Multi-coloured milling blank for implant-supported dental prosthetic restorations

Abstract

Dental blank for the production of a dental prosthetic restoration, in particular of a multi-coloured dental prosthetic restoration, by processing removing the outer region of the blank, comprising (i) an inner connecting element having an preferably peg-shaped scaffold region in the direction of the coronal region of the dental blank and an implant connection geometry in the radicular direction of the dental blank, (ii) wherein the scaffold region of the connecting element is connected to a dentin scaffold region in the direction of the coronal region of the blank, and wherein (iii) the dentin scaffold region is connected to an (iv) outer region of the blank in the region of enamel in the direction of the coronal region of the blank, and wherein (v) the dental blank has an inner elongated lumen for fastening of the produced dental prosthetic restoration on an implant or abutment by means of a connecting screw or a bolt. Moreover, a subject matter of the invention is a system for the production of a dental blank as well as the method for the production of the blank.

Claims

1. A dental blank (1) for the production of a dental prosthetic restoration (10) by material-removing processing, comprising: an inner connecting element (2) having a scaffold region (3a) in the direction of the coronal region of the dental blank and having an implant connection geometry (3b) in the radicular direction of the dental blank; (ii) wherein the scaffold region (3a) of the connecting element (2) is connected to a dentin scaffold region (4) in the direction of the coronal region of the blank; (1), and (iii) the dentin scaffold region (4) is connected to (iv) an outer region (5) of the blank in the direction of the coronal region of the blank (1), and (v) the dental blank has an elongated lumen (6) within the implant connection geometry (3b) of the inner connecting element (2), which extends from the top side (2.1) to the bottom side (2.2) of the implant connection geometry (3b) of the inner connecting element (2), and the lumen has an opening in crestal or lingual direction and an opening in radicular direction, wherein the outer region (5) of the blank is made of a dental hybrid ceramic comprising polymer content and ceramic content wherein the hybrid ceramic comprises ceramic content, wherein the ceramic content is a ceramic scaffold, wherein the ceramic scaffold comprises from 50 to 70% by weight SiO.sub.2, from 15 to 30% by weight Al.sub.2O.sub.3, from 5 to 15% by weight Na.sub.2O, from 2 to 10% by weight K.sub.2O, from 0.05 to 5% by weight B.sub.2O.sub.3, from 0.0001 to 1% by weight ZrO.sub.2, and from 0.0001 to 1% by weight CaO, wherein the total composition amounts to 100% by weight.

2. The blank according to claim 1, wherein the dental blank (1) comprises an elongated lumen (6) which extends from the top side (8.1) of the outer region (5) to the bottom side (2.2) of the implant connection geometry (3b) of the connecting element (2), and the lumen (6) extends through the inner connecting element (2), the dentin scaffold region (4) and the outer region (5) and has an opening in crestal or lingual direction and an opening in radicular direction.

3. The blank according to claim 1, wherein the dental blank (1) comprises an elongated lumen (6) which extends from the top side (8.1) of the outer region (5) to the bottom side (2.2) of the implant connection geometry (3b) of the connecting element (2), wherein the elongated lumen a) has at least one longitudinal axis, (b) the elongated lumen is angled and has at least two intersecting longitudinal axes, (c) the elongated lumen (6) is arched and/or (d) the opening of the elongated lumen in crestal or lingual direction has at least a greater diameter than the opening at the bottom side (2.2) of the implant connection geometry (3b) of the inner connecting element (2) in radicular direction.

4. The blank according to claim 1, wherein (i) the inner connecting element (2) comprising the scaffold region (3a) and the implant connection geometry (3b) is made of at least one metal or one metal alloy.

5. The blank according to claim 1, wherein (iii) the dentin scaffold region (4) is made of a metal oxide or metal oxide mixture.

6. The blank according to claim 1, wherein (iii) the dentin scaffold region (4) is made of a metal oxide or metal oxide mixture, and is selected from zirconium oxide, aluminum oxide or a zirconium oxide/aluminum oxide mixture, wherein the metal oxide or metal oxide mixture optionally has magnesium oxide (MgO) content and/or ytterbium oxide (Y.sub.2O.sub.3) content.

7. The blank according to claim 1, wherein (iv) the outer region (5) of the blank is made of a dental composite material or a dental glass ceramic.

