UNITARY DENTAL MODEL

• US 20150359615A1
• Filed: 06/16/2014
• Published: 12/17/2015
• Est. Priority Date: 06/16/2014
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Cadent Incorporated
• Inventors: Sabina, Michael, Kopelman, Avi, Sharabi, Yoram
• Granted Patent: US 10,016,262 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61C 13/0004 Computer-assisted sizing or machining of dental prostheses
• CPC Class Codes: A61C 13/34 Making or working of models, e.g. preliminary castings, trial dentures; Dowel pins [4]
• CPC Class Codes: A61C 8/0001 Impression means for implants, e.g. impression coping
• CPC Class Codes: A61C 9/0053 Optical means or methods, e.g. scanning the teeth by a laser or light beam
• CPC Class Codes: G16H 20/40 relating to mechanical, radiation or invasive therapies, e.g. surgery, laser therapy, dialysis or acupuncture

Abstract

Improved dental models for use in dental procedures are provided. In one aspect, a unitary dental model of an intraoral cavity of a patient having a dental implant comprises a physical surface representative of gingival tissue of the patient. The model can comprise a channel shaped and oriented to receive an abutment corresponding to a physical abutment to be connected to the dental implant, in which the channel extends to an opening in the physical surface. The channel can comprise a first portion shaped to receive and constrain a corresponding structure of the abutment to a position and orientation and a second portion shaped to receive a fastener to couple the abutment to the unitary dental model. In many embodiments, the first portion comprises a shoulder shaped to receive the corresponding structure of the abutment in order to position the abutment along the channel.

Claims

1. A unitary dental model of an intraoral cavity of a patient having a dental implant, the model comprising:

a physical surface representative of gingival tissue of the patient; and

a channel shaped and oriented to receive an abutment corresponding to a physical abutment to be connected to the dental implant, wherein the channel extends to an opening in the physical surface, the channel comprising a first portion and a second portion, the first portion shaped to receive and constrain a corresponding structure of the abutment to a position and orientation, the second portion shaped to receive a fastener to couple the abutment to the unitary dental model;

wherein the first portion comprises a shoulder shaped to receive the corresponding structure of the abutment in order to position the abutment along the channel.

2. The model of claim 1, wherein the physical surface comprises physical models of one or more teeth and a physical model of gingival tissue extending between the one or more teeth, and wherein the physical models of the one or more teeth are representative of one or more teeth of the intraoral cavity near the dental implant.

3. The model of claim 1, wherein the opening comprises a maximum cross-sectional dimension sized larger than a maximum cross-sectional dimension of the second portion.

4. The model of claim 1, wherein the first portion is shaped to correspond to a portion of the dental implant that receives and constrains a corresponding structure of the physical abutment.

5. The model of claim 1, wherein the second portion extends to an opening in a bottom surface opposite the physical surface, and wherein the opening in the bottom surface is shaped to accommodate a nut for securing the abutment and fastener to the unitary dental model.

6. The model of claim 1, wherein the first portion is shaped to receive and constrain the corresponding structure of the abutment to a predetermined position and orientation.

7. The model of claim 6, wherein the predetermined position and orientation corresponds to a position and orientation of the physical abutment when connected to the dental implant in the intraoral cavity.

8. The model of claim 6, wherein the channel is an elongate channel comprising a longitudinal axis, and the predetermined position and orientation is defined by one or more of the longitudinal axis, shoulder, or opening.

9. The model of claim 8, wherein the predetermined orientation comprises a rotation about the longitudinal axis.

10. The model of claim 8, wherein the predetermined orientation comprises a rotation away from the longitudinal axis.

11. The model of claim 8, wherein the corresponding structure of the abutment comprises a lower engagement surface and the shoulder is shaped to receive and mate with the lower engagement surface in order to position the corresponding structure at a location along the longitudinal axis.

12. The model of claim 11, further comprising the abutment comprising the corresponding structure comprising the lower engagement surface.

13. A computer-implemented method for creating a virtual model of an intraoral cavity of a patient having a dental implant, the method comprising:

receiving three-dimensional (3D) topographical data of the intraoral cavity having the dental implant; and

generating a virtual model with the 3D topographical data, the virtual model comprising,

a virtual surface representative of gingival tissue of the patient, and

a channel shaped and oriented to receive a virtual abutment model corresponding to one or more of a physical abutment to be connected to the dental implant or an abutment to be connected to a unitary dental model fabricated from the virtual model, wherein the channel extends to an opening in the surface, the channel comprising a first portion and a second portion, the first portion shaped to receive and constrain a corresponding structure of the virtual abutment model to a position and orientation, the second portion shaped to receive a virtual fastener model corresponding to a fastener used to couple the abutment to the unitary dental model,

wherein the first portion comprises a shoulder shaped to receive the corresponding structure of the virtual abutment model in order to position the virtual abutment model along the channel.

