DENTAL KIT-OF-PARTS AND METHOD OF ASSEMBLING THE SAME

• US 20160242877A1
• Filed: 09/25/2014
• Published: 08/25/2016
• Est. Priority Date: 10/01/2013
• Status: Active Grant

• Current Assignee: Nobel Biocare Services AG (Envista Holdings Corporation)
• Original Assignee: Nobel Biocare Services AG (Envista Holdings Corporation)
• Inventors: Bernhard, Nicolai
• Granted Patent: US 10,111,734 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61C 13/0013 using stereolithographic techniques
• CPC Class Codes: A61C 13/0018 using laser
• CPC Class Codes: A61C 13/0019 using three dimensional printing
• CPC Class Codes: A61C 19/02 Protective casings, e.g. boxes for instruments; Bags A61C5/44 takes precedence
• CPC Class Codes: A61C 8/0016 polymeric material
• CPC Class Codes: A61C 8/005 Connecting devices for joining an upper structure with an implant member, e.g. spacers
• CPC Class Codes: A61C 8/0068 with an additional screw
• CPC Class Codes: A61C 8/0089 Implanting tools or instruments
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

The present invention describes a dental kit-of-parts comprising an implant abutment, a dental restoration and a screw. The head of the screw is provided in a recess formed in the kit-of-parts, with the screw shaft extending through a hole in the implant abutment. A channel in the dental restoration allows access to the screw head by a tool, wherein the diameter of the channel is smaller than the diameter of the screw head. The dental kit-of parts can be manufactured using rapid prototyping such that the captive screw is formed within the combination of the implant abutment and the dental restoration or through conventional means, with the dental abutment and the dental restoration being ex-situ connected to enclose the screw.

Claims

1. Dental kit-of-parts comprising:

an implant abutment having

an inner surface and an outer surface, and

a through hole configured to accommodate at least part of a screw shaft herein, the implant abutment being configured to be connected to a dental implant implanted in a jawbone;

a dental restoration having

an inner surface and an outer surface and

a channel through which a tool is insertable, the dental restoration being configured to be connected with its inner surface to the inner surface of the implant abutment; and

a screw having

a screw head and a threaded screw shaft, the diameter of the screw head being larger than the diameter of the screw shaft;

the kit-of-parts being so configured that the screw can connect a pre-assembly of the implant abutment and the dental restoration to the dental implant; and

the pre-assembly being so configured as to comprise therein a recess that encloses the screw head, whereby the screw is a captive screw;

in which kit-of-parts the channel of the dental restoration connects the outer surface of the dental restoration to the recess and has a diameter smaller than a diameter of the screw head of the screw; and

/or and in which kit-of-parts the recess is formed within the dental restoration such that the recess is enclosed by the dental restoration and has no open sides to a peripheral surface of the dental restoration.

2. Dental kit-of-parts according to claim 1, wherein the recess is positioned between the implant abutment and the dental restoration.

3. Dental kit-of-parts according to claim 1, wherein the dental restoration is connected to the outer surface of the dental restoration via a through hole in the dental restoration configured to accommodate at least part of the screw shaft therein and having a diameter smaller than a diameter of the screw head and larger than a diameter of the screw shaft.

4. Dental kit-of-parts according to claim 1, wherein the dental restoration is configured to be splittable in at least two parts.

5. Dental kit-of-parts according to claim 1, wherein a longitudinal extension of the channel coincides with or is angled relative to a longitudinal axis of the screw shaft.

6. Dental kit-of-parts according to claim 5, wherein an angulation of the longitudinal extension of the channel relative to the longitudinal axis of the screw shaft is 0°

to 30°

.

7. Dental kit-of-parts according to claim 1, wherein the implant abutment is provided with a protrusion and the dental restoration with a receiving section, wherein in the pre-assembly, the protrusion and the receiving section matingly engage each other.

8. Dental kit-of-parts according to claim 1, wherein the dental restoration comprises a crown, a bar, or a bridge structure.

9. Dental kit-of-parts according to claim 1, wherein at least one of the parts of the dental kit-of-parts comprises at least one material selected from the group of:

polymers, polymethylmethacrylate, polyurethane, polyether ether ketone;

reinforced polymers, reinforced by glass fibers, carbon fibers and ceramic particles;

dental hybrid ceramics;

glass ceramics;

titanium and titanium alloys;

cobalt chromium alloys;

zirconia and alumina.

