comprises 36 scan posts 10, which responds to the combination between four different shapes (rectangular with round edges, triangular with round edges, ovoid and square with round edges), three different sizes (small, medium and large) and three different heights (short, medium and long).

[0147] Every scan post 10 comprises several scan marks 4, one of them containing information about the shape, the size and the height of the scan post 10, which may be easily read and interpreted by a scanning tool. Further, other scan marks will be also useful for the scanning tool to provide position and orientation information of the scan post 10.

[0148] FIG. 2 shows a vertical section view of a particular embodiment of a scan post 10 belonging to a scan posts system according to the invention.

[0149] This scan post 10 comprises a scan post core 1 and a scan post body 2. The scan post core 1 comprises a prosthetic connection 11, a pillar 12 defining a pillar axis 12a and a protruding shoulder 13 between the pillar 12 and the prosthetic connection 11. The scan post body 2 in turn surrounds the pillar 12 and rests in the shoulder 13. This scan post body 2, or at least part of it, is intended to be in contact with healing tissue. The scan post 10 further comprises a retention screw 3 which is configured to provide a secure attachment between the scan post body 2 and the scan post core 1. An auxiliary securing screw 30 is used to provide a secure attachment between the scan post core 1 and an implant (not shown in this figure). In different embodiments, the same securing screw is used to securely attach the scan post body to the scan post core and to an implant. In yet different embodiments, other fixing means, such as glue or a friction fit connection is used to attach these elements.

[0150] The lateral surface of the scan post body and the shoulder form a continuous and derivable surface. This surface comprises a convex portion 51 and a concave portion 52, the concave portion 52 is closer to the prosthetic connection 11 than the convex portion 51.

[0151] The height h of the scan body of this scan post is defined as the distance between the plane with minimum diameter and the plane with maximum diameter. In this figure, these planes are seen as lines 53, 54, since they are perpendicular to the pillar axis 12a.

[0152] FIG. 3 shows the same scan post 10 as the FIG. 2, but to show different features.

[0153] In this figure, the pillar 12 comprises a portion of a cylinder 12b which has an outer diameter od and a protrusion 14 which protrudes a protrusion length pl from the pillar 12. In this figure, the protrusion 14 is shown to the right, and comprises a protrusion mark 15 on top thereof.

[0154] As shown in FIG. 4, the scan post body 2 comprises a central cavity with a first portion 21 having a cylindrical shape with a diameter substantially identical to the outer diameter of the cylinder of the pillar and a second portion 22 which extends over 180° and has a cylindrical shape with a diameter corresponding to the sum of the outer diameter and the protrusion length. With this shape, the first portion 21 is suitable to receive the portion of a cylinder of the pillar while the second portion 22 is suitable for letting the protrusion (not shown in this figure) to freely rotate so that the scan post body 2 may be oriented in different orientations with respect to the scan post core 1.

[0155] As is clearly shown in this picture, there is a cross section to the scan post body perpendicular to the body axis (i.e. a horizontal plane) which cuts both the first portion and the second portion of the central cavity, since both first and second portions are located at the same height of the scan post body.

[0156] This scan post 10 comprise one mark 4 located on top of the scan post body 2, but any other location would be suitable as well. This scan mark 4 is capable of providing the necessary information for identifying the three dimensional position of the said scan post in the jaw, since the scan post body comprising a non-circular shape provides reference points due to its shape that, in combination with the scan mark, are enough to provide all the necessary information needed to the CAD-CAM station.

[0157] FIG. 5 shows a particular embodiment of a scan post 10 according to the invention, where the securing screw 3 comprises an opening 31 configured to allow the protrusion and the protrusion mark 15 of the scan post core to be visible from outside the scan post. This is useful so that there is no need to remove the scan post body 2 to scan the position of the protrusion mark 15.

[0158] FIG. 6 shows a particular feature which may be comprised in any of the scan posts according to the invention.

[0159] In this figure, it may be seen how the scan post body comprises a protruding arc 23 and the scan post core comprises a recess 16. The protruding arc 23 and the recess 16 are configured to match due to the fact that they have the same height (measured in the direction of the pillar axis), thus reversibly blocking the movement of the scan post body 2 with respect to the scan post core 1 in a direction parallel to the pillar axis, while at the same time allowing the free rotation of the scan post body 2 with respect to the scan post core 1.

[0160] The protruding arc 23 extends only along a part of the second portion of the scan post body, leaving a free space 24 so that the protrusion is introduced. Once the protrusion is introduced, the protruding arc 23 and the recess 16 are at the same height and the blocking may take place by the rotation of the scan post body with respect to the scan post core.

[0161] FIG. 7 shows an alternative of the feature illustrated in FIG. 6. In this case, the protruding arc 23 and the recess 16 are not located adjacent to the shoulder of the core, but at a height which is located approximately in the middle of the protrusion.

