Integrated Porcelain System for a Dental Prosthesis

Abstract

An integrated dental porcelain system for making dental prostheses and restorations is provided. The system includes three universal major components: a) opaque porcelain composition; b) pressable dentin ingot; and c) veneering porcelain composition that can be used interchangeably for making restorations. Techniques for making the prostheses and restorations include porcelain fused-to-metal (PFM), press-to-metal (PTM), and either pressed and/or machined all-ceramic methods. The system uses both a hand-layering of veneering porcelain (PFM technique) and a hot-pressing process (PTM and all-ceramic technique) to fabricate the prostheses and restorations.

1 . An opaque composition for coating a metal substructure of a dental prosthesis, the opaque composition comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Components 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   42-46%  
                 
                     
                   Al 2 O 3   
                   8-12%  
                 
                     
                   Na 2 O 
                   2-5% 
                 
                     
                   K 2 O 
                   6-9% 
                 
                     
                   Li 2 O 
                   0-2% 
                 
                     
                   CaO 
                   0-2% 
                 
                     
                   MgO 
                   0-2% 
                 
                     
                   ZrO 2   
                   20-30%  
                 
                     
                   SnO 2   
                   1-4% 
                 
                     
                   Tb 4 O 7   
                   0-2% 
                 
                     
                   CeO 2   
                   0-3% 
                 
                     
                   TiO 2   
                   0-2% 
                 
                     
                   Sb 2 O 3   
                   0-0.1%     
                 
                     
                   Fluorescing agent 
                   0-5% 
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
               
            
           
         
         wherein the composition, after firing to a temperature in the range of about 860° to about 900° C., forms an opaque coating over the metal substructure, the opaque coating being thermally compatible and thermally stable with a porcelain veneer layer that is later applied over the opaque coating. 
       
     
     
         2 . The opaque composition of  claim 1 , wherein the composition is in powder or paste form prior to being fired. 
     
     
         3 . The opaque composition of  claim 1 , wherein the composition is applied to the metal substructure by spraying, slurry dipping, or electro-depositing. 
     
     
         4 . The opaque composition of  claim 1 , wherein the later applied porcelain veneer layer is applied by a hot pressing technique or hand build-up technique. 
     
     
         5 . The opaque composition of  claim 1 , wherein the composition, after firing to a temperature in the range of about 800° to about 1000° C., has flexural strength of greater than 100 MPa. 
     
     
         6 . An ingot porcelain composition for making a dental prosthesis using a hot-pressing technique, the prosthesis having an opaqued metal substructure or all-ceramic core, and the porcelain composition comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Oxide 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   63-66%  
                 
                     
                   Al 2 O 3   
                   10-14%  
                 
                     
                   Na 2 O 
                   3-7% 
                 
                     
                   K 2 O 
                   9-12%  
                 
                     
                   Li 2 O 
                   0-2% 
                 
                     
                   CaO 
                   1-4% 
                 
                     
                   BaO 
                   0-3% 
                 
                     
                   Tb 4 O 7   
                   0-2% 
                 
                     
                   CeO 2   
                   0-2% 
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
               
            
           
         
         wherein the composition, after pressing at a temperature in the range of about 870° C. to about 910° C., forms a dentin body layer, the layer being thermally compatible with the opaqued metal substructure and a porcelain veneer layer that is later applied over the body layer 
       
     
     
         7 . The porcelain composition of  claim 6 , wherein the composition, after pressing at a temperature in the range of about 870° C. to about 910° C., has flexural strength of greater than 100 MPa. 
     
     
         8 . The porcelain composition of  claim 6 , wherein the later applied porcelain enamel veneer layer is applied by a hand build-up technique. 
     
