Hybrid Dental Implant and Production Method

Abstract

A dental implant includes an insert element of a titanium-based material inserted and soldered into a blind hole in an anchoring element of a ceramic material. An outer surface of the insert element has spacer members to center the insert element in the blind hole, with a uniform circumferential gap space relative to the anchoring element. The insert element is longer than the blind hole, so that a portion of the insert element protrudes outwardly beyond an end face of the anchoring element. The blind hole is partly filled with a glass solder suspension, and the insert element is inserted into the blind hole, whereby an excess amount of the glass solder is displaced out of the gap space onto the end face of the anchoring element and the protruding portion of the insert element. A thermal soldering process secures the insert element into the anchoring element. The protruding portion of the insert element and remaining excess solder is removed to form a planar surface.

Claims

1. A dental implant comprising: an anchoring element made of a ceramic material, having a blind hole extending into said anchoring element from an end face of said anchoring element, wherein an inner wall surface of the anchoring element bounds the blind hole; an insert element comprising an insert element body made of a titanium-based material, wherein the insert element is at least partially received in the blind hole with a gap space between the insert element body and the inner wall surface of the anchoring element in the blind hole; and a solder joint layer of a glass solder material that is disposed in the gap space, by which the insert element is joined with the anchoring element; and having at least one of the following features: a first feature wherein the insert element further includes lateral spacer members, which protrude laterally outwardly from a lateral surface of the insert element body, and which define and maintain the gap space between the insert element body and the inner wall surface of the anchoring element in the blind hole, and a second feature wherein the insert element has an axial length greater than an axial depth of the blind hole, a protruding portion of the insert element protrudes out of the blind hole outwardly beyond the end face of the anchoring element, and an excess portion of the glass solder material protrudes from the solder joint layer out of the gap space and adjoins at least partially onto the protruding portion of the insert element and the end face of the anchoring element.

2. The dental implant according to claim 1, having the first feature.

3. The dental implant according to claim 2, wherein the lateral spacer members have a punctual configuration that is shorter than and non-continuous over an axial dimension and a circumferential dimension of the insert element body.

4. The dental implant according to claim 3, wherein the punctual configuration of each one of the lateral spacer members is a configuration selected from studs, knobs, bumps, nubs and stumps.

5. The dental implant according to claim 2, wherein the insert element further comprises at least one terminal spacer member, which protrudes from a terminal end of the insert element body in the blind hole, and which defines and maintains an end gap between the terminal end of the insert element and a blind end wall of the anchoring element bounding a blind end of the blind hole, and wherein the solder joint layer of the glass solder material further extends into the end gap.

6. The dental implant according to claim 2, further having the second feature.

7. The dental implant according to claim 6, wherein the dental implant is in a semi-finished state.

8. The dental implant according to claim 1, having the second feature.

9. The dental implant according to claim 8, wherein the dental implant is in a semi-finished state.

10. The dental implant according to claim 1, wherein the dental implant has the first feature, and wherein the dental implant is produced by a process in which the dental implant in a semi-finished state had the second feature, and was then further processed by removing the protruding portion of the insert element and the excess portion of the glass solder to form the dental implant in a finished state characterized by a flat planar surface of the insert element, the glass solder material of the solder joint layer and the end face of the anchoring element without any shrinkage void of the glass solder material retracting from the flat planar surface into the gap space.

11. The dental implant according to claim 1, wherein the ceramic material is a ceramic based on zirconium oxide.

12. The dental implant according to claim 1, wherein the insert element has therein an internally threaded receiver hole extending coaxially with an axis of the blind hole of the anchoring element.

13. The dental implant according to claim 12, further comprising a prosthetic tooth abutment threaded into the receiver hole.

14. The dental implant according to claim 1, wherein the dental insert is in a semi-finished state, in which the insert element is a solid body of the titanium-based material without any hole therein extending coaxially with an axis of the blind hole of the anchoring element.

15. The dental implant according to claim 1, wherein the gap space has a width of at most 0.5 mm.

16. The dental implant according to claim 1, wherein the insert element further comprises an outer coating of a ceramic primer.