10. Dental kit-of-parts according to claim 1, wherein at least one of the parts of the dental kit-of-parts is formed by at least one selected from the group of:

rapid manufacturing, selective laser melting, selective laser sintering, electron beam melting, direct metal laser sintering, stereolithography, three-dimensional printing and fused deposition modeling;

casting, molding and machining.

11. Dental kit-of-parts according to claim 1, wherein the connection between the inner surface of the implant abutment and the inner surface of the dental restoration is formed by at least one selected from the group of:

chemical bonding, gluing, bonding and cementing;

thermal bonding, laser welding, friction welding; and

mechanical bonding, press-fitting, shrink-fitting, screwing and bolting.

12. Dental kit-of-parts according to claim 1, wherein the screw comprises an amorphous metal material and an amorphous metal alloy, wherein the amorphous metal material and the amorphous metal alloy is a bulk metallic glass.

13. Dental kit-of-parts according to claim 12, wherein the screw comprises the amorphous metal material or the amorphous metal alloy in bulk.

14. Dental kit-of-parts according claim 1, comprising:

a dental implant configured to be implanted into a jawbone; and

tooling configured to adjust and fasten the dental implant, the implant abutment and the dental restoration.

15. Dental kit-of-parts according to claim 14, wherein the tooling comprises an amorphous metal material and an amorphous metal alloy, wherein the amorphous metal material and the amorphous metal alloy is a bulk metallic glass

16. Dental kit-of-parts according to claim 15, wherein the part of the tooling which engages the screw comprises the amorphous metal material or the amorphous metal alloy in bulk.

17. Dental kit-of-parts according to claim 1, comprising:

a plurality of said screws, individual ones of the plurality of screws having different geometrical features for engagement of a tool, and

a plurality of said implant abutments, individual ones of the implant abutments having different geometrical features capable of preventing rotation between the individual abutment and a dental implant.

18. Method of manufacturing a dental kit-of-parts, as claimed in claim 1, comprising the following steps:

aligning the implant abutment and the dental restoration;

positioning the screw between the implant abutment and the dental restoration;

assembling the implant abutment and the dental restoration via the surface of the implant abutment and the inner surface of the dental restoration, with the screw head positioned in the recess and at least part of the screw shaft accommodated in the through hole of the implant abutment, thereby forming a pre-assembly of the implant abutment and the dental restoration for subsequent assembly of the pre-assembly with a dental implant and

prior to the step of forming the pre-assembly, the steps of;

manufacturing the dental restoration by means of rapid manufacturing such that the recess and the through hole of the dental restoration are formed within the dental restoration; and

manufacturing of the screw simultaneously with the previous step, such that the screw head is formed in the recess and the screw shaft is formed in the through hole of the dental restoration and the screw is a captive screw enclosed by the dental restoration.

19. Method of manufacturing a dental kit-of-parts according to claim 18, wherein the step of assembling the implant abutment and the dental restoration further comprises:

a step of fixedly connecting the implant abutment and the dental restoration with the screw head enclosed therein, wherein the step of fixedly connecting the implant abutment and the dental restoration comprises at least one step selected from the group of;

chemical bonding, gluing, bonding and cementing;

thermal bonding, laser welding, friction welding; and

mechanical bonding, press-fitting, shrink-fitting, screwing and bolting.

21. Method of manufacturing a dental kit-of-parts according to claim 18 further comprising, prior to the step of forming a pre-assembly, the steps of:

manufacturing a dental restoration by means of rapid manufacturing such that a recess and a through hole of the dental restoration are formed within the dental restoration; and

pausing the method of rapid manufacturing at a stage where the recess is partially formed;

positioning the screw inside the dental restoration such that the screw head is positioned in the partial recess and the screw shaft is at least partially accommodated in the through hole;

continuing the rapid manufacturing process until the inlayed screw is fully enclosed by the dental restoration and the dental restoration is completed.

23. Method of manufacturing a dental kit-of-parts according to claim 18, wherein at least the step of forming a pre-assembly is performed ex-situ.

24. Method of manufacturing a dental kit-of-parts according to claim 18, wherein the screw and the tooling are formed by net shape casting.

20. (canceled)

22. Method of manufacturing a dental kit-of-parts according to claim 20, wherein the method of rapid manufacturing comprises at least one selected from the group of:

laser melting, selective laser sintering, electron beam melting, direct metal laser sintering, stereolithography, three-dimensional printing and fused deposition modeling.