     
         9 . The porcelain composition of  claim 6 , wherein a shade stain composition and a glaze composition are applied over the pressed dentin body layer to form an overlayer, the shade stain and the glaze compositions, each comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Oxide 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   56-64%  
                 
                     
                   Al 2 O 3   
                   6-13%  
                 
                     
                   Na 2 O 
                   7-15%  
                 
                     
                   K 2 O 
                   7-15%  
                 
                     
                   Li 2 O 
                   0-5% 
                 
                     
                   CaO 
                   0-3% 
                 
                     
                   MgO 
                   2-5% 
                 
                     
                   SnO 2   
                   0-4% 
                 
                     
                   Tb 4 O 7   
                   0-3% 
                 
                     
                   CeO 2   
                   0-2% 
                 
                     
                   B 2 O 3   
                   0-5% 
                 
                     
                   Sb 2 O 3   
                   0-0.5%     
                 
                     
                   F 
                   0-2.5%     
                 
                     
                   TiO 2   
                   0-1% 
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
               
            
           
         
         wherein the compositions, after firing to a temperature in the range of about 780° to about 840° C., form a shade stain and glaze overlayer over the pressed dentin body layer, the shade stain and glaze overlayer being thermally compatible and thermally stable with the pressed dentin body layer. 
       
     
     
         10 . A veneering porcelain composition for making a dental prosthesis having an opaqued metal substructure, the porcelain composition comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Oxide 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   62-65%  
                 
                     
                   Al 2 O 3   
                   8-11%  
                 
                     
                   Na 2 O 
                   8-11%  
                 
                     
                   K 2 O 
                   4-7% 
                 
                     
                   Li 2 O 
                   0-2% 
                 
                     
                   CaO 
                   2-5% 
                 
                     
                   BaO 
                   0-3% 
                 
                     
                   MgO 
                   1-4% 
                 
                     
                   SnO 2   
                   0-2% 
                 
                     
                   Tb 4 O 7   
                   0-2% 
                 
                     
                   CeO 2   
                   0-2% 
                 
                     
                   Sb 2 O 3   
                   0-2% 
                 
                     
                   P 2 O 5   
                   0-0.1%     
                 
                     
                   TiO 2   
                   0-0.1%     
                 
                     
                   F 
                   0-1% 
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
               
            
           
         
         wherein the opaqued metal substructure has not been coated with a porcelain dentin body layer, so that the veneering porcelain, after firing at a temperature in the range of about 810° C. to about 860° C., forms a dentin-enamel layer over the opaqued metal substructure, the dentin-enamel layer being thermally compatible with the opaqued metal substructure. 
       
     
     
         11 . The veneering porcelain composition of  claim 10 , wherein a glaze composition is applied over the fired dentin-enamel layer to form an overlayer, the glaze composition comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Oxide 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   56-64%  
                 
                     
                   Al 2 O 3   
                   6-13%  
                 
                     
                   Na 2 O 
                   7-15%  
                 
                     
                   K 2 O 
                   7-15%  
                 
                     
                   Li 2 O 
                   0-5% 
                 
                     
                   CaO 
                   0-3% 
                 
                     
                   MgO 
                   2-5% 
                 
                     
                   SnO 2   
                   0-4% 
                 
                     
                   Tb 4 O 7   
                   0-3% 
                 
                     
                   CeO 2   
                   0-2% 
                 
                     
                   B 2 O 3   
                   0-4% 
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
                
                
               
            
           
         
         wherein the composition, after firing to a temperature in the range of about 780° to about 840° C., forms a glaze overlayer over the fired dentin-enamel layer, the glaze overlayer being thermally compatible with the dentin-enamel layer. 
       
     
     
         12 . The veneering porcelain composition of  claim 10 , wherein the composition, after firing at a temperature in the range of about 810° C. to about 860° C., has flexural strength of greater than 80 MPa. 
     
     
         13 . A veneering porcelain composition for making a dental prosthesis having an opaqued metal substructure, the porcelain composition comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Oxide 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   62-65%  
                 
                     
                   Al 2 O 3   
                   8-11%  
                 
                     
                   Na 2 O 
                   8-11%  
                 
                     
                   K 2 O 
                   4-7% 
                 
                     
                   Li 2 O 
                   0-2% 
                 
                     
                   CaO 
                   2-5% 
                 
                     
                   BaO 
                   0-3% 
                 
                     
                   MgO 
                   1-4% 
                 
                     
                   SnO 2   
                   0-2% 
                 
                     
                   Tb 4 O 7   
                   0-2% 
                 
                     
                   CeO 2   
                   0-2% 
                 
                     
                   Sb 2 O 3   
                   0-2% 
                 
                     
                   P 2 O 5   
                   0-0.1%     
                 
                     
                   TiO 2   
                   0-0.1%     
                 
                     
                   F 
                   0-1% 
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
               
            
           
         
         wherein the opaqued metal substructure has been coated with a porcelain dentin body layer, so that the veneering porcelain, after firing at a temperature in the range of about 810° C. to about 860° C., forms an enamel layer over the dentin body layer, the enamel layer being thermally compatible with the opaqued metal substructure and the dentin body layer. 
       