8. The blank according to claim 1, wherein the (iv) outer region has a hybrid ceramic comprising from 50 to 98% by weight of a ceramic scaffold as well as 2 to 50% by weight of polymer content, wherein the total composition of the hybrid ceramic amounts to 100% by weight.

9. The blank according to claim 1, wherein the (iv) outer region has a hybrid ceramic comprising a ceramic scaffold, which comprises a zirconium oxide content of 50 to 99.9% by weight, and at least one other metal oxide content, metalloid oxide and/or silicon carbide or mixtures thereof having a content of 0.1 to 50% by weight, wherein the metals of the other metal oxide, metalloid oxide and/or silicon carbide are selected from yttrium, aluminum, magnesium, potassium, calcium, lithium and silicon, wherein the total composition of the ceramic scaffold amounts to 100% by weight.

10. The blank according claim 1, wherein (iv) the outer region (5) of the dental blank (1) is made of: A) a dental composite material comprising: (a) 40 to 80% by weight inorganic fillers, (b) 60 to 20% by weight polymer component being based on polymerisation of at least one monomer or one monomer mixture comprising urethane (meth)acrylate, tricyclo[5.2.1.02.6]decane (TCD) urethane derivative, TCD-di-HEA, TCD-di-HEMA, TEGDMA, or B) a lithium silicate as dental glass ceramic, or C) a hybrid ceramic having 2 to 25% by weight polymer content and a ceramic content of 75 to 98% by weight, based on the total composition of the hybrid ceramic, wherein the hybrid ceramic contains 0.0 to 8.0% by weight pigments in the polymer content and/or in the ceramic content respectively.

11. The blank according to claim 1, wherein: (iii) the dentin scaffold region (4) of the blank has the following colours according to colour space L*a*b L 50 to 80, a 2 to 5 and b 15 to 22, and/or (iv) the outer region (5) of the blank has the following colours according to colour space L*a*b L 60 to 95, a −5 to 3 and b 3 to 2.

12. The dental blank according to claim 1, wherein the dental blank has an elongated lumen (6) within the implant connection geometry (3b) of the inner connecting element (2) and within the scaffold region (3a) of the inner connecting element (2), which extends from the top side (2.1) to the bottom side (2.2) of the implant connection geometry (3b) of the inner connecting element (2) and from the top side (3.1) to the bottom side (3.2) of the scaffold region (3a) of the inner connecting element (2), and the lumen has an opening in a crestal or lingual direction and an opening in a radicular direction.

13. A method for producing a dental blank according to claim 1, the method comprising: providing an inner connecting element (2) having a scaffold region (3a) in the direction of the coronal region of the blank and an implant connection geometry (3b) in the radicular direction of the blank, and (ii) connecting the scaffold region (3a) of the inner connecting element (2) to a dentin scaffold region (4) in the direction of the coronal region of the blank (1), and (iii) connecting the dentin scaffold region (4) to an (iv) outer region (5) of the blank in the direction of the coronal region of the blank (1), and wherein (v) the dental blank having an elongated lumen (6) within the implant connection geometry (3b) of the inner connecting element (2), and the lumen extending from the top side (2.1) to the bottom side (2.2) of the implant connection geometry (3b) of the inner connecting element (2), and the lumen having an opening in crestal or lingual direction and an opening in radicular direction, wherein the outer region (5) of the blank is made of a dental hybrid ceramic comprising polymer content and ceramic content wherein the hybrid ceramic comprises ceramic content, wherein the ceramic content is a ceramic scaffold, wherein the ceramic scaffold comprises from 50 to 70% by weight SiO.sub.2, from 15 to 30% by weight Al.sub.2O.sub.3, from 5 to 15% by weight Na.sub.2O, from 2 to 10% by weight K.sub.2O, from 0.05 to 5% by weight B.sub.2O.sub.3, from 0.0001 to 1% by weight ZrO.sub.2, and from 0.0001 to 1% by weight CaO, wherein the total composition amounts to 100% by weight.

14. The method according to claim 13, wherein the (ii) scaffold region (3) and the dentin scaffold region (4) have a geometric indexing on their opposite inner surfaces in order to make the scaffold region (3) and the dentin scaffold region (4) connectable in a defined position and (iii) the dentin scaffold region (4) and the outer region (5) have a geometric indexing on their opposite inner surfaces in order to make the dentin scaffold region (4) and the outer region (5) connectable in a defined position.

