US4828495A — Sintered alloy dental prosthetic devices and meth…

Claim 1

Independent Claim 35 words

A dental article comprising a dental prosthetic device being a liquid-phase sinterable metallic alloy, characterized by a multiphase, composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix.

Claim 2

Dependent Claim 35 words

A dental article comprising a dental prosthetic device being a liquid-phase sinterable metallic alloy, characterized by a multiphase, composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix.

Claim 3

Dependent Claim 26 words

The dental prosthetic device of claim 1, wherein the device is a full cast crown, a coping, a pontic, an inlay, an onlay, or a bridge.

Claim 4

Dependent Claim 38 words

The dental prosthetic device of claim 1, wherein the alloy is chosen from the group consisting of nickel-chromium, gold-palladium chromium-cobalt, a high gold alloy, a high palladium alloy, a silver-palladium alloy, a nickel-boron-silicon alloy, and a titanium alloy.

Claim 5

Dependent Claim 98 words

A dental assembly comprising in combination: (a) a dental prosthetic device being a liquid sinterable, metallic alloy portion characterized by a multiphase composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix; and (b) a siliceous die material portion characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, whereby the dental surface of the die material portion is removable from the alloy portion with a separation of about 2 to about 25 micrometers.

Claim 6

Dependent Claim 98 words

A dental assembly comprising in combination: (a) a dental prosthetic device being a liquid sinterable, metallic alloy portion characterized by a multiphase composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix; and (b) a siliceous die material portion characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, whereby the dental surface of the die material portion is removable from the alloy portion with a separation of about 2 to about 25 micrometers.

Claim 7

Dependent Claim 26 words

An assembly as in claim 4, wherein the fit between the alloy portion and a prepared tooth is from about 10 microns to about 75 microns.

Claim 8

Dependent Claim 23 words

The assembly of claim 4 wherein the device is a full cast crown, a veneer crown, a coping, an inlay or an onlay.

Claim 9

Dependent Claim 135 words

A dental assembly comprising in combination: (a) a multitooth dental prosthetic device being a liquid sinterable, metallic alloy portion characterized by a multiphase composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix; and (b) a siliceous die material portion having abutments characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, and having a base die material characterized by a thermal expansion between ambient and 600° C. between about 0.004 mm/mm and about 0.015 mm/mm and a physical expansion approximately zero, whereby the dental surface of the die material portion is separable from the abutments of the alloy portion with a separation of from about 2 to about 25 microns.

Claim 10

Dependent Claim 135 words

A dental assembly comprising in combination: (a) a multitooth dental prosthetic device being a liquid sinterable, metallic alloy portion characterized by a multiphase composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix; and (b) a siliceous die material portion having abutments characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, and having a base die material characterized by a thermal expansion between ambient and 600° C. between about 0.004 mm/mm and about 0.015 mm/mm and a physical expansion approximately zero, whereby the dental surface of the die material portion is separable from the abutments of the alloy portion with a separation of from about 2 to about 25 microns.

Claim 11

Dependent Claim 34 words

The assembly of claim 7, wherein the fit between the abutments of the alloy portion and the prepared teeth is from about 10 microns to about 75 microns and the abutments are well aligned.

Claim 12

Independent Claim 153 words

A method for fabricating a single coping dental prosthetic device comprising the steps of: (a) forming an impression of the prepared dental surface; (b) mixing a siliceous abutment die material having a thermal expansion between ambient and 600° C. greater than 0.008 mm/mm and a physical expansion between zero and 0.03 mm/mm; (c) filling the impression with the abutment die material to form a die preform; (d) separating the preform from the impression; (e) firing the abutment die material at a temperature below 1500° C. (f) covering the die material with a powdered metal alloy having an expansion between ambient and 600° C. between 0.004 mm/mm and 0.015 mm/mm; (g) firing the alloy composite under vacuum at a temperature between 900° C. and 1400° C. to form a single coping of the single crown by sintering; whereby the separation between the die and the alloy is from about 2 to about 25 microns.

Claim 13

Independent Claim 153 words

A method for fabricating a single coping dental prosthetic device comprising the steps of: (a) forming an impression of the prepared dental surface; (b) mixing a siliceous abutment die material having a thermal expansion between ambient and 600° C. greater than 0.008 mm/mm and a physical expansion between zero and 0.03 mm/mm; (c) filling the impression with the abutment die material to form a die preform; (d) separating the preform from the impression; (e) firing the abutment die material at a temperature below 1500° C. (f) covering the die material with a powdered metal alloy having an expansion between ambient and 600° C. between 0.004 mm/mm and 0.015 mm/mm; (g) firing the alloy composite under vacuum at a temperature between 900° C. and 1400° C. to form a single coping of the single crown by sintering; whereby the separation between the die and the alloy is from about 2 to about 25 microns.