     
     
         14 . The veneering porcelain composition of  claim 13 , wherein a glaze composition is applied over the fired enamel layer to form an overlayer, the glaze composition comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Oxide 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   56-64%  
                 
                     
                   Al 2 O 3   
                   6-13%  
                 
                     
                   Na 2 O 
                   7-15%  
                 
                     
                   K 2 O 
                   7-15%  
                 
                     
                   Li 2 O 
                   0-5% 
                 
                     
                   CaO 
                   0-3% 
                 
                     
                   MgO 
                   2-5% 
                 
                     
                   SnO 2   
                   0-4% 
                 
                     
                   Tb 4 O 7   
                   0-3% 
                 
                     
                   CeO 2   
                   0-2% 
                 
                     
                   B 2 O 3   
                   0-4% 
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
                
                
               
            
           
         
         wherein the composition, after firing to a temperature in the range of about 780° to about 840° C., forms a glaze overlayer over the pressed dentin body layer, the glaze overlayer being thermally compatible with the dentin body layer. 
       
     
     
         15 . A veneering porcelain composition for making a dental prosthesis having an all-ceramic core, the porcelain composition comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Oxide 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   62-65%  
                 
                     
                   Al 2 O 3   
                   8-11%  
                 
                     
                   Na 2 O 
                   8-11%  
                 
                     
                   K 2 O 
                   4-7% 
                 
                     
                   Li 2 O 
                   0-2% 
                 
                     
                   CaO 
                   2-5% 
                 
                     
                   BaO 
                   0-3% 
                 
                     
                   MgO 
                   1-4% 
                 
                     
                   SnO 2   
                   0-2% 
                 
                     
                   Tb 4 O 7   
                   0-2% 
                 
                     
                   CeO 2   
                   0-2% 
                 
                     
                   Sb 2 O 3   
                   0-2% 
                 
                     
                   P 2 O 5   
                   0-0.1%     
                 
                     
                   TiO 2   
                   0-0.1%     
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
                
                
                
                
                
               
            
           
         
         wherein the all-ceramic core contains a porcelain dentin body layer, so that the veneering porcelain, after firing at a temperature in the range of about 810° C. to about 860° C., forms an enamel layer over the dentin body layer, the enamel layer being thermally compatible with the all-ceramic core. 
       
     
     
         16 . The veneering porcelain composition of  claim 15 , wherein a glaze composition is applied over the fired enamel layer to form an overlayer, the glaze composition comprising the following components: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   Oxide 
                   Concentration Range (Wt. %) 
                 
                     
                     
                 
                     
                   SiO 2   
                   56-64%  
                 
                     
                   Al 2 O 3   
                   6-13%  
                 
                     
                   Na 2 O 
                   7-15%  
                 
                     
                   K 2 O 
                   7-15%  
                 
                     
                   Li 2 O 
                   0-5% 
                 
                     
                   CaO 
                   0-3% 
                 
                     
                   MgO 
                   2-5% 
                 
                     
                   SnO 2   
                   0-4% 
                 
                     
                   Tb 4 O 7   
                   0-3% 
                 
                     
                   CeO 2   
                   0-2% 
                 
                     
                   B 2 O 3   
                   0-4% 
                 
                     
                     
                 
             
                
                
                
               
               
                
                
                
                
                
                
                
                
                
                
                
                
               
            
           
         
       
       wherein the composition, after firing to a temperature in the range of about 780° to about 840° C., forms a glaze overlayer over the dentin body laer, the glaze overlayer being thermally compatible with the dentin body layer.