Bar manufacturing and denture reference and registration system

Abstract

An improved denture system is disclosed. An improved denture system has a support bar and a denture material blank. The denture material blank has an oversize cutout to secure the support bar. The support bar has oversized implant interfaces and optional oversized tooth abutments. After securing the support bar in the denture material blank the final shape and dimensions of the implant interfaces and optionally the final shape and dimensions of the tooth abutments will be machined. The denture system will result in an accurate reference and registration between the denture teeth and base and the implant interfaces.

Claims

1. A denture material blank having a top surface correlating to a coronal portion of a denture and a bottom surface correlating to an implant interfacing portion of a denture, with one of the top surface or bottom surface having a flat profile, the denture material blank comprising: a support bar within the denture material blank and the support bar at least partially comprising a material different than that of the denture material blank, the support bar further comprising two or more solid cylindrical shapes capable of being milled into a smaller volume, the two or more solid cylindrical shapes capable of being milled into a smaller volume extending in a first direction towards the bottom surface from the support bar, the two or more solid cylindrical shapes each extending in the first direction toward an end, the two or more solid cylindrical shapes being integrated within the denture material blank and an added denture material at least up to the end of each of the two or more solid cylindrical shapes.

2. The denture material blank according to claim 1, the support bar further comprising at least one oversized tooth abutment extending in a second direction towards the top surface from the support bar.

3. The denture material blank according to claim 1, whereby the denture material blank enables a known reference for the support bar to be capable of reference and registration to a milling device allowing for milling of the support bar within the denture material blank.

4. The denture material blank according to claim 2 capable of being further processed into at least one of the following: a final denture; a final implant interface; and a final tooth abutment.

5. The denture material blank according to claim 2 wherein said at least one oversized tooth abutment comprises one to fourteen tooth abutments.

6. The denture material blank according to claim 1 wherein said two or more solid cylindrical shapes comprises two to ten solid cylindrical shapes.

7. The denture material blank according to claim 1, the denture material blank further comprising at least one tooth cut-out extending in a second direction towards the top surface from the support bar.

8. The denture material blank according to claim 7 further comprising a tooth portion applied to the at least one tooth cut-out.

9. The denture material blank according to claim 2 further comprising a tooth portion applied to the at least one tooth abutments.

10. The denture material blank according to claim 4 whereby the system enables a reference and registration relationship between a final tooth portion and the final implant interface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, where like reference numbers refer to similar elements throughout the Figures, and:

(2) FIGS. 1A and 1B are views of a prior art system having a plaster model and a support bar;

(3) FIG. 2A is a view of an exemplary embodiment of a support bar positioned in a denture material blank

(4) FIG. 2B is a panoramic view A-A of an exemplary embodiment of a support bar with oversized implant interfaces, according to FIG. 2A;

(5) FIG. 2C is a panoramic view A-A of an exemplary embodiment of a support bar with oversized implant interfaces and oversized tooth abutments, according to FIG. 2A;

(6) FIG. 3A is a view of a comparison between a final milled implant interface and an oversized implant interface.

(7) FIG. 3B is a section view A-A of a comparison between a final milled implant interface and an oversized implant interface, according to FIG. 3A;

(8) FIG. 4A is a panoramic view of an exemplary embodiment of a bar with oversized implant interfaces positioned into a cutout in a denture material blank, along with a detailed view thereof a portion of the bar, blank and cutout;

(9) FIG. 4B is a panoramic view of an exemplary embodiment of a bar with oversized implant interfaces according to FIG. 4A integrated in a denture material blank with the cutout filled with denture material resin, along with a detailed view thereof a portion of the bar, blank and filled cutout filled with resin;

(10) FIG. 4C panoramic view of an exemplary embodiment of a bar with oversized implant interfaces according to FIG. 4A integrated in a denture material blank with the cutout filled with denture material resin, further having tooth root structures cut into the top of the material blank;

(11) FIG. 4D is panoramic view of an exemplary embodiment of a bar with oversized implant interfaces according to FIG. 4A integrated in a denture material blank with first cutout filled with denture material resin, the material blank having a second cutout at the top of the material blank;

(12) FIGS. 5A-5C are views of an exemplary embodiment, according to FIGS. 4A-4C including tooth abutments, along with detailed views thereof;

(13) FIG. 6A is a panoramic view of an exemplary embodiment of a denture material blank with an integrated bar with a finished intaglio surface, finished implant interfaces milled to the exact dimensions and finished screw holes, along with a detailed view thereof.

(14) FIG. 6B is a panoramic view of an exemplary embodiment of a denture material blank with an integrated bar with a finished intaglio surface, finished implant interfaces milled to the exact dimensions, finished screw holes and finished tooth abutments, along with a detailed view thereof.

(15) FIG. 7 is a view of an exemplary embodiment finished denture in a denture material blank with an integrated bar.

DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

(16) The following description is of various exemplary embodiments only, and is not intended to limit the scope, applicability or configuration of the present disclosure in any way. Rather, the following description is intended to provide a convenient illustration for implementing various embodiments including the best mode. As will become apparent, various changes may be made in the function and arrangement of the elements described in these embodiments without departing from the scope of the appended claims.

(17) For the sake of brevity, conventional techniques for manufacturing and construction may not be described in detail herein. Furthermore, the connecting lines shown in various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical method of construction.

(18) In accordance with various aspects of the present invention, an improved bar manufacturing and denture reference and registration system are provided. In accordance with an exemplary embodiment, a support bar comprising a plurality of implant interfaces may be inserted into an improved denture material blank having an oversize cutout, wherein the cutout is configured to interface with support bar, and as a result, securing the denture material blank with the support bar.

(19) Securing the denture material blank, may in some example embodiments have multiple meanings or configurations. For example, securing can mean retaining the denture components, such as a denture system, a denture bar, or a denture material blank. Alternatively, securing may mean stabilizing the denture components, such as a denture system, a denture bar, or a denture material blank. Furthermore, securing may mean aligning the denture components, such as a denture system, a denture bar, or a denture material blank. Still furthermore, securing may mean reinforcing the denture or denture bar or denture material blank. In some embodiments securing may mean any combination of these meanings and configurations.

(20) With reference to FIGS. 4A-4D, an improved denture system 400 is illustrated. Additionally, with reference to FIGS. 2A-2B, 3A-3B, 5A-5D, improved denture system 400 may comprise a support bar 202 and denture material blank 406. Support bar 202 may have a plurality of oversized implant interfaces 204. The denture material blank 406 may have at least one oversized cutout 402, or a void within the material blank whose space is larger than the support bar.

(21) Support bar 202 may be placed in oversize cutout 402. Support bar 202 may be held in substantially fixed position, or is maintained, or otherwise coupled or retained in communication with the denture material blank 406 or to otherwise secure the denture material blank 406 or providing for easy positioning of the denture bar 202 relative to the denture material blank 406.

(22) With reference to FIGS. 2A-2C, a support bar 202 for use in an improved denture system 400 is illustrated. Support bar 202 may be made of joined or integrally manufactured segments to approximately follow the contour of a patient's edentulous ridges. Alternatively, support bar 202 may be segmented, or straight, or curved, or any other shape adapted to provide support to an improved denture system 400.

(23) Support bar 202 may further comprise an oversized implant interface 204. In one exemplary embodiment, a support bar 202 may comprise four oversized implant interfaces 204. In another example embodiment, a support bar 202 may comprise six oversized implant interfaces 204, or five oversized implant interfaces 204, or three oversized implant interfaces 204, or two oversized implant interfaces 204, or one oversized implant interface 204. In one embodiment, support bar 202 comprises oversized implant interfaces 204 located at the joint of each segment of support bar 202. Alternatively, support bar 202 may comprise oversized implant interfaces 204 spaced evenly along support bar 202. Still further, alternatively, support bar 202 may comprise oversized implant interfaces 204 located at places corresponding to suitable sites along a patient's edentulous ridges for the installation of implants. Support bar 202 may comprise any number or configuration of implant interfaces 204 adapted to support an improved denture system 400.

(24) With reference to FIGS. 6A-6B oversized implant interface 204 may be machined into an accurate final implant interface 604. With momentary reference to FIGS. 6A-6B, generally, final implant interface 604 comprises holes for insertion of fasteners 602 whereby support bar 202 may be secured to a patient's implants. Alternatively, final implant interface 604 may comprise captive bolds, threaded holes, captive nuts, or any other fastening mechanism. In another embodiment of the invention, the intaglio surface of the denture structure may also be milled to a final specification in the same step as the milling of the final implant interface, so that when the bar is secured to the patient's implants, the intaglio surface of the denture structure is already completed. Other sequencing of steps described herein may be available in other embodiments of the invention not illustrated.

(25) Furthermore, in FIG. 6B are the optional oversized tooth abutments 207 machines to an accurate sized and shaped tooth abutment 603.

(26) Support bar 202 may also comprise a plurality of oversized tooth abutments 207. In one exemplary embodiment, each oversized tooth abutment 207 will extend into a corresponding cutout 402. For example, with momentary reference to FIGS. 5A-5B a corresponding cutout 402 in the denture material blank 406. The oversized tooth abutments 207 and the oversized implant interfaces 206 will typically be manufactured in one piece with the support bar 202, for example by machining, 3D printing or other technologies known in the dental arts to produce such devices. Other approaches to manufacturing the abutments and implant interfaces with the support bar, in segments or other piecemeal construction techniques, are well-within the scope of the invention.

(27) Oversized implant interfaces 206 may be any size or shape adapted to the support bar 202.