17. A method of producing and further processing the dental implant according to claim 6, comprising the steps: a) introducing a prescribed quantity of a glass solder suspension into the blind hole in the anchoring element; b) after the step a), inserting the insert element into the blind hole in the anchoring element, whereby the prescribed quantity of the glass solder suspension is greater than a volume of the gap space, whereby the inserting of the insert element displaces the glass solder suspension so that a main portion of the glass solder suspension fills the gap space and an excess portion of the glass solder suspension is displaced out of the gap space and adjoins onto the protruding portion of the insert element and the end face of the anchoring element; c) after the step b), performing a thermal soldering process on the anchoring element, the insert element and the glass solder suspension under vacuum at a soldering temperature followed by cooling to form the dental implant, whereby the main portion of the glass solder suspension in the gap space forms the solder joint layer of the glass solder material which joins the insert element with the anchoring element, and the excess portion of the glass solder suspension forms the excess portion of the glass solder material adjoining on the protruding portion of the insert element and the end face of the anchoring element; and d) after the step c), further processing the dental implant by separating and removing the protruding portion of the insert element and the excess portion of the glass solder material to form a flat planar surface on the end face.

18. The method according to claim 17, wherein during the soldering process of the step c), the glass solder suspension in the gap space contracts and draws some of the excess portion of the glass solder suspension into the gap space and thereby keeps the gap space filled void-free with the glass solder suspension during the soldering process.

19. The method according to claim 17, further comprising wetting an outer surface of the insert element with some of the glass solder suspension before the step b).

20. The method according to claim 17, further comprising applying a vibration to the insert element after the step b).

21. The method according to claim 17, wherein the glass solder suspension has a grain size of less than 15 m.

22. A kit of components for producing a dental implant, comprising: an anchoring element made of a ceramic material, having a blind hole extending into said anchoring element from an end face of said anchoring element, wherein an inner wall surface of the anchoring element bounds the blind hole; an insert element comprising an insert element body made of a titanium-based material, and lateral spacer members that protrude laterally outwardly from a lateral surface of the insert element body, wherein the insert element has an axial length greater than an axial depth of the blind hole, and wherein the insert element is configured and dimensioned to be inserted into the blind hole of the anchoring element whereby the lateral spacer members define and maintain a gap space between the insert element body and the inner wall surface of the anchoring element in the blind hole and whereby a protruding portion of the insert element protrudes out of the blind hole outwardly beyond the end face of the anchoring element; and a glass solder suspension in an amount greater than a volume of the gap space so that when the glass solder suspension and the insert element are introduced into the blind hole then an excess portion of the glass solder suspension is displaced out of the blind hole and adjoins at least partially onto the protruding portion of the insert element and the end face of the anchoring element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order that the invention may be clearly understood, it will now be explained in further detail in connection with example embodiments thereof, with reference to the accompanying drawings, wherein:

[0020] FIG. 1 is a schematic side perspective view of an insert element for a dental implant according to an embodiment of the invention;

[0021] FIG. 2 is a schematic perspective sectional view of the insert element about to be inserted into an associated anchoring element of the dental implant;

[0022] FIG. 3 is a schematic perspective view of the dental implant including the insert element received in the anchoring element, wherein a protrusion of the insert element and excess glass solder material can be seen protruding on the shoulder of the implant; and

[0023] FIG. 4 is a schematic view, partially sectioned, of the assembled dental implant according to FIG. 3.

DETAILED DESCRIPTION OF PREFERRED EXAMPLE EMBODIMENTS

[0024] As can be seen in FIGS. 1 to 4, a hybrid dental implant according to an embodiment of the invention includes an endosseus anchoring element 1 made of a ceramic material, preferably based on zirconium oxide in this embodiment, and an insert element 3 made of a titanium-based material, e.g. titanium metal or a titanium alloy. The anchoring element 1 has a blind hole 2 introduced axially into an end face, e.g. the cervical end face, of the anchoring element 1. The insert element 3 is to be inserted into the blind hole 2 of the anchoring element 1, and secured in place by a soldered joint formed of a glass solder.

