MACHINABLE ABUTMENT-INTEGRATED PROSTHETIC BLOCK AND METHOD FOR MANUFACTURING SAME

Abstract

Provided is a machinable abutment-integrated prosthetic block. The machinable abutment-integrated prosthetic block is structured such that an abutment is integrated with a crown block made of a material requiring no heat treatment after undergoing machining processing. The abutment and the crown block are integrated by an adhesive layer containing a cured product of a polymerizable organic compound. Therefore, the prosthetic block which is an integrated form of the abutment and the crown block can be processed by machining processing such as CAD/CAM processing. Therefore, the prosthetic block can be processed, by machining processing, into artificial teeth to be used as temporary teeth or permanent teeth and does not require no additional heat treatment after undergoing the machining processing, thereby shortening a treatment time for implant restoration, resulting in a one-day prosthesis procedure.

Claims

1. A machinable abutment-integrated prosthetic block which is a machinable dental prosthetic block formed by integrating an abutment and a crown block made of a material requiring no heat treatment after machining, wherein the integration is achieved through an adhesive layer comprising a cured product of a polymerizable organic compound, wherein the cured product of the polymerizable organic compound comprises: an organic matrix, which is a cured product of (a) two or more compounds selected from 2,2-bis[4-(2-hydroxy-3-methacryloyloxy propoxy) phenyl]propane (Bis-GMA), triethylene glycol dimethacrylate (TEGDMA), and diurethane dimethacrylate (UDMA); and (b)two or more compounds selected from 2-hydroxy ethyl methacrylate (HEMA), bis[2-[(2-methyl-1-oxoallyl)oxy]ethyl]dihydrogen benzene-1,2,4,5-tetracarboxylate (PMDM), and 10-methacryloyloxydecyl dihydrogen phosphate (10-MDP) and at least one inorganic filler selected from barium silicate (BaO.sub.3Si) and silicon dioxide (SiO.sub.2) dispersed in the organic matrix.

2. The prosthetic block of claim 1, wherein each of the compounds (a) is provided as a mixture of triethylene glycol dimethacrylate (TEGDMA) with at least one selected from 2,2-bis[4-(2-hydroxy-3-methacryloyloxy propoxy) phenyl] propane (bis-GMA) and urethanedimethacrylate (UDMA).

3. The prosthetic block of claim 1, wherein the crown block made of a material that requires no heat treatment after machining comprises at least one material selected from polymethyl methacrylate-based polymer (PMMA), a ceramic-resin composite, zirconia, and crystallized glass.

4. The prosthetic block of claim 3, wherein the ceramic-resin composite is a cured product of: at least two polymerizable organic compounds selected from hydroxy ethyl methacrylate (HEMA), 2,2-bis[4-(2-hydroxy-3-methacryloyloxy propoxy)phenyl]propane (Bis-GMA), triethylene glycoldimethacrylate (TEGDMA), diurethanedimethacrylate (UDMA), urethane dimethacrylate (UDM), biphenyldimethacrylate (BPDM), n-tolylglycine-glycidylmethacrylate (NTGE), polyethylene glycol dimethacrylate (PEG-DMA), and oligocarbonate dimethacrylic esters; and at least one inorganic material selected from barium silicate-based crystallized glass, leucite-based crystallized glass, alumina, zirconia, and glass.

5. The prosthetic block of claim 1, wherein the abutment comprises at least one material selected from titanium, alloys of titanium, and zirconia.

6. The prosthetic block of claim 1, wherein the cured product of a polymerizable organic compound is a product produced by photocuring or thermal curing.

7. The prosthetic block of claim 1, wherein a surface of the crown adjacent to the adhesive layer or a surface of the abutment adjacent to the adhesive layer is a surface treated by acid etching or sandblasting.