(28) Various materials may be used to manufacture support bar 202. In one exemplary embodiment, support bar 202 may comprise metal, such as titanium, aluminum or stainless steel, though it may alternatively comprise numerous other materials configured to provide support, such as, for example, carbon fiber, a Kevlar-brand material, Dynema-brand material, Aramid-brand material, alloy, glass, binder, epoxy, polyester, acrylic, or any material or combination of materials having a desired strength, stiffness, or flexibility sufficient to reinforce said denture. In one example embodiment, oversized implant interfaces 206 are made of different material than support bar 202. For example, a support bar 202 may be titanium and oversized implant interface 206 may be zirconia. In another embodiment, the oversized implant interfaces 206 may be manufactured separately from the support bar 202 and are utilized in conjunction with the support bar 202 according to the principles described herein.

(29) In some embodiments, a support bar 202 may comprise multiple materials, or any material configuration suitable to enhance or reinforce the resiliency and/or support of the denture when subjected to wear in a wearer's mouth or to satisfy other desired chemical, physical, or biological properties. Furthermore, a support bar 202 may comprise materials with differing grain structures or grain direction or with similar grain structures or grain direction or any grain structure or direction suitable for achieving desired properties in the denture; for example, resiliency under torsional loads.

(30) Now, having described various components of an improved denture system 400, the assembly of an improved denture system 400 may be appreciated with reference to FIGS. 6A-6B.

(31) The oversize cutout 402 may be made in denture material blank 406 by milling, or molding, or 3D printing, or any other method for making an improved denture. For example, the oversize cutout 402 may be machined by a CAD/CAM machining device, although any process suited for accurate forming of the material may be utilized. For example, said oversize cutout 402 may be formed by machining, etching, waterjet, laser cutting, 3D printing, or chemical mask processes.

(32) Turning to FIGS. 6A-6C, the process for manufacturing an improved denture system 400 continues with the securing the bar 202 into oversize cutout 402. In one embodiment, a second material (FIG. 4B, 403) may be filled into any remaining voids in oversize cutout by use of high pressure injection or other techniques known in the arts to inject fluids or materials into such remaining voids.

(33) In an exemplary embodiment of the invention, the denture system illustrated in FIG. 6a may be manufactured through a number of different processes beginning with the intermediate denture product in 4b. For instance, FIG. 4c shows a version of the intermediate denture product in 4b, with tooth pockets or tooth cut-outs 407 having been cut from the material blank 406, or with such blank material 406 being removed from the denture product to form tooth pockets or at least one tooth cut-out 407. Similarly, the embodiment in FIG. 4d illustrates the intermediate denture product from 4b, but with a second cut-out applied at the top (or side opposite that of the first cut-out) of the material blank. In this embodiment, a tooth portion 411 may be applied to the second cut-out by way of adhesive, friction fit, locking mechanism, or other means of mating known in the dental arts. By way of specific example and not limitation, a dental practitioner may glue the tooth portion comprising PMMA directly into the second cut-out. Tooth portion is shown as being an integral piece adhered to the second cut-out, but tooth portion may also comprise sub-sections 408, 409 and 410 of the tooth portion.

(34) The various components of an improved denture system 400 may be made of various different materials in different shapes. For example, various materials may be used to the denture material blank 406. In one exemplary embodiment, a hardened polymethyl methacrylate (PMMA) material is used. However, the denture material blank 406 may comprise any material having sufficiently low porosity so as to be hygienic for extended placement in a wearer's mouth. For example, the denture material blank may be made of a plastic, ceramic, metal, or acrylic, including for instance, a polymer, monomer, composite, or alloy.

(35) In various embodiments of the invention, the dental blank material may comprise a single tooth material, with layered tooth materials, and/or the blank comprising the denture base material.

(36) Furthermore, the shape of the denture material blank 406 can be oval, or multisided, for example trapezoidal, heptagonal, hexagonal, septagonal, or octagonal or any other number of sides, or may be irregularly shaped, or may be T-shaped, L-shaped or horseshoe shaped or may comprise any other shape.

(37) The present disclosure has been described with reference to various embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present disclosure. Accordingly, the specification is to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present disclosure. Likewise, benefits, other advantages, and solutions to problems have been described above with regard to various embodiments. However, benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims.

(38) As used herein, the terms comprises, comprising, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Also, as used herein, the terms proximate, proximately, or any other variation thereof, are intended to cover a physical connection, an electrical connection, a magnetic connection, an optical connection, a communicative connection, a functional connection, and/or any other connection. When language similar to at least one of A, B, or C is used, the phrase is intended to mean any of the following: (1) at least one of A; (2) at least one of B; (3) at least one of C; (4) at least one of A and at least one of B; (5) at least one of B and at least one of C; (6) at least one of A and at least one of C; or (7) at least one of A, at least one of B, and at least one of C.