14. The method of claim 13, wherein said using the 3D topographical data to create a virtual model comprises:

positioning a virtual model of an implant analog relative to an as-scanned 3D virtual model that embodies the 3D topographical data of the intraoral cavity having the implant so that the implant analog virtual model matches the position and orientation of the implant in the as-scanned 3D virtual model; and

modifying the as-scanned 3D virtual model by merging the implant analog virtual model with the as-scanned 3D virtual model, thereby creating a modified as-scanned model.

15. The method of claim 14, wherein said using the 3D topographical data to create a virtual model further comprises subtracting an extraction virtual model from the modified as-scanned model so as to at least one of:

a) create the second portion of the channel shaped to receive the virtual fastener model, and b) remove one or more virtual model elements corresponding to a scan body or an impression body coupled with the implant in the as-scanned virtual model.

16. A method for creating a unitary dental model of an intraoral cavity of a patient having a dental implant;

the method comprising;

receiving 3D topographical data of the intraoral cavity having the implant; and

fabricating the unitary dental model with the 3D topographical data, the unitary dental model comprising,

a physical surface representative of gingival tissue of the patient, and

a channel shaped and oriented to receive an abutment corresponding to a physical abutment to be connected to the dental implant, wherein the channel extends to an opening in the surface, the channel comprising a first portion and a second portion, the first portion shaped to receive and constrain a corresponding structure of the abutment to a position and orientation, the second portion shaped to receive a fastener to couple the abutment to the unitary dental model,

wherein the first portion comprises a shoulder shaped to receive the corresponding structure of the abutment in order to position the abutment along the channel.

17. The method of claim 16, further comprising:

mounting the abutment to the unitary dental model via the first portion of the channel; and

securing the abutment to the unitary dental model using the fastener received within the second portion of the channel.

18. The method of claim 16, wherein using the 3D topographical data to fabricate the unitary dental model comprises:

positioning a virtual model of an implant analog relative to an as-scanned 3D virtual model that embodies the 3D topographical data of the intraoral cavity having the implant so that the implant analog virtual model matches the position and orientation of the implant in the as-scanned 3D virtual model; and

modifying the as-scanned 3D virtual model by merging the implant analog virtual model with the as-scanned 3D virtual model, thereby creating a modified as-scanned model.

19. The method of claim 18, further comprising subtracting an extraction virtual model from the modified as-scanned model so as to one or more of:

a) create the second portion of the channel shaped to receive the fastener, or b) remove one or more virtual model elements corresponding to a scan body or an impression body coupled with the implant in the as-scanned virtual model.

20. The method of claim 18, further comprising modifying one or more portions of the modified as-scanned model in order to provide a desired amount of clearance between the first portion and the corresponding structure of the abutment.

21. The method of claim 16, wherein the fabricating step is performed using a computer-controlled material removing process.

22. A system for modeling of an intraoral cavity of a patient having a dental implant;

the system comprising;

one or more processors;

memory storing instructions that, when executed by the one or more processors, cause the one or more processors to;

receive 3D topographical data of the intraoral cavity having the implant; and

generate a virtual model with the 3D topographical data, the virtual model comprising,

a virtual surface representative of gingival tissue of the patient, and

a channel shaped and oriented to receive a virtual abutment model corresponding to one or more of a physical abutment to be connected to the dental implant or an abutment to be connected to a unitary dental model fabricated from the virtual model, wherein the channel extends to an opening in the surface, the channel comprising a first portion and a second portion, the first portion shaped to receive and constrain a corresponding structure of the virtual abutment model to a position and orientation, the second portion shaped to receive a virtual fastener model corresponding to a fastener used to couple the abutment to the unitary dental model,

wherein the first portion comprises a shoulder shaped to receive the corresponding structure of the virtual abutment model in order to position the virtual abutment model along the channel.

23. The system of claim 22, wherein the instructions, when executed by the one or more processors, cause the one or more processors to:

position a virtual model of an implant analog relative to an as-scanned 3D virtual model that embodies the 3D topographical data of the intraoral cavity having the implant so that the implant analog virtual model matches the position and orientation of the implant in the as-scanned 3D virtual model; and

modify the as-scanned 3D virtual model by merging the implant analog virtual model with the as-scanned 3D virtual model, thereby creating a modified as-scanned model.

24. The system of claim 23, wherein the instructions, when executed by the one or more processors, cause the one or more processors to subtract an extraction virtual model from the modified as-scanned model so as to one or more of:

a) create the second portion of the channel shaped to receive the virtual fastener model, or b) remove one or more virtual model elements corresponding to a scan body or an impression body coupled with the implant in the as-scanned virtual model.

25. The system of claim 22, wherein the instructions, when executed by the one or more processors, cause the one or more processors to generate output configured to control a fabrication machine to fabricate a unitary dental model corresponding to the virtual model.