8. A method for manufacturing a machinable abutment-integrated prosthetic block, the method comprising: a step of preparing S1 a crown block made of a material that requires no heat treatment after machining; a step S2 of preparing an abutment; a step S3 of processing the crown block so that the crown has a hole having a shape conforming to the abutment; a step S4 of applying an adhesive composition comprising a polymerizable organic compound onto the abutment, a step S5 of fastening the abutment coated with the adhesive composition to the hole-processed crown block; and a step S6 of integrating the abutment and the crown block by curing the crown block to which the abutment is fastened, wherein the adhesive composition comprising the polymerizable organic compound comprises (a) two or more compounds selected from 2,2-bis[4-(2-hydroxy-3-methacryloyloxy propoxy) phenyl] propane (Bis-GMA), triethylene glycol dimethacrylate (TEGDMA), and diurethane dimethacrylate (UDMA), (b) two or more compounds selected from 2-hydroxy ethyl methacrylate(HEMA), bis[2-[(2-methyl-1-oxoallyl)oxy]ethyl]dihydrogen benzene-1,2,4,5-tetracarboxylate (PMDM), and 10-methacryloyloxydecyl dihydrogen phosphate (10-MDP), (c) at least one inorganic filler selected from barium silicate (BaO.sub.3Si) and silicon dioxide (SiO.sub.2) , and (d) a photoinitiator or a thermal initiator.

9. The method of claim 8, wherein in the step S3, the hole-processed surface of the crown block is further surface-treated by acid etching or sandblasting.

10. The method of claim 8, wherein in step S4, the surface of the abutment is surface-treated by acid etching or sandblasting and then coated with the adhesive composition comprising the polymerizable organic compound.

11. The method of claim 8, wherein in the step S6, photocuring is performed at a wavelength in a range of 350 nm to 450 nm.

12. The method of claim 8, wherein in the step S6, thermal curing is performed at a temperature in a range of 80° C. to 150° C.

13. An abutment-integrated artificial tooth obtained by Computer-Aided Design/Computer-Aided Manufacturing (CAD/CAM) processing or laser milling of the machinable abutment-integrated prosthetic block of claim 1.

14. An abutment-integrated artificial tooth obtained by CAD/CAM processing or laser milling of the machinable abutment-integrated prosthetic block manufactured by the method of claim 8.

15. The abutment-integrated artificial tooth of claim 13, wherein the artificial tooth is a temporary tooth or a permanent tooth.

16. The abutment-integrated artificial tooth of claim 14, wherein the artificial tooth is a temporary tooth or a permanent tooth.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0022] FIG. 1 is a schematic diagram illustrating a machinable abutment-integrated prosthetic block.

[0023] FIG. 2 illustrates an example of a flowchart of manufacturing a machinable abutment-integrated prosthetic block, according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

[0024] Hereinafter, the present disclosure will be described in more detail with reference to the drawing.

[0025] The foregoing and further aspects of the present disclosure will become more apparent through the preferred embodiments described with reference to the accompanying drawing. Hereinafter, the embodiment of the present disclosure will be described in detail so that those skilled in the art can easily understand and reproduce the present disclosure.

[0026] A structure of a typically operated implant is divided into a fixture, an abutment, and a crown. The fixture is embedded in the alveolar bone and is osseointegrated over time, and serves as a support. The abutment, the part to which the top of the fixture is connected, serves to connect the fixture to the crown which serves as a tooth, and is generally connected to the crown through cementation. Such procedures are generally performed in stages over a long period of time.

[0027] FIG. 1 is a schematic diagram illustrating a machinable abutment-integrated prosthetic block according to the present disclosure, which is a machinable dental prosthetic block formed by integrating an abutment 2 and a crown block 1 made of a material that requires no heat treatment after machining. The integration is achieved through an adhesive layer 4 which contains a cured product of a polymerizable organic compound.

[0028] It is noted that such a prosthetic block may include a screw access channel 3 ultimately in consideration of connection of the fixture, and be prepared with a mandrel 5 in consideration of machining.

[0029] To perform machining such as CAD/CAM processing or laser milling in a state where the abutment 2 made of various materials is integrated with the crown block 1 made of a material that requires no heat treatment after machining, each of the integration methods and materials may play significant roles.

[0030] In this aspect, the adhesive layer preferably includes the cured product of the polymerizable organic compound. That is, the abutment 2 and the crown block 1 are preferably integrated through a curing reaction of the polymerizable organic compound. Particularly, in this case, depending on a composition of the cured product, the abutment 2 and the crown block 1 may overcome the material difference and be bonded to each other. Specifically, the cured product preferably includes an organic matrix, which is a cured product of (a) two or more compounds selected from 2,2-bis[4-(2-hydroxy-3-methacryloyloxy propoxy) phenyl]propane (Bis-GMA), triethylene glycol dimethacrylate (TEGDMA), and diurethane dimethacrylate (UDMA); and (b)two or more compounds selected from 2-hydroxy ethyl methacrylate (HEMA), bis[2-[(2-methyl-1-oxoallyl)oxy]ethyl]dihydrogen benzene-1,2,4,5-tetracarboxylate (PMDM), and 10-methacryloyloxydecyl dihydrogen phosphate (10-MDP) and at least one inorganic filler selected from barium silicate (BaO.sub.3Si) and silicon dioxide (SiO.sub.2) dispersed in the organic matrix.

[0031] In this case, preferably the compounds (a) are organic compounds allowing each material to exhibit a viscosity capable of being applied and each of the compound (a) is provided as a mixture of compounds having low viscosity and compounds having high viscosity. Specifically, each of the compounds (a) is provided as a mixture of triethylene glycol dimethacrylate (TEGDMA) and at least one selected from 2,2-bis[4-(2-hydroxy-3-methacryloyloxy propoxy) phenyl]propane (Bis-GMA) and urethanedimethacrylate (UDMA).

[0032] The compound (b) may act as an adhesive compound that improves adhesion of each material.

[0033] Also, it is preferable to include at least one type of inorganic filler selected from barium silicate (BaO.sub.3Si) and silicon dioxide (SiO.sub.2) to improve the physical properties of the adhesive layer from a perspective of improving the adhesive strength between organic and inorganic materials.

[0034] In the case of the adhesive layer 4, it is noted that each content of the organic matrix and the inorganic filler, and the mixing ratio of the compounds (a) in a mixture form and the compounds (b) constituting the organic matrix may be appropriately adjusted in consideration of each material of the crown block and the abutment.

[0035] In such an adhesive layer, the cured product of a polymerizable organic compound may be a product produced by photocuring or thermal curing.

[0036] According to the machinable abutment-integrated prosthetic block of the present disclosure, the crown block 1 is preferably made of a material that requires no heat treatment after machining. It is because when the material only exhibits required properties only after undergoing additional heat treatment in a block state where the crown has a shape conforming to the abutment through machining, it may contain a problem that the size of the crown block after additional heat treatment can be changed by circumstances. The crown block of the prosthetic block, according to one aspect of the present disclosure, preferably includes at least one material selected from polymethyl methacrylate-based polymer (PMMA), a ceramic-resin composite, zirconia, and crystallized glass. Particularly, in the case of the crystallized glass, it is preferable that the crystallized glass is capable of being cut while containing lithium disilicate crystal as the main crystal.

[0037] In this case, the PMMA polymer has lower physical properties than other materials, so it is generally applicable as a block for temporary teeth. Temporary teeth implanted in the oral cavity after implantation and before using permanent teeth prostheses are used to check whether the fixture and the periodontal portion are well fixed and if there is any pain in the patient during mastication. Temporary teeth are also used for aesthetic functions before manufacturing permanent teeth prostheses. Each of the ceramic-resin composite, zirconia, and crystallized glass is a material that exhibits higher physical properties than the PMMA polymer and can constitute the crown block 1 which can be applied as a permanent tooth prosthesis.