[0025] The insert element 3 includes a generally cylindrical insert element body, and lateral spacer members 4 protruding radially outwardly from the cylindrical outer surface of the cylindrical body. In this embodiment, the spacer members 4 are non-continuous and shorter than the cylindrical body in the axial and radial directions of the insert element 3, and thus have generally punctual or point-shaped configurations, e.g. as studs, knobs, bumps, nubs, stumps or protrusions extending in the radial direction, but with limited dimensions in the axial and circumferential directions. The lateral spacer members 4 are configured, dimensioned and located to ensure that the insert element 3 is properly centered within the blind hole 2 of the anchoring element 1, and to ensure that a consistent uniform gap space 5 is formed circumferentially around the insert element 3, between the insert element 3 and the inner wall of the blind hole 2 of the anchoring element 1. For example, in this regard, lateral spacer members 4 are provided at preferably at least three locations uniformly circumferentially spaced around the circumference of the insert element 3, and at least two locations spaced axially from one another in the axial direction of the insert element 3. Additionally in this illustrated embodiment, axial or terminal spacer members 6 are provided protruding axis-parallel from a bottom end face of the body of the insert element 3 to form and maintain a proper gap space relative to the bottom floor of the blind hole 2 of the anchoring element 1. The spacer members are preferably, but not necessarily, formed of the titanium-based material, integrally and monolithically as one piece with the generally cylindrical body of the insert element 3.

[0026] As can be seen especially in FIGS. 3 and 4, the insert element 3 in this embodiment has an axial length greater than the axial depth of the blind hole 2 of the anchoring element 1, so that in the inserted condition, a protrusion portion 7 of the insert element 3 protrudes axially from the end face or shoulder 11 of the anchoring element 1, as will be discussed further below.

[0027] The insert element 3 is further provided with a receiver hole 8, which is preferably a threaded receiver hole having an internal screw threading, in order to receive a threaded pin or threaded stud of a prosthetic tooth abutment after the completed hybrid implant has been surgically implanted into the alveolar bone of the mandible or maxilla of a dental patent. For improved osseointegration, the outer surface of the anchoring element 1 may have a threading, ridges, grooves, roughened texture, angular faces, etc. in any known manner and configuration, for example as depicted in FIG. 3. In the present illustrated embodiment, the threaded receiver hole 8 is previously provided in the insert element 3, as can be seen in FIG. 1, before the insert element is inserted and soldered into the anchoring element 1 as shown in FIGS. 2 to 4. Alternatively, the insert element 3 can initially be formed of a solid material without the receiver hole 8. In such an alternative embodiment, the receiver hole 8 is bored axially into the insert element 3 after the insert element 3 has been secured into the anchoring element 1 by completion of the soldering process, for example at the stages shown in FIGS. 3 and 4. Note that FIG. 3 does not show the receiver hole 8, as an example of such an alternative embodiment, and FIG. 4 shows the anchoring element 1 and the glass solder material 9 sectioned on a section plane parallel to the axis of the dental implant, but shows the insert element 3 merely from its outside without sectional illustration thereof. Thus, FIG. 4 applies to both embodiments, namely with and without a previously formed receiver hole 8 in the insert element 3. An internal threading may be tapped into the hole after it has been bored. As a further alternative, the receiver hole 8 may be previously provided as a smooth-bore cylindrical hole in the insert element 3 before inserting and soldering the insert element 3 into the anchoring element 1, but then an internal threading is tapped into the receiver hole 8 after completion of the soldering process, to ensure that the threading is precise, clean and not oxidized.

[0028] Before carrying out the thermal soldering process, the blind hole in the anchoring element 1 is partially filled with a predetermined amount of a glass solder suspension 9, and then the insert element 3 is inserted, as represented in the transition from FIG. 2 to FIG. 3. The amount of the glass solder suspension 9 is determined in connection with the dimensions and configuration of the components, so that insertion of the insert element 3 causes a pre-determined excess amount 10 of the glass solder suspension to be displaced and squeezed out of the blind hole 2 after the glass solder suspension has entirely filled the gap space 5 around the insert element 3. The excess amount 10 of solder material is thus disposed on the end face or shoulder 11 of the anchoring element 1 and on the protrusion portion 7 of the insert element 3 protruding beyond the end face 11, as shown in FIGS. 3 and 4. This assembled arrangement is then subjected to the thermal soldering process under vacuum at a temperature in a range up to or around 800 C. After completion of the soldering process and cooling of the soldered arrangement, the remaining excess amount 10 of the solder material and the protrusion portion 7 of the insert element 3 are preferably removed, for example by sawing, grinding, polishing, etc. to form a flat planar end face of the finished dental implant.