Claim 14

Dependent Claim 14 words

An alloy coping for a single crown made by the method of claim 9.

Claim 15

Dependent Claim 36 words

The method of claim 9 wherein the alloy is selected from the group consisting of nickel-chromium, gold-palladium, silver-palladium, chromium cobalt, a high gold alloy, a high palladium alloy, a nickel-boron-silicon alloy, and an alloy of titanium.

Claim 16

Dependent Claim 17 words

The method of claim 11, wherein the palladium content of the alloy is between 50% to 95%.

Claim 17

Dependent Claim 17 words

The method of claim 11, wherein the palladium content of the alloy is between 79% and 95%.

Claim 18

Dependent Claim 40 words

The method of claim 9 wherein the abutment die material comprises 50% to 95% alpha-quartz, up to 50% alpha-cristobalite, up to 40% zircon 5% to 40% magnesium oxide, 5% to 40% monoammonium phosphate, and up to 40% colloidal silica suspension.

Claim 19

Dependent Claim 17 words

The method of claim 9 wherein the pressure of step (g) is between 10 and 100 millitorr.

Claim 20

Dependent Claim 21 words

The method of claim 9, wherein the siliceous abutment die material of step (b) contains from 10% to 50% ethyl silicate.

Claim 21

Dependent Claim 17 words

The method of claim 9, wherein the preform of step (d) contains at least one alumina dowel.

Claim 22

Dependent Claim 29 words

A method as in claim 9, further comprising a step (e') between steps (e) and (f) as follows: (e') metallizing the die material with a high melting fine powder.

Claim 23

Dependent Claim 24 words

A method as in claim 18, wherein the metallizing layer is about 8-40 microns thick before firing and about 2-8 microns thick after firing.

Claim 24

Dependent Claim 14 words

An alloy coping for a single crown made by the method of claim 18.

Claim 25

Independent Claim 245 words

A method of fabricating a multitooth dental prosthetic device comprising the steps of: (a) forming an impression of a multitooth dental surface comprising a base with abutments; (b) mixing separately a siliceous base die material having a thermal expansion between ambient and 600° C. between 0.004 mm/mm and 0.015 mm/mm and a physical expansion approximately zero and a siliceous abutment die material having a thermal expansion between ambient and 600° C. between 0.008 mm/mm and 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm; (c) filling the base of the multitooth impression with the base die material and the abutments of the multitooth impression with the abutment die material to form a multitooth die preform with at least one base and a least two abutments; (d) separating the multitooth preform from the impression; (e) firing the die material at a temperature below 1500° C. to form a solid die having a preform of the multitooth surface; (f) covering the preform of the surface with a powdered metal alloy having an expansion between ambient and 600° C. between 0.004 mm/mm and 0.015 mm/mm to form copings on the abutment die areas and a pontic on the base die area; (g) firing the alloy preform composite under vacuum at a temperature between 900° C. and 1400° C. to form a bridge by sintering; whereby the separation between the alloy bridge and the preform of the dental surface is from about 2 to about 25 microns.

Claim 26

Independent Claim 245 words

A method of fabricating a multitooth dental prosthetic device comprising the steps of: (a) forming an impression of a multitooth dental surface comprising a base with abutments; (b) mixing separately a siliceous base die material having a thermal expansion between ambient and 600° C. between 0.004 mm/mm and 0.015 mm/mm and a physical expansion approximately zero and a siliceous abutment die material having a thermal expansion between ambient and 600° C. between 0.008 mm/mm and 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm; (c) filling the base of the multitooth impression with the base die material and the abutments of the multitooth impression with the abutment die material to form a multitooth die preform with at least one base and a least two abutments; (d) separating the multitooth preform from the impression; (e) firing the die material at a temperature below 1500° C. to form a solid die having a preform of the multitooth surface; (f) covering the preform of the surface with a powdered metal alloy having an expansion between ambient and 600° C. between 0.004 mm/mm and 0.015 mm/mm to form copings on the abutment die areas and a pontic on the base die area; (g) firing the alloy preform composite under vacuum at a temperature between 900° C. and 1400° C. to form a bridge by sintering; whereby the separation between the alloy bridge and the preform of the dental surface is from about 2 to about 25 microns.

Claim 27

Dependent Claim 40 words

The method of claim 21 wherein the base die material comprises 30% to 75% alpha-quartz, up to 40% alpha-cristobalite, up to 40% zircon, 5% to 40% magnesium oxide, 5% to 40% monoammonium phosphate, and up to 40% colloidal silica suspension.