[0038] More specifically, the ceramic-resin composite may be a cured product of: at least two or more polymerizable organic compounds selected from hydroxy ethyl methacrylate (HEMA), 2,2-bis[4-(2-hydroxy-3-methacryloyloxy propoxy) phenyl] propane (Bis-GMA), triethylene glycoldimethacrylate (TEGDMA), diurethanedimethacrylate (UDMA), urethane dimethacrylate (UDM), biphenyldimethacrylate (BPDM), n-tolylglycine-glycidylmethacrylate (NTGE), polyethylene glycol dimethacrylate (PEG-DMA), and oligocarbonate dimethacrylic esters; and at least one inorganic material selected from barium silicate-based crystallized glass, leucite-based crystallized glass, alumina, zirconia, and glass. Such a ceramic-resin composite is a material applicable to anterior teeth and premolar teeth. It is noted that the contents described in Korean Patent Application Publication No. 10-2017-0173152 by the present applicant may be referred to in detail.

[0039] In the case of zirconia as the material of the crown block 1, it is preferable to contain 2 mol % to 10 mol % of yttria, which can be applied immediately after machining without additional heat treatment so that it can be used in the posterior region which generally requires high physical properties.

[0040] On the other hand, the material of the abutment 2 of the machinable abutment-integrated prosthetic block according to the present disclosure is not limited and may include at least one material selected from titanium, an alloy of titanium, and zirconia as one example.

[0041] When the abutment 2 and the crown block 1 of the above materials are integrated through the adhesive layer 4 containing the cured product of the polymerizable organic compound, a surface of the crown adjacent to the adhesive layer 4 or a surface of the abutment adjacent to the adhesive layer 4 is preferably a surface treated by acid etching or sandblasting for the purpose of improving the interlayer adhesion.

[0042] FIG. 2 illustrates an example method of a flowchart of manufacturing a machinable abutment-integrated prosthetic block, according to one embodiment of the present disclosure.

[0043] The method for manufacturing such a machinable abutment-integrated prosthetic block includes step S1 of preparing a crown block made of a material requires no heat treatment after machining, step S2 of preparing an abutment, step S3 of processing the crown block so that the crown block has a hole having a shape conforming to the abutment, step S4 of applying an adhesive composition containing a polymerizable organic compound onto the abutment, step S5 of fastening the abutment coated with the adhesive composition to the hole-processed crown block, and a step S6 of integrating the abutment and the crown block by curing the crown block to which the abutment is fastened.

[0044] In this case, the adhesive composition containing the polymerizable organic compound preferably includes (a) two or more compounds selected from 2,2-bis[4-(2-hydroxy-3-methacryloyloxy propoxy) phenyl] propane (Bis-GMA), triethylene glycol dimethacrylate (TEGDMA), and diurethane dimethacrylate (UDMA), (b) two or compounds more selected from 2-hydroxy ethyl methacrylate(HEMA), bis[2-[(2-methyl-1-oxoallyl)oxy]ethyl]dihydrogen benzene-1,2,4,5-tetracarboxylate (PMDM), and 10-methacryloyloxydecyl dihydrogen phosphate (10-MDP), (c) at least one type of inorganic filler selected from barium silicate (BaO.sub.3Si) and silicon dioxide (SiO.sub.2) , and (d) a photoinitiator or a thermal initiator.

[0045] In this case, the compounds (a), (b), and (c) are as described above.

[0046] When (d) is a photoinitiator, it is preferably a compound or polymerization initiating system in which curing is initiated at a wavelength in a range of 350 nm to 450 nm. Camphorquinone (CQ) can be one example of the photoinitiator. The polymerization initiating system may include at least one or more photosensitizer selected from 1-phenyl-1,2-propanedione (PPD), diphenyliodonium hexafluorophosphate (DPIHP), and p-octyloxy-phenyl-phenyl iodonium hexafluoroantimonate (OPPI), and may include a catalyst which is tertiary amine such as ethyl-4-dimethylaminobenzoate (EDMAB), which is a relatively hydrophobic aromatic compound, or 2-(dimethylamino)ethyl methacrylate (DMAEMA), which is a hydrophilic aliphatic compound.

[0047] On the other hand, thermal curing is preferably performed with the use of the thermal initiator at a temperature in a range of 80° C. to 150° C. and may include a peroxide-based initiator such as benzoyl peroxide (BPO) as an example.

[0048] In the step S1 of preparing the crown block of the material that requires no heat treatment after machining, the material as described above may constitute the crown block 1 . In this case, the crown block may have the mandrel 5 attached thereto.

