Dental device and method to manufacture the same

[0001] The invention relates in general to a dental device and to a method to manufacture the same, and in particular to a dental implant and to a method to manufacture the same.

[0002] Dental devices in general and dental implants in particular are nowadays made basically of two classes of materials: metals and ceramics.

[0003] With regards to metal, several metals are used for forming implants. Each metal has its own characteristic which renders the metal a possible suitable choice for the dental implants. For example, Ti (titanium) or titanium alloy are generally used. Titanium dental implants are relatively light, have high strength, and they have excellent corrosion resistance and bio-compatibility.

[0004] Alternatively ceramic materials such as zirconia-based, alumina-based and/or sapphire-based ceramics have been used for manufacturing dental implants or dental devices.

[0005] Dental devices, in general, and dental implants, in particular, formed from ceramic materials have the disadvantage that the material is more brittle as shown by a low value for the notched bar impact test. Ceramic materials are also susceptible to uncontrolled internal and external micro-cracks, and therefore they are prone to fail catastrophically. Moreover, artificial ceramic dental devices are rather expensive. However, the ceramic dental devices in general and the visible section of dental implants in particular, have a better aesthetic impact with respect to the metal implant and therefore enjoy a higher acceptance with the dental device bearer.

[0006] Furthermore, in some instances, a dental implant which is made of metal only may come into contact with an abutment/crown which is also made of a metal like for instance titanium, titanium alloy, gold or a gold alloy. Alternatively the abutment/crown is made of ceramic such as zirconia-based, alumina-based (for instance in-ceram®) and/or sapphire-based ceramics, or a ceramic glass composite. In the first metal to metal case, saliva or tissue fluid, acting as an electrolyte, may cause a galvanic electric current to flow which in extreme cases may have unpleasant effects for the dental prosthesis bearer. Also the metal, in particular if metals other than titanium are used in contact with a titanium implant, may cause inflammation and irritation of the soft tissue which it contacts.

[0007] In view of the above, there is the need of a dental device that combines the advantages of the metal made dental devices with those of the ceramic made dental devices and which can be easily manufactured.

[0008] Furthermore, in view of the foregoing, there is the particular need for a dental implant that combines the advantages of the metal made dental implants with those of the ceramic made dental implants and which can be easily manufactured.

[0009] The object of the present invention is to provide dental device such as dental implant, dental prosthesis and the like that are easy to manufacture and have good bio-compatibility, high strength and a good aesthetic impact.

[0010] In one preferred embodiment thereof the present invention is directed to a dental device, in particular a dental implant, which comprises an outer body made of ceramic or metal; and an inner body made of metal or ceramic, provided that when the outer body is made of metal the inner body is made of ceramic and when the outer body is made of ceramic the inner body is made of metal, wherein the metal body is produced by metal injection molding and the ceramic body is produced by ceramic injection molding.

[0011] Furthermore, in one embodiment of the present invention the inner/outer ceramic body is formed in a first step by ceramic injection molding and the metal body is formed/molded on or in the ceramic body.

[0012] Preferably the metal according to the present invention is titanium, titanium alloy or any other comparable materials. Preferably the ceramic material is an aluminum or zirconium or magnesium based ceramic material, such as aluminum oxide, zirconium oxide or magnesium oxide or combinations thereof. Preferably, according to the invention, the ceramic material is electrically insulating.

[0013] In the case that the present invention is embodied as an endosseous dental implant it may be comprised of a metal implant part which is to be implanted in a bone tissue, that implant part having a portion defining an outer body or a sheath thereof; and a ceramic inner body. Both bodies are manufactured by metal injection molding and ceramic injection molding, respectively. Furthermore, the ceramic inner body may comprise a core, a collar and a hollow. Again, preferably the metal is titanium or a titanium alloy or the like and the ceramic is an aluminum or zirconium or magnesium based ceramic material or an oxide thereof, alone or in combination. Additionally the endosseous dental implant may be provided with an inner titanium sleeve which provides means for fixing to an abutment, cap, crown etc. wherein the titanium inner sleeve is located in the hollow of the inner body. Nevertheless, the material of the inner and outer bodies may be inverted. Also the inner sleeve may be chosen among metal or ceramics and preferably manufactured by metal injection molding and ceramic injection molding, respectively.

[0014] The outer body of the dental implant according to the present invention is manufactured using a metal injection molding method or a ceramic injection molding method in dependence to the material chosen for the outer body. The inner body is manufