Method of producing plate denture, curable composition for stereolithography, and plate denture production kit

Abstract

[Object] To provide a method of producing a plate denture using a stereolithography 3D printer, which is capable of producing a plate denture in a short time with a more simplified production process, the plate denture exhibiting excellent occlusion. [Solving Means] The problem is solved by a method of producing a plate denture, including: adhering an artificial tooth and a denture base photochemically solidified by a stereolithography 3D printer to each other by polymerizing an unpolymerized curable composition for stereolithography present on a surface of the denture base. Further, stronger adhesion between the artificial tooth and the denture base is achieved by mixing, in the curable composition for stereolithography, a polymerization initiator other than a photopolymerization initiator for stereolithography.

Claims

1. A method of producing a plate denture characterized by comprising: preparing a denture base having an artificial-tooth-arrangement recessed portion by stereolithography by a 3D printer using a curable composition for stereolithography including a first polymerization initiator for stereolithography and a second polymerization initiator different from the first polymerization initiator, an unpolymerized portion including the second polymerization initiator being present on a surface of the denture base; and directly adhering, after arranging an artificial tooth in the artificial-tooth-arrangement recessed portion, the artificial tooth and the denture base to each other without using an adhesive by causing the second polymerization initiator to act to polymerize the unpolymerized portion present on the surface of the denture base.

2. The method of producing a plate denture according to claim 1, wherein the artificial tooth and the denture base are adhered to each other in a fitted state.

3. The method of producing a plate denture according to claim 1, wherein the second polymerization initiator is a radical polymerization initiator.

4. The method of producing a plate denture according to claim 1, wherein the second polymerization initiator is a photopolymerization initiator having an excitation wavelength different from that of the first polymerization initiator.

Description

EXAMPLE

(1) Although the present invention will be specifically described below on the basis of Examples and Comparative Examples, the present invention is not limited to the following Examples. The materials used are shown below.

(2) <Compound>

(3) Photocurable monomer;

(4) Methylmethacrylate,

(5) Urethane dimethacrylate, 2,2-bis(4-methacryloyloxypolyethoxyphenyl)propane (hereinafter, abbreviated as D-2.6E),

(6) Trimethylolpropane trimethacrylate.

(7) Photopolymerization initiator (absorption wavelength effective for initiation of polmerization);

(8) Bis(2,4,6-trimethylbenzoyl)phenylphosphineoxide (ultraviolet to 420 nm)

(9) Camphorquinone (450 to 490 nm)

(10) Reducing compound;

(11) 4-(N,N-dimethylamino)ethyl benzoate

(12) Filler;

(13) PMMA (molecular weight of 100,000 to 400,000): manufactured by Negami Chemical Industrial Co. Ltd., D250ML, average particle diameter of 36 m

(14) <Artificial Tooth>

(15) Acrylic resin artificial tooth;

(16) Commercially available artificial tooth: New Ace Anterior and Million Posterior (manufactured by YAMAHACHI DENTAL MFG., CO.)

(17) Custom artificial tooth: custom artificial tooth with a projecting shape (edge structure for snap fit) having a height of 1 mm connected around the side surface of the artificial tooth on the basis of the shapes of New Ace Anterior and Million Posterior

(18) Three-dimensional data of the custom artificial tooth was created by using a model scanner (manufactured by Dental Wings Inc., 3 series) to acquire three dimensional data of New Ace Anterior and Million Posterior and giving a projecting shape having a height of 1 mm so as to be connected at a position of 1 mm from the basal place of the artificial tooth of the obtained three-dimensional data. A resin disk formed of PMMA (manufactured by YAMAHACHI DENTAL MFG., CO., Product name: Resin Disk) was set in a milling machine DWX-50 (manufactured by Roland DG Corporation.), the resin disk was cut on the basis of the three-dimensional data of the custom artificial tooth, and a custom artificial tooth having an edge was prepared.

(19) <Design of Plate Denture and Method of Creating Three-Dimensional Data of Denture Base>

(20) The design of a maxillary plate denture for preparing a maxillary plate denture and three-dimensional data of a maxillary denture base were created as follows.

(21) A mandibular model (including 14 teeth) that matches with a maxillary edentulous model was prepared, and a model scanner (manufactured by Dental Wings Inc., 3 series) was used to acquire three-dimensional data of the maxillary edentulous model and the mandibular model. Further, a model scanner was used to acquire three-dimensional data of the artificial teeth (anterior teeth and posterior teeth, 14 teeth in total) to be used. After arranging the three-dimensional data of 14 artificial teeth at the ideal position with respect to the obtained three-dimensional data of the maxillary edentulous model, the position of the artificial teeth data arranged on the maxillary edentulous model is adjusted such that the three-dimensional data of the mandibular model and all the artificial teeth are engaged with each other, a denture base shape was given in accordance with the edentulous mucosal surface, and three-dimensional data of a plate denture (full denture) was created. Finally, the shape data of the artificial teeth was deleted from the three-dimensional data of the plate denture (full denture) to create three-dimensional data of a maxillary denture base including an artificial-tooth-arrangement recessed portion.

(22) The evaluation method is shown below.

(23) <Evaluation of Plate Denture Preparation Time>

(24) The total time of the denture base preparation time, the cleaning process time, and the artificial tooth adhesion or preparation time was used as the plate denture preparation time, and the lengths of the times were compared with each other.

(25) (Plate Denture Preparation Time)

(26) The time during which a 3D printer or a cutting machine had been actually driven when modeling a denture base by stereolithography or cutting was used as the denture base preparation time.

(27) (Cleaning Process Time)

(28) The time required for the cleaning work was used as the cleaning process time. In the case where there was no cleaning process, it is described as none.

(29) (Artificial Tooth Adhesion or Preparation Time)

(30) The time required for applying an adhesive (only when necessary), arranging artificial teeth, and performing polymerization work for adhering the artificial teeth to/on the modeled denture base or for performing stereolithography of artificial teeth on the denture base was used as the artificial tooth adhesion or preparation time.

(31) <Evaluation of Occlusion of Plate Denture>

(32) The occlusion of a plate denture was evaluated by visually observing the occlusion between the plate denture (maxillary full denture) and the mandibular model in accordance with the following criteria.

(33) A: Very good. All the artificial teeth of the maxillary full denture are in occlusal contact.

(34) B: Good. Eight or more artificial teeth of the maxillary full denture are in occlusal contact and rattling does not occur.

(35) C: There is partial rattling. Four to seven teeth of the maxillary full denture are in occlusal contact and slight rattling occurs.

(36) D: There is a lot of rattling. Three or less teeth of the maxillary full denture are in occlusal contact and rattling occurs with two occlusal contacts as fulcrums.

(37) <Evaluation of Adhesion Between Artificial Tooth and Denture Base>

(38) A test piece for adhesion evaluation was prepared by the method described in Examples, and the adhesiveness thereof was evaluated.

(39) The evaluation of adhesiveness was performed by the following method. A hole was formed in the center of the right central incisor of the plate denture (maxillary full denture) in advance, an S-shaped hook was attached to the tooth of the test piece obtained above, a weight of 10 Kg was put thereon, and the degree of adhesion when the denture base was pulled up by hand was evaluated in accordance with the following criteria.

(40) A: It cannot come off even if it is pulled for 30 seconds or more.

(41) B: It comes off if it is pulled for 30 seconds.

(42) C: The artificial tooth came off immediately.

Example 1

(43) A maxillary plate denture was prepared as a plate denture.

(44) First, the photocurable composition for stereolithography described in Table 1 was used to perform stereolithography of the maxillary denture base data obtained by designing in accordance with commercially available artificial teeth by the method of designing a plate denture and creating three-dimensional data of a denture base described above using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm) to prepare a maxillary denture base having a recessed shape for arranging artificial teeth. After that, the obtained denture base is not cleaned, and commercially available artificial teeth were arranged on the recessed portion and irradiated with light for 3 minutes by a polymerization apparatus for dental technicians (-light V manufactured by MORITA TOKYO MFG. CORP., wavelength of 400 to 408 nm, 465 to 475 nm) while being immersed in hot water of 40 C. to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, evaluation of the plate denture preparation time and evaluation of occlusion of the plate denture were performed.

(45) Further, similarly, a denture base having a recessed shape in which a maxillary right central incisor of commercially available artificial teeth can be arranged with a length of 30 mma width of 30 mma height of 10 mm was modeled using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm). After that, the obtained denture base was not cleaned, and the commercially available artificial teeth were arranged on the recessed portion and irradiated with light for 3 minutes by a polymerization apparatus for dental technicians (-light V manufactured by MORITA TOKYO MFG. CORP., wavelength of 400 to 408 nm, 465 to 475 nm) while being immersed in hot water of 40 C. to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, the adhesiveness was evaluated.

(46) The evaluation results are shown in Table 2.

Example 2

(47) The photocurable composition for stereolithography described in Table 1 was used to perform stereolithography of the maxillary denture base data obtained by designing in accordance with custom artificial teeth having an edge structure for snap fit by the method of designing a plate denture and creating three-dimensional data of a denture base described above using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm) to prepare a maxillary denture base having a catch structure corresponding to the edge structure given to the artificial teeth in a recessed shape for arranging artificial teeth. After that, the obtained denture base was not cleaned, and the custom artificial teeth were arranged so as to be fitted into the recessed portion and irradiated with light for 3 minutes by a polymerization apparatus for dental technicians (-light V manufactured by MORITA TOKYO MFG. CORP., wavelength of 400 to 408 nm, 465 to 475 nm) while being immersed in hot water of 40 C. to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, evaluation of the plate denture preparation time and evaluation of occlusion of the plate denture were performed.

(48) Further, a denture base having a recessed shape in which a maxillary right central incisor can be arranged with a length of 30 mma width of 30 mma height of 10 mm was modeled using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm). At this time, three-dimensional data was created such that the recessed shape gives a catch structure corresponding to the edge structure for snap fit of the custom artificial teeth to be used, and modeling was performed. After that, the obtained denture base was not cleaned, and the custom artificial tooth were arranged on the recessed portion and irradiated with light for 3 minutes by a polymerization apparatus for dental technicians (-light V manufactured by MORITA TOKYO MFG. CORP., wavelength of 400 to 408 nm, 465 to 475 nm) while being immersed in hot water of 40 C. to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, the adhesiveness was evaluated.

(49) The evaluation results are shown in Table 2.

Example 3

(50) The photocurable composition for stereolithography described in table 1 was used to perform stereolithography of the maxillary denture base data obtained by designing in accordance with commercially available artificial teeth by the method of designing a plate denture and creating three-dimensional data of a denture base described above using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm) to prepare a maxillary denture base having a recessed shape for arranging artificial teeth. After that, the obtained denture base was not cleaned, and the commercially available artificial tooth were arranged on the recessed portion and irradiated with light for 3 minutes by a polymerization apparatus for dental technicians (-light V manufactured by MORITA TOKYO MFG. CORP., wavelength of 400 to 408 nm, 465 to 475 nm) while being immersed in hot water of 40 C. to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, evaluation of the plate denture preparation time and evaluation of occlusion of the plate denture were performed.

(51) Further, similarly, a denture base having a recessed shape in which a maxillary right central incisor of commercially available artificial teeth can be arranged with a length of 30 mma width of 30 mma height of 10 mm was modeled using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm). After that the obtained denture base was not cleaned, and the commercially available artificial teeth were arranged on the recessed portion and irradiated with light for 3 minutes by a polymerization apparatus for dental technicians (-light V manufactured by MORITA TOKYO MFG. CORP., wavelength of 400 to 408 nm, 465 to 475 nm) while being immersed in hot water of 40 C. to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, the adhesiveness was evaluated. After that, the adhesiveness was evaluated.

(52) The evaluation results are shown in Table 2.

