Integrated Porcelain System for a Dental Prosthesis
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.