[0162] This makes the recess 16 to be fitted between two protrusions of the pillar, thus increasing stability.

[0163] FIGS. 8a and 8b show different cross sections of this scan body 10, the two of them being according to these aforementioned planes of maximum and minimum equivalent diameter. The cross section shown in FIG. 8a is made according to the plane 53 where the equivalent diameter is the maximum one, and in this case corresponds to the top portion of the scan post body. The cross section shown in FIG. 8b is made according to the plane 54 where the equivalent diameter is the minimum one, and in this case corresponds to the bottom portion of the scan post body.

[0164] The equivalent diameter is considered as the maximum distance between two points belonging to said cross section.

[0165] FIG. 8a shows the cross section of a particular example of a scan post where the shape in this maximum equivalent diameter section is an ovoid with rounded edges.

[0166] FIG. 8b shows in turn the cross section of the same scan post wherein the shape in this minimum equivalent diameter section is a circle.

[0167] The size of the scan body of each scan post is defined by the equivalent diameter of the cross section of the scan body in a plane perpendicular to the pillar axis which crosses the scan post at its maximum equivalent diameter. As a consequence, in this case, this scan post would be considered as an ovoid scan post. However, the rounded cylindrical shape in the bottom portion is advantageous, since maximum tissue thickness is desired in this zone and a circular cylindrical shape is advantageous to provide the least diameter circumferentially in comparison to other shapes.

[0168] This scan post starts with a cylindrical shape and then expands laterally upwards in a concave manner till it reaches its maximum diameter and at which point comprises a generally ovoid shape with rounded edges. The vertical location of the maximum diameter and thus the location of the anatomical shape may be different in the different groups and within the same group of shapes. The inventive custom scan posts comprise marks that additionally provide this information.

[0169] This size may be classified into at least three categories, the small one being comprised between 4 and 6 mm, the medium one being comprised between 6.5 and 8.5 mm and the big one being comprised between 9 and 12 mm.

[0170] FIGS. 9a and 9b show the feature of a cap to be installed in a scan post according to the invention.

[0171] FIGS. 9a shows a cap 6. This cap 6 comprises a first recess 61 to match the protrusion of the scan post core and a second recess 62 which is located at the same angular position than the first recess 61.

[0172] The scan cap can be installed onto at least part of the core's pillar and within at least part of the housing of the scan post body, engaging at least part of the protrusion of the pillar as seen in FIG. 9b. Since the scan mark of the scan cap and the one of the scan post core have a stable relationship to each other when the scan post system is assembled. The goal of this scan cap is to “transfer” the scan mark of the core on a more coronal position that is easier to be identified and marked by the intra-oral scanner during the scanning process. Therefore, it is understood that the protrusion of the pillar per se does not need to be a scan mark for the scan mark of the cap to maintain its functionality as a scan mark providing the information of the core and thus of the implant 3D position and orientation.

[0173] In some particular embodiments the scan marks present on the core, and, or the body and/or the cap are all identified and processed through suitable CAD-CAM software so that the final configuration, of the generated by the practitioner scan post after final assembly of all components, is achieved.

[0174] FIGS. 10 and 11 show a particular example of a scan post body belonging to a scan post according to an embodiment of the invention.

[0175] In this case, the scan post body comprises two different parts 17, 18 which are manufactured separately and then attached to each other by means of an adhesive.

[0176] FIG. 10 shows an exploded view of a scan post where the scan post body comprises these two parts 17, 18. The first part 17 reproduces the internal geometry of the scan post body. In this first part 17, the relevant geometry is the internal one, which in this case reproduces the internal shape of the scan post of FIG. 6.

[0177] The external geometry of this first part 17 is designed to match with the internal geometry of the second part.

[0178] The second part 18 reproduces the external geometry of the scan post body and is coupled to the first part to form a scan post according to the invention.

[0179] These two parts may be produced by milling and then may be coupled and attached by means of an adhesive. Alternatively, these parts may be produced by injection molding where the first part is installed onto the scan post core present in a suitable well of a mould that comprises wells with anatomical shape and a suitable material is injected within the well so that it covers at least part of the first part without reaching the scan post core. Once the material is set, it will form an anatomical external shape that has become one piece with the first part or a second piece that provides for the second part with anatomical shape that will then be attached to the first part.

[0180] The main advantage of splitting the manufacturing of the scan post body into these two pieces is that they can be used in an in-office tool, so that the anatomical shapes can be formed through injection moulding process by the dentist. The internal connection is therefore uncoupled from the manufacturing process of the anatomical external shape.

[0181] In an example of a manufacturing method, the dentist first installs the scan post core inside a mould. Then, the cap is installed on the pillar of the scan post core. Next step comprises introducing flowable composite material, to be cured by light. Thus, the cap and the composite become one piece with the desired shape. After this process, the scan post core and the customised cap may be used.