Claim 28

Dependent Claim 17 words

The method of claim 21 wherein the pressure of step (g) is between 10 and 100 millitorr.

Claim 29

Dependent Claim 21 words

The method of claim 21, wherein the siliceous base die material of step (b) contains from 10% to 50% ethyl silicate.

Claim 30

Dependent Claim 18 words

The method of claim 21, wherein the multitooth preform of step (d) contains at least one alumina dowel.

Claim 31

Dependent Claim 28 words

A method as in claim 21, further comprising a step (e') between steps (e) and (f) as follows: (e') metallizing the die material with a high-melting fine powder.

Claim 32

Dependent Claim 24 words

A method as in claim 26, wherein the metallizing layer is about 8-40 microns thick before firing and about 2-8 microns thick after firing.

Claim 33

Dependent Claim 10 words

An alloy bridge made by the method of claim 26.

Claim 34

Dependent Claim 12 words

A multitooth dental prosthetic device made by the method of claim 21.

Claim 35

Dependent Claim 34 words

A biomechanical article comprising a biomechanical device being a liquid-phase sinterable metallic alloy, characterized by a multiphase, composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix.

Claim 36

Dependent Claim 34 words

A biomechanical article comprising a biomechanical device being a liquid-phase sinterable metallic alloy, characterized by a multiphase, composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix.

Claim 37

Dependent Claim 37 words

A biomechanical device of claim 30, wherein the alloy is chosen from the group consisting of nickel-chromium, gold-palladium, chromium-cobalt, a high gold alloy, a high palladium alloy, a silver-palladium alloy, a nickel-boron-silicon alloy, and a titanium alloy.

Claim 38

Dependent Claim 96 words

A biomechanical assembly comprising in combination: (a) a biomechanical device comprising a liquid sinterable, metallic alloy portion characterized by a multiphase composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix; and (b) a siliceous die material portion characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, whereby the surface of the die material portion is removable from the alloy portion with a separation of about 2 to about 25 micrometers.

Claim 39

Dependent Claim 96 words

A biomechanical assembly comprising in combination: (a) a biomechanical device comprising a liquid sinterable, metallic alloy portion characterized by a multiphase composite microstructure of isolated spherical grains approximately 50 microns in diameter distributed in an essentially nonporous matrix; and (b) a siliceous die material portion characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, whereby the surface of the die material portion is removable from the alloy portion with a separation of about 2 to about 25 micrometers.

Claim 40

Dependent Claim 26 words

An assembly as in claim 32, wherein the fit between the alloy portion and a bone surface is from about 10 microns to about 75 microns.

Claim 41

Independent Claim 151 words

A method for fabricating a single coping biomechanical device comprising the steps of: (a) forming an impression of the prepared surface; (b) mixing a siliceous abutment die material having a thermal expansion between ambient and 600° C. greater than 0.008 mm/mm and a physical expansion between zero and 0.03 mm/mm; (c) filling the impression with the abutment die material to form a die preform; (d) separating the preform from the impression; (e) firing the abutment die material at a temperature below 1500° C.; (f) covering the die material with a powdered metal alloy having an expansion between ambient and 600° C. between 0.004 mm/mm and 0.015 mm/mm; (g) firing the alloy composite under vacuum at a temperature between 900° C. and 1400° C. to form a single coping of the single crown by sintering; whereby the separation between the die and the alloy is from about 2 to about 25 microns.

Claim 42

Independent Claim 151 words

A method for fabricating a single coping biomechanical device comprising the steps of: (a) forming an impression of the prepared surface; (b) mixing a siliceous abutment die material having a thermal expansion between ambient and 600° C. greater than 0.008 mm/mm and a physical expansion between zero and 0.03 mm/mm; (c) filling the impression with the abutment die material to form a die preform; (d) separating the preform from the impression; (e) firing the abutment die material at a temperature below 1500° C.; (f) covering the die material with a powdered metal alloy having an expansion between ambient and 600° C. between 0.004 mm/mm and 0.015 mm/mm; (g) firing the alloy composite under vacuum at a temperature between 900° C. and 1400° C. to form a single coping of the single crown by sintering; whereby the separation between the die and the alloy is from about 2 to about 25 microns.

Claim 43

Dependent Claim 35 words

The method of claim 34 wherein the alloy is selected from the group consisting of nickel-chromium, gold-palladium, silver-palladium, chromium-cobalt, a high gold alloy, a high palladium alloy, a neckel-boron-silicon alloy, and an alloy of titanium.

Claim 44

Dependent Claim 28 words

A method as in claim 34, further comprising a step (e') between steps (e) and (f) as follows: (e') metallizing the die material with a high-melting fine powder.

Claim 45

Dependent Claim 33 words

A biomechanical article comprising a biomechanical device being a liquid-phase sinterable metallic alloy, characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns.