15. The method according to claim 13, wherein the (ii) scaffold region (3) and the dentin scaffold region (4) are connectable to each other in a positive locking, force-fitted and/or firmly bonded manner and/or (iii) the dentin scaffold region (4) and the outer region (5) are connectable to each other in a positive locking, force-fitted and/or firmly bonded manner.

16. The method according to claim 13, wherein the dental blank having an elongated lumen (6) within the implant connection geometry (3b) of the inner connecting element (2) and within the scaffold region (3a) of the inner connecting element (2), and the lumen extending from the top side (2.1) to the bottom side (2.2) of the implant connection geometry (3b) of the inner connecting element (2) and from the top side (3.1) to the bottom side (3.2) of the scaffold region (3a) of the inner connecting element (2), and the lumen having an opening in a crestal or lingual direction and an opening in a radicular direction.

17. A system for producing a dental blank according to claim 1, wherein the system comprises as single components connectable to each other: an inner connecting element (2) having a scaffold region (3a) in the direction of the coronal region of the blank and an implant connection geometry (3b) in the radicular direction of the blank, a dentin scaffold region (4), to which the scaffold region (3a) of the connecting element (2) is connectable in the direction of the coronal region of the blank, and an outer region (5), to which the dentin scaffold region (4) is connectable in the direction of the coronal region of the blank (1), wherein the dental blank has an elongated lumen (6) within the implant connection geometry (3b) of the inner connecting element (2), which extends from the top side (2.1) to the bottom side (2.2) of the implant connection geometry (3b) of the inner connecting element (2), and the lumen has an opening in crestal or lingual direction and an opening in radicular direction, wherein the outer region (5) of the blank is made of a dental hybrid ceramic comprising polymer content and ceramic content wherein the hybrid ceramic comprises ceramic content, wherein the ceramic content is a ceramic scaffold, wherein the ceramic scaffold comprises from 50 to 70% by weight SiO.sub.2, from 15 to 30% by weight Al.sub.2O.sub.3, from 5 to 15% by weight Na.sub.2O, from 2 to 10% by weight K.sub.2O, from 0.05 to 5% by weight B.sub.2O.sub.3, from 0.0001 to 1% by weight ZrO.sub.2, and from 0.0001 to 1% by weight CaO, wherein the total composition amounts to 100% by weight.

18. The system according to claim 17, wherein the system comprises an adhesive, a plastic or liquid hybrid material for firmly bonded connection and/or an implant screw.

19. The system according to claim 1, wherein the dental blank has an elongated lumen (6) within the implant connection geometry (3b) of the inner connecting element (2) and within the scaffold region (3a) of the inner connecting element (2), which extends from the top side (2.1) to the bottom side (2.2) of the implant connection geometry (3b) of the inner connecting element (2) and from the top side (3.1) to the bottom side (3.2) of the scaffold region (3a) of the inner connecting element (2), and the lumen has an opening in a crestal or lingual direction and an opening in a radicular direction.

20. A use of a blank according to claim 1 for the production of a multi-coloured dental prosthetic restoration (100) in a material-removing process.

Description

(1) Another subject matter of the invention is a method for the production of a dental blank as well as a blank obtainable according to the method, wherein a dental prosthetic restoration preferably is obtainable from the blank by (material-)removing processing, wherein the blank is produced by

(2) (i) providing an inner connecting element having a scaffold region, in particular a peg-shaped scaffold region, in the direction of the coronal region of the blank and an implant connection geometry in the radicular direction of the blank, and

(3) (ii) connecting the scaffold region of the inner connecting element to a dentin scaffold region in the direction of the coronal region of the blank, in particular the scaffold region is connected to the dentin scaffold region in a non-detachable manner, preferably the scaffold region is connected to the dentin region in a positive locking, force-fitted, firmly bonded or, according to a combination, positive locking and/or force/fitted and/or firmly bonded manner, and

(4) (iii) connecting the dentin scaffold region to an

(5) (iv) outer region of the blank in the direction of the coronar region of the blank, in particular the dentin scaffold region is connected to the outer region in a non-detachable manner, preferably the dentin scaffold region is connected to the outer region in a positive locking, force-fitted, firmly bonded or, according to a combination, positive locking and/or force/fitted and/or firmly bonded manner, and

(6) (v) the dental blank having an elongated lumen within the implant connection geometry of the inner connecting element and, optionally, within the scaffold region of the inner connecting element, which extends from the top side to the bottom side of the implant connection geometry of the inner connecting element and, optionally, from the top side to the bottom side of the scaffold region of the inner connecting element, and the lumen having an opening in crestal or lingual direction and an opening in radicular direction. Particularly preferably, the lumen extends from the top side of the outer region to the bottom side of the implant connection geometry.