[0182] The abutment core is not affected by this process and the inner surface of the inventive cap that interacts with the core is not affected by the process either. Hence, the inventive scan post's function is not affected with its methodology of use.

[0183] Thus, the proposed embodiment allows a dentist to have a customisation mould to create different shapes and sizes of anatomical bodies without the need of different cores and caps available in their office.

[0184] FIG. 11 shows a cross section of these elements when they have been partially assembled. The first and second portions 17, 18 have been attached to form the scan post body, which is to be inserted in the scan post core 1.

[0185] This scan posts system may be used in a method for manufacturing dental implants prostheses as shown in FIGS. 12 and 13, the method comprising the steps of [0186] attaching a scan post core 1 belonging to the scan posts system 100 according to the present invention to a dental implant 50 present in an edentulous space, [0187] placing a scan post body 2 belonging to the scan posts system 100 around the scan post core 1; [0188] rotating the scan post body 2 with respect to the scan post core 1 until the scan post body 2 reaches a correct orientation; [0189] fixing the scan post body 2 with respect to the scan post core 1; [0190] letting healing tissue grow around the scan post body; [0191] removing the scan post body 2 from the scan post core 1; [0192] scanning the scan mark 4 present in the scan post core to obtain the position and orientation of the scan post and a map of the healing tissue 64 around the scan post core 1; and [0193] manufacture a dental implant prosthesis with the information obtained in the previous step.

[0194] The scan post is chosen from the scan post system after identifying the type and size of tooth missing and thus the best corresponding shape and size of scan body and measuring the distance between the dental implant and a cervical margin location, either directly on the patient's mouth or extra-orally.

[0195] The exact orientation of the scan post body 2 with respect to the scan post core 1 is chosen by the free rotation provided by the invention, where the practitioner may choose the orientation in a continuous range from 0 to 180°, or even more.

[0196] Then, the chosen scan post 10 is attached to a dental implant 50 which is already present in the edentulous space of a patient. This scan post 10 comprises a core with a protrusion mark 15, so that it may be scanned in a subsequent step.

[0197] During the healing process, the scan post core is installed on the implant. The implant has a prosthetic connection which is configured to receive the prosthetic connection of the core.

[0198] Once the core is assembled to the implant, the shoulder of the core sits on the platform of the implant and the prosthetic connection of the core engages to the prosthetic connection of the implant and no rotation is possible. The protrusion mark 15 provides the information with regards to the orientation of the prosthetic connection and/or the platform of the implant. This prosthetic connection can have a polygonal shape, mainly a hexagon, a triangle or an octagon. Thus, the core can be assembled onto the implant in 6, or 3, or 8 different positions, respectively. However, all of these positions lead to same clinical effect, since the scan mark of the core still provides the necessary information of the orientation of the platform and prosthetic connection, in particular of the flat seat of the prosthetic connection of the hexagonal or triangular or octagonal connection.

[0199] Once the healing tissue has been grown around the scan post, the scan post may be scanned with a scanner device 60 to obtain the position and orientation of the scan post, but also the gingival tissue profile 64 around the scan post. This map of the healing tissue is important to manufacture the final dental implant prosthesis which will be installed instead of the scan post.

[0200] FIG. 13 shows an alternative method, wherein the scan post 10 comprises a cap 6, as described in FIGS. 8a and 8b. Since this cap comprises a second recess 62 which contains the information about the orientation of the protrusion of the core, it can be scanned directly without removing of the cap or of the scan post body.

[0201] These data are sent to a CAD station where these data are received, and the final prosthesis is designed, taking into account the data obtained from the scan post and the healing tissue map also obtained by the scanner.

[0202] With these data, a suitable dental implant prosthesis will be manufactured. This prosthesis will adapt in an advantageous way to the edentulous space and to the gingival profile which has been sculpted by the scan post of the invention, and at least part of the prosthesis comprising its cervical profile and/or part of its subgingival portion will be a replicate of the inventive scan post.

[0203] FIG. 14 shows an alternative, where the method comprises the steps of [0204] attaching a scan post core 1 belonging to the scan posts system according to the invention to a dental implant present in an edentulous space, [0205] placing a scan post body 2 belonging to the scan posts system around the scan post core 1;

[0206] rotating the scan post body 2 with respect to the scan post core 1 until the scan post body 2 reaches a correct orientation; [0207] fixing the scan post body 2 with respect to the scan post core 1; [0208] letting healing tissue grow around the scan post body; [0209] scanning the scan post scan marks to obtain the position and orientation of the scan post and a map of the healing tissue around the scan post body; and [0210] manufacture a dental implant prosthesis with the information obtained in the previous step.

[0211] In this figure, the scanning is performed directly on the scan mark 15 which is comprised in the protrusion of the core. It is more difficult to scan it directly, since it is less accessible than in the case of the cap, but is also possible and does not require the installation of a cap.