Claim 46

Dependent Claim 33 words

A biomechanical article comprising a biomechanical device being a liquid-phase sinterable metallic alloy, characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns.

Claim 47

Dependent Claim 12 words

The biomechanical device of claim 37, which is a dental prosthetic device.

Claim 48

Dependent Claim 95 words

A biomechanical assembly comprising in combination: (a) a biomechanical device being a liquid-sinterable, metallic alloy portion characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns; and (b) a siliceous die material portion characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, whereby the dental surface of the die material portion is removable from the alloy portion with a separation of about 2 to about 25 micrometers.

Claim 49

Dependent Claim 95 words

A biomechanical assembly comprising in combination: (a) a biomechanical device being a liquid-sinterable, metallic alloy portion characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns; and (b) a siliceous die material portion characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, whereby the dental surface of the die material portion is removable from the alloy portion with a separation of about 2 to about 25 micrometers.

Claim 50

Dependent Claim 14 words

The assembly of claim 39, wherein the biomechanical device is a dental prosthetic device.

Claim 51

Dependent Claim 134 words

A dental assembly comprising in combination: (a) a multitooth dental prosthetic device being a liquid sinterable, metallic alloy portion, characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns; and (b) a siliceous die material portion having abutments characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, and having a base die material characterized by a thermal expansion between ambient and 600° C. between about 0.004 mm/mm and about 0.015 mm/mm, and a physical expansion approximately zero, whereby the dental surface of the die material portion is separable from the abutments of the alloy portion with a separation of from about 2 to about 25 microns.

Claim 52

Dependent Claim 134 words

A dental assembly comprising in combination: (a) a multitooth dental prosthetic device being a liquid sinterable, metallic alloy portion, characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns; and (b) a siliceous die material portion having abutments characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, and having a base die material characterized by a thermal expansion between ambient and 600° C. between about 0.004 mm/mm and about 0.015 mm/mm, and a physical expansion approximately zero, whereby the dental surface of the die material portion is separable from the abutments of the alloy portion with a separation of from about 2 to about 25 microns.

Claim 53

Dependent Claim 108 words

A biomechanical assembly comprising in combination: (a) a biomechanical device being a liquid-sinterable, metallic alloy portion characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns; (b) a siliceous die material portion characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm; and (c) a metallizing layer between said metallic alloy portion and said die material; whereby the dental surface of the die material portion is removable from the alloy portion with a separation of about 2 to about 25 micrometers.

Claim 54

Dependent Claim 108 words

A biomechanical assembly comprising in combination: (a) a biomechanical device being a liquid-sinterable, metallic alloy portion characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns; (b) a siliceous die material portion characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm; and (c) a metallizing layer between said metallic alloy portion and said die material; whereby the dental surface of the die material portion is removable from the alloy portion with a separation of about 2 to about 25 micrometers.

Claim 55

Dependent Claim 14 words

The assembly of claim 42, wherein the biomechanical device is a dental prosthetic device.

Claim 56

Dependent Claim 147 words

A dental assembly comprising in combination: (a) a multitooth dental prosthetic device being a liquid sinterable, metallic alloy portion, characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns; (b) a siliceous die material portion having abutments characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, and having a base die material characterized by a thermal expansion between ambient and 600° C. between about 0.004 mm/mm and about 0.015 mm/mm, and a physical expansion approximately zero; and (c) a metallizing layer between said metallic alloy portion and said die material; whereby the dental surface of the die material portion is separable from the abutments of the alloy portion with a separation of from about 2 to about 25 microns.

Claim 57

Dependent Claim 147 words

A dental assembly comprising in combination: (a) a multitooth dental prosthetic device being a liquid sinterable, metallic alloy portion, characterized by a grain structure of grains having an average size of from about 20 microns to about 80 microns; (b) a siliceous die material portion having abutments characterized by a thermal expansion between ambient and 600° C. between about 0.008 mm/mm and about 0.015 mm/mm and a physical expansion between zero and 0.03 mm/mm, and having a base die material characterized by a thermal expansion between ambient and 600° C. between about 0.004 mm/mm and about 0.015 mm/mm, and a physical expansion approximately zero; and (c) a metallizing layer between said metallic alloy portion and said die material; whereby the dental surface of the die material portion is separable from the abutments of the alloy portion with a separation of from about 2 to about 25 microns.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1992-05-08	1992-11-07	1993-05-09	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1996-05-08	1996-11-07	1997-05-09	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2000-05-08	2000-11-07	2001-05-09	$7700.00	Window Closed / Lapsed

Sintered alloy dental prosthetic devices and method

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