Dental restorations using nanocrystalline materials and methods of manufacture
First Claim
1. A dental article comprising:
- a single component yttria-stabilized tetragonal zirconia ceramic material having grains of average grain size exceeding 100 nanometers and not exceeding about 400 nanometers, wherein the theoretical density of the ceramic material is known;
wherein the ceramic material is fabricated of particulate material consisting essentially of ceramic crystallites with an average size of less than about 20 nm;
wherein the particulate material is sintered without application of external pressure at a temperature less than about 1300°
C.;
wherein the ceramic material has a final density exceeding 95% and less than 97% of the theoretical density of the ceramic material; and
wherein the ceramic material exhibits at least 30% relative transmission of visible light when measured through a thickness of about 0.3 to about 0.5 mm.
5 Assignments
0 Petitions
Accused Products
Abstract
Dental articles are produced using relatively low sintering temperatures to achieve high density dental articles exhibiting strengths equal to and greater than about 700 MPa. Ceramic powders comprised of nanoparticulate crystallites are used to manufacture dental articles. The ceramic powders may include sintering agents, binders and other similar additives to aid in the processing of the ceramic powder into a dental article. The ceramic powders may be processed into dental articles using various methods including, but not limited to, injection molding, gel-casting, slip casting, or electroforming, hand, cad/camming and other various rapid prototyping methods. The ceramic powder may be formed into a suspension, pellet, feedstock material or a pre-sintered blank prior to forming into the dental article.
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Citations
16 Claims
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1. A dental article comprising:
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a single component yttria-stabilized tetragonal zirconia ceramic material having grains of average grain size exceeding 100 nanometers and not exceeding about 400 nanometers, wherein the theoretical density of the ceramic material is known; wherein the ceramic material is fabricated of particulate material consisting essentially of ceramic crystallites with an average size of less than about 20 nm; wherein the particulate material is sintered without application of external pressure at a temperature less than about 1300°
C.;wherein the ceramic material has a final density exceeding 95% and less than 97% of the theoretical density of the ceramic material; and wherein the ceramic material exhibits at least 30% relative transmission of visible light when measured through a thickness of about 0.3 to about 0.5 mm. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A dental article comprising:
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a single component yttria-stabilized tetragonal zirconia ceramic material having grains of average grain size exceeding 100 nanometers and not exceeding about 400 nanometers, wherein the theoretical density of the ceramic material is known; wherein the ceramic material is fabricated of particulate material consisting essentially of ceramic crystallites with an average size of less than about 20 nm; wherein the particulate material is sintered without application of external pressure at a temperature less than about 1300°
C.;wherein the ceramic material has a density exceeding 95% of the theoretical density of the ceramic material; wherein the final grain size is about 10-20 times larger than the ceramic crystallite size and the final pore size does not exceed the size of the ceramic crystallite size; and wherein the ceramic material exhibits at least 30% relative transmission of visible light when measured through a thickness of about 0.3 to about 0.5 mm.
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Specification