[0049] In addition, in the step S2 of preparing the abutment, the abutment 2 and its related materials as described above may be prepared.

[0050] In the step S3 of processing the prepared crown block so that the crown has a hole having a shape conforming the abutment, the hole-processing is performed conforming the structure so that the abutment is fixed to the crown block 1 which is typically manufactured with the mandrel 5 attached thereto. In this case, in the expression “conforming the abutment”, the abutment may be understood as a structure of the abutment including the screw access channel 3 to be connected to the fixture in consideration of the ultimate implantation of the prosthesis.

[0051] As described above, the surface of the crown block adjacent to the adhesive layer 4 or a surface of the abutment adjacent to the adhesive layer 4 is preferably a surface-treated layer. In this regard, it is preferable to perform surface treatment of the hole-processed surface of the crown block by acid etching or sandblasting and fasten the surface of the crown block to the abutment 2 coated with the adhesive composition.

[0052] On the other hand, in the step S4 of applying the adhesive composition containing the polymerizable organic compound onto the abutment, it is preferable to perform surface treatment of the abutment by acid etching or sandblasting and to apply the adhesive composition containing the polymerizable organic compound onto the surface of the abutment, in the same context.

[0053] In this case, the surface treatment is preferably performed in both steps S3 and S4 or may be performed only in one of the steps.

[0054] After the step (S5) of fastening the abutment coated with the adhesive composition to the hole-processed crown block, the step S6 includes the integration of the abutment and the crown block by curing the crown block to which the abutment is fastened

[0055] As the simultaneous curing reaction integrates the abutment and the crown block, the interlayer bonding strength may be effectively enhanced.

[0056] In the step S6, it is preferable that photocuring is performed at a wavelength in a range of 350 nm to 450 nm, or thermal curing is performed at a temperature in a range of 80° C. to 150° C.

[0057] According to the manufacturing method as described above, the integration of the crown block 1 made of various materials and the abutment 2 made of various materials by a curing reaction of a specific polymerizable organic compound is advantageous in that, as a relatively mild process enables the integration without severe heat treatment, concerns about changes in the physical properties of the crown block material can be dispelled.

[0058] In addition, the machinable abutment-integrated prosthetic block manufactured by the same method as above can be directly processed by machining such as CAD/CAM processing or laser milling depending on the needs of the patient to produce an abutment-integrated artificial tooth. When the abutment-integrated prosthetic block is connected to the fixture, a treatment time for implant restoration can be shortened, thereby enabling a one-day implant procedure.

[0059] Particularly, even when machining such as CAD/CAM processing or laser milling is involved, the prosthetic block in the abutment-integrated state can maintain mechanical stability by having excellent adhesive strength and shear bonding strength. Also, the integrated body of the abutment and the crown can reduce the possibility of secondary infection of bacterial infiltration resulting from individual procedures.

[0060] The artificial tooth obtained by machining the abutment-integrated prosthetic block may be a temporary tooth or a permanent tooth depending on the crown block material.

[0061] Although the present disclosure has been described with reference to one embodiment shown in the drawing, this is merely exemplary, and those skilled in the art will understand that various modifications and equivalent other embodiments are possible therefrom.

[0062] The present disclosure relates to a machinable abutment-integrated prosthetic block. Provided is a machinable abutment-integrated prosthetic block which is a machinable dental prosthetic block formed by integrating an abutment and a crown block made of a material that requires no heat treatment after machining, and can be processed by machining such as CAD/CAM processing in a state where the abutment is integrated with the crown.

[0063] The machinable abutment-integrated prosthetic block of the present disclosure can be processed by severe machining like machining such as CAD/CAM processing in a block state where the abutment is integrated with the crown. Therefore, the machinable abutment-integrated prosthetic block can be manufactured into artificial teeth such as temporary and permanent teeth suitable for individual patients while requiring no additional heat treatment after machining, and since implantation procedure can be finished by implanting an abutment-integrated crown after machining, a treatment time for implant restoration can be shortened, thereby enabling a one-day prosthesis procedure.