Comparative Example 1

(53) IvoBase (manufactured by Ivoclar) that is a resin disk for cutting a denture base formed of an acrylic resin was attached to a cutting machine (DWX-50 manufactured by Roland DG Corporation.), and the maxillary denture base data obtained by designing in accordance with commercially available artificial teeth by the method of designing a plate denture and creating three-dimensional data of a denture base described above was used to prepare a maxillary denture base having a recessed shape for arranging artificial teeth by cutting. After that, a small amount (0.1 to 0.3 g) of Beautiful II manufactured by SHOFU INC., which is a dental composite resin, was built-up as a temporary adhesive on the respective recessed portions, and then, commercially available artificial teeth were arranged on the recessed portion on which the temporary adhesive was built-up. After that, light was applied thereto for 30 seconds by a visible light irradiator (light source wavelength of 470 nm) to cure the temporary adhesive, and thus, the commercially available artificial teeth were temporarily adhered to the maxillary denture base. Next, as an acrylic resin, PalaXpress ultra manufactured by Heraeus Kulzer GmbH (chemically polymerized resin for denture base) was poured into the gap between the denture base and the artificial teeth and polymerized to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, evaluation of the plate denture preparation time and evaluation of occlusion of the plate denture were performed.

(54) Further, similarly, a denture base having a recessed shape in which a maxillary right central incisor of commercially available artificial teeth can be arranged with a length of 30 mma width of 30 mma height of 10 mm was prepared using a cutting machine (DWX-50 manufactured by Roland DG Corporation.). After that, as a temporary adhesive, a small amount (0.1 to 0.3 g) of Beautiful II manufactured by SHOFU INC., which is a dental composite resin, was built-up on the recessed portion, and then, commercially available artificial teeth were arranged on the recessed portion on which the temporary adhesive was built-up. After that, light was applied thereto for 30 seconds by a visible light irradiator (light source wavelength of 470 nm) to cure the temporary adhesive, and thus, the commercially available artificial teeth were temporarily adhered to the denture base. Next, as an acrylic resin, PalaXpress ultra manufactured by Heraeus Kulzer GmbH (chemically polymerized resin for denture base) was poured into the gap between the denture base and the artificial teeth and polymerized to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, the adhesiveness was evaluated.

(55) The evaluation results are shown in Table 2.

Comparative Example 2

(56) The photocurable composition for stereolithography described in Table 1 was used to perform stereolithography of the maxillary denture base data obtained by designing in accordance with commercially available artificial teeth by the method of designing a plate denture and creating three-dimensional data of a denture base described above using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm) to prepare a maxillary denture base having a recessed shape for arranging artificial teeth. After that, the obtained denture base was placed in a cleaning bath of isopropyl alcohol, cleaned twice, and dried. After that, as a temporary adhesive, a small amount (0.1 to 0.3 g) of Beautiful II manufactured by SHOFU INC., which is a dental composite resin, was built-up on the respective recessed portions, and then, commercially available artificial teeth were arranged on the recessed portion on which the temporary adhesive was built-up. After that, light was applied thereto for 30 seconds by a visible light irradiator (light source wavelength of 470 nm) to cure the temporary adhesive, and thus, the commercially available artificial teeth were temporarily adhered to the denture base. Next, as an acrylic resin, PalaXpress ultra manufactured by Heraeus Kulzer GmbH (chemically polymerized resin for denture base) was poured into the gap between the denture base and the artificial teeth and polymerized to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, evaluation of the plate denture preparation time and evaluation of occlusion of the plate denture were performed.

(57) Further, similarly, a denture base having a recessed shape in which a maxillary right central incisor of commercially available artificial teeth can be arranged with a length of 30 mma width of 30 mma height of 10 mm was modeled using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm). After that, the denture base was placed in a cleaning bath of isopropyl alcohol, cleaned twice, and dried. After that, as a temporary adhesive, a small amount (0.1 to 0.3 g) of Beautiful II manufactured by SHOFU INC., which is a dental composite resin, was built-up on the respective recessed portions, and then, commercially available artificial teeth were arranged on the recessed portion on which the temporary adhesive was built-up. After that, light was applied thereto for 30 seconds by a visible light irradiator (light source wavelength of 470 nm) to cure the temporary adhesive, and thus, the commercially available artificial teeth were temporarily adhered to the denture base. Next, as an acrylic resin, PalaXpress ultra manufactured by Heraeus Kulzer GmbH (chemically polymerized resin for denture base) was poured into the gap between the denture base and the artificial teeth and polymerized to adhere the artificial teeth and the denture base to each other, thereby preparing a plate denture. After that, the adhesiveness was evaluated.