[0029] An example embodiment of a method for producing the dental implant according to the invention is thus performed essentially by carrying out the following method steps. The outer surface of the insert element 3 is wetted with some of the glass solder suspension to form a coating 9 of the glass solder suspension on the insert element 3. Optionally, a coating 3 of a ceramic primer may also be provided on the outer surface of the insert element 3 before its insertion into the blind hole 2 of the anchoring element 1, to further improve the adhesion of the glass solder material. The blind hole 2 of the anchoring element 1 is partially filled with (preferably a predetermined amount of) the glass solder suspension 9. Then the pre-coated insert element 3 is inserted into the solder-filled blind hole 2 of the anchoring element 1. By its spacer members 4 and 6, the insert element 3 is positioned centered within the blind hole 2 while forming the consistent uniform gap space 5 between the insert element 3 and the anchoring element 1. Vibration is applied to the insert element 3, which in turn imposes vibration onto the glass solder suspension 9, whereby the glass solder suspension is dispersed, uniformly distributed, and compacted. The introduced amount of the glass solder suspension 9 was preferably predetermined such that the insertion and vibration of the insert element 3 causes a pre-defined limited excess amount 10 of the glass solder material to be displaced and squeezed out of the blind hole 2 such that the excess amount 10 of solder is disposed outside of the gap space 5 adjoining on the upper shoulder 11 of the end face of the anchoring element 1 and on the protrusion 7 of the insert element 3. The excess amount 10 of solder material may adhere by a capillary effect and surface tension onto the protrusion 7 of the insert element 3 and the end face of the shoulder 11 of the anchoring element 1 at the open end of the gap space 5. The protrusion 7 of the insert element 3 forms a boundary to limit or contain the flow of the excess solder 10. Thus, the excess solder 10 cannot flow into the receiver hole 8 of the insert element 3. Instead the excess solder 10 is maintained at the upper open end of the gap space 5 in a controlled space so that it provides a supply reservoir of extra solder suspension that can be drawn into the gap space 5 as the solder suspension in the gap space shrinks or contracts during the soldering process.

[0030] The soldering process comprises a thermal firing at a temperature in a range up to or around 800 C. under vacuum, whereby the glass solder suspension 9 shrinks or contracts. At that time, solder suspension from the excess amount 10 at the open end of the gap space 5 is drawn into the gap space 5 to become part of the solder joint. This helps to avoid the formation of shrinkage cavities or voids in the finished solder joint. After completion of the thermal firing process, and cooling of the components, the protrusion 7 of the insert element 3 and any remaining excess amount 10 of the solder material is removed, e.g. by sawing, grinding, polishing and the like, so as to form a flat planar surface at this end face of the finished hybrid implant.

[0031] The dental implant as shown in FIGS. 3 and 4 can be regarded as representing a semi-finished state, after the soldering is completed, but before removal of the protruding portion 7 of the insert element 3 and the remaining excess solder 10 to form a finished dental implant. The illustrated configuration could also be regarded as a finished state of the dental implant. In any event, the illustrated state or condition is still termed a dental implant, e.g. as covered in the appended claims.

[0032] The glass solder suspension can refer to any known suspension, slurry or other composition of glass and other ingredients to prepare the starting solder material to be fired to form a soldered glass joint. The term glass solder also covers and can be referred to as a ceramic solder. The term made of generally means comprising, and not strictly consisting only and entirely of.

[0033] Although the invention has been described with reference to specific example embodiments, it will be appreciated that it is intended to cover all modifications and equivalents within the scope of the appended claims. It should also be understood that the present disclosure includes all possible combinations of any individual features recited in any of the appended claims. The abstract of the disclosure does not define or limit the claimed invention, but rather merely abstracts certain features disclosed in the application.