(7) According to a preferred alternative, (iii) the dentin scaffold region may comprise one or more layers of a metal oxide or a metal oxide mixture, wherein the several layers preferably have different colours according to colour space L*a*b. According to an embodiment, the overall impression of the dental blank comprising the inner connecting element, the dentin scaffold region and the outer region is set to Vita classical colour key/Vita classical shade guide A1 to D4. In this context, the colours correspond to A1 to A4 (reddish-brownish), B1 to B4 (reddish-yellowish), C1-C4 (grey shades), D2-D4 (reddish-grey).

(8) According to the invention, it is thereby preferred for the overall impression of all colour layers to have L 50 to 80, a 2 to 5 and b 15 to 22 of colour space L*a*b in the dentin scaffold region and/or L 60 to 95, a −5 to 3 and b 3 to 2 of colour space L*a*b in the outer region.

(9) According to a preferred alternative, the dentin scaffold region may have one to five layers of a metal oxide or a metal oxide mixture as well as, optionally, pigments. The layer thicknesses, each independently of each other, may be from 200 μm to 5 mm, in particular from 200 μm to 1 mm, preferably from 0.5 mm to 1 mm. Particularly preferably, the one to five layers completely enclose the outer scaffold region which, for example, is made of a titanium alloy.

(10) The dentin scaffold region, in particular the respective layers of the dentin scaffold region, preferably each independently from each other, have pigments. Usually, the pigments have a particle size of d.sub.90 less than 20 μm to less than 15 μm and also less than 10 μm. Typically, d.sub.50 of the pigment particles is about 0.001 to 10 μm. Usual inorganic pigments may be used as inorganic pigments. Inorganic pigments substantially being colour stable beyond 850° C., preferably up to 1200° C., are suitable for the production of the dentin scaffold region. Thus, the inorganic pigments preferably have a colour stability beyond 850° C., in particular from 850 to 1050° C., preferably from 900 to 930° C., The respectively selected pigment, according to the one or more layers of a metal oxide or a metal oxide mixture in the dentin scaffold region, is preferably selected from oxides, hydrated oxides, sulfides, sulfates, carbonates and silicates of the transition metals, such as preferably pigments comprising zirconium and/or iron. Known pigments comprise zirconium silicates, iron silicates, manganese oxides, chromium oxide, γ-Fe.sub.2O.sub.3, Fe.sub.3O.sub.4/Fe.sub.2O.sub.3, Cr.sub.2O.sub.3, TiO.sub.2. Moreover, the inorganic pigments may comprise coloured pigments, gloss pigments, metallic effect pigments, in particular gloss pigments having platelike or scalelike metal particles, such as iron oxide red, strontium yellow, aluminum or silver bronzes, pearlescent pigments or gold bronze, aluminum bronze.

(11) Particularly preferred inorganic coloured pigments comprise iron oxide, zirconium praseodymium silicate (Zr,Pr)SiO.sub.4 (CAS-No: 68187-15-5), zirconium iron silicate (Zr,Fe)SiO.sub.4 (CAS-No: 68412-79-3), zinc iron chromite brown spinel (Zn,Fe)(Fe,Cr).sub.2O.sub.4 (CAS-Nr.: 68186-88-9), Chrome tin pink sphene CaO:SnO.sub.2:SiO.sub.2:Cr.sub.2O.sub.3 (CAS-Nr.: 68187-12-2).

(12) According to a further embodiment variant, in the method, in the blank as well as in the system for the production of the blank, (ii) the scaffold region and the dentin scaffold region may have a geometric indexing on their opposite inner surfaces, preferably in order to make the scaffold region and the dentin scaffold region connectable in a defined position and, optionally, (iii) the dentin scaffold region and the outer region may have a geometric indexing on their opposite inner surfaces, preferably in order to make the dentin scaffold region and the outer region connectable in a defined position. The indexing preferably corresponds to a complementary structure of the opposite inner surfaces, complementary structuring of the surfaces, such as, for example, at least one protrusion, and at least one complementary recess.