(58) The evaluation results are shown in Table 2.

Comparative Example 3

(59) The photocurable composition for stereolithography described in Table 1 was used to perform stereolithography of the maxillary denture base data obtained by designing in accordance with commercially available artificial teeth by the method of designing a plate denture and creating three-dimensional data of a denture base described above using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm) to prepare a maxillary denture base having a recessed shape for arranging artificial teeth. The obtained maxillary denture base was placed in a cleaning bath of isopropyl alcohol, cleaned twice, and dried. After that, commercially available artificial teeth were arranged on the recessed portion and irradiated with light for 3 minutes by a polymerization apparatus for dental technicians (-light V manufactured by MORITA TOKYO MFG. CORP., wavelength of 400 to 408 nm, 465 to 475 nm) while being immersed in hot water of 40 C., thereby preparing a plate denture. After that, evaluation of the plate denture preparation time and evaluation of occlusion of the plate denture were performed.

(60) Further, similarly, a denture base having a recessed shape in which a maxillary right central incisor of commercially available artificial teeth can be arranged with a length of 30 mma width of 30 mma height of 10 mm was modeled using a stereolithography 3D printer (Formlabs, Form2, irradiation wavelength of 405 nm). After that, the obtained denture base was placed in a cleaning bath of isopropyl alcohol, cleaned twice, and dried. After that, commercially available artificial teeth were arranged on the recessed portion and irradiated with light for 3 minutes by a polymerization apparatus for dental technicians (-light V manufactured by MORITA TOKYO MFG. CORP., wavelength of 400 to 408 nm, 465 to 475 nm) while being immersed in hot water of 40 C. to prepare a test piece. After that, the adhesiveness was evaluated.

(61) The evaluation results are shown in Table 2.

(62) TABLE-US-00001 TABLE 1 Components (mass parts) of curable Exam- Exam- Comparative composition for stereolithography ple1.2 ple3 Example2,3 Photocurable Methyl methacrylate 20 20 20 D2.6E 38 38 38 monomer Urethane dimethacrylate 30 30 30 Trimethylolpropane 10 10 10 trimethacrylate First Bis(2,4,6- 2 1.2 2 polymer- trimethylbenzoyl) ization phenylphosphineoxide initiator Filler PMMA 10 10 10 Second Camphorquinone 0.6 polymer- 4-(N,N-dimethylamino) 0.2 ization ethylbenzoate initiator

(63) TABLE-US-00002 TABLE 2 Denture preparation time Cleaning Artificial tooth Denture base preparation process adhesion or preparation Total Engage- Adhesion Method Time Time Method Time Time ment strength Example1 Stereolithography 1 hour None Only light irradiation 5 minutes 1 hour B B 30 minutes 35 minutes Example2 Stereolithography 1 hour None Artificial tooth fitting 5 minutes 1 hour A A 30 minutes shape + light irradiation 35 minutes Example3 Stereolithography 1 hour None Stereolithography 5 minutes 1 hour A A 30 minutes Photopolymerization 35 minutes (different wavelength) Comparative Cutting 5 hours None Dental resin adhesion 30 minutes 5 hours D B Example 1 30 minutes Comparative Stereolithography 1 hour 10 Dental resin adhesion 30 minutes 2 hours D B Example 2 30 minutes minutes 10 minutes Comparative Stereolithography 1 hour 10 Cleaning and light 5 minutes 1 hour D * C Example 3 30 minutes minutes irradiation 45 minutes * Artificial tooth and denture base are not bonded to each other