(13) Moreover, in the method, it is preferred for the (ii) scaffold region and the dentin scaffold region to be connected to each other in a positive locking, force-fitted, firmly bonded or, according to an alternative, positive locking and/or force-fitted and/or firmly bonded manner, and/or (iii) the dentin scaffold region and the outer region to be connected to each other in a positive locking, force-fitted, firmly bonded or, according to an alternative, positive locking and/or force-fitted and/or firmly bonded manner.

(14) According to the invention, an open-pored ceramic scaffold, in particular a sintered scaffold, is infiltrated by at least one monomer, optionally by polymerisation initiator(s). Subsequent to infiltration and polymerisation into polymers, the ceramic scaffold has improved material properties. The material thus produced is a dental hybrid ceramic. Infiltration of the open-pored ceramic scaffold may be carried out in a bath comprising the at least one monomer, optionally with polymerisation inhibitor(s). Subsequently, polymerisation of a liquid infiltrated monomer or a monomer mixture may be carried out.

(15) Likewise, a subject matter of the invention is a system for the production of a dental blank, wherein the system comprises a) an inner connecting element, a dentin scaffold region and an outer region as single components connectable to each other, or b) a blank according to the invention and, preferably, an adhesive, a plastic or liquid hybrid material for firmly bonded connection and/or an implant screw.

(16) The respective lumen is designed in the connecting element, dentin scaffold region, outer region or in the blank for receiving of a connecting screw in order to be able to fasten the prosthetic restoration with an implant or an abutment on an implant.

(17) According to a further alternative, the system may comprise an adhesive, a plastic or liquid hybrid material for firmly bonded connection and/or an implant screw.

(18) According to a further alternative, a subject matter of the invention is the use of a blank or of a system for the production of a multi-coloured dental prosthetic restoration, in particular an implant-supported single-tooth restoration, such as a crown, in a material-removing process.

(19) In the following, the invention is illustrated in more detail on the basis of the schematic figures without limiting the invention to these embodiments.

(20) FIG. 1a shows a blank 1 according to the invention with an inner connecting element 2, see also FIG. 3, having a scaffold region 3a and an implant connection geometry 3b as well as a dentin scaffold region 4 and an outer region 5. The outer region 5 is processed in a material-removing process such that the region takes the contour of at least one tooth surface of a single-tooth restoration, such as a crown. The elongated straight lumen 6 has a longidutinal axis (x). The lumen extends until the outer region. The blank has an elongated lumen 6 in the implant connection geometry 3b and in the scaffold region 3a which extends from the top side 2.1 to the bottom side 2.2 of the implant connection geometry 3b and from the top side 3.1 to the bottom side 3.2 of the scaffold region 3a and has an opening in crestal direction and an opening in radicular direction. Moreover, the elongated lumen 6 extends from the top side 8.1 of the outer region 5 to the bottom side 2.2 of the implant connection geometry 3b.

(21) In FIG. 1b, a blank is shown whose lumen 6 does not extend into the outer region 5. The lumen 6 may be widened crestalwards in the dentin scaffold region 4 and optionally in the scaffold region 3a and may be milled in the outer region in the future milling process. Preferably, the lumen is cylindrical at least in the region of the implant connection geometry 3b. In FIG. 1b, the dentin scaffold region 4 has two layers 4a and 4b.

(22) FIG. 1c shows a processed blank according to the invention with an inner connecting element 2 having a scaffold region 3a and an implant connection geometry 3b as well as a dentin scaffold region 4 and an outer region 5, which has been processed in a material-removing process and takes the contour of at least one tooth surface of a prosthetic single-tooth restoration 10. The elongated lumen 6 in the blank is arched lingualwards in the outer region 5. The blank of FIG. 1c had a lumen in the scaffold region before processing. The lumen in the dentin scaffold region and in the outer region 5 has been produced in material-removing process, in particular milled. Alternatively, the blank may have an elongated lumen being accordingly arched lingualwards. In this case, the blank carries a reference on its outside in order to determine the lingual side of the prosthesis to be produced, prior to drilling.

(23) FIG. 2 shows a system according to the invention for the production of a dental blank 1 comprising single components being connectable to each other: inner connecting element 2, dentin scaffold region 4 and outer region 5.

(24) The blank according to the invention may then preferably be used in an automated milling process with a significantly reduced material scrap, since fracture strength and E-modulus will make the blank significantly better survive milling processing without chipping of parts of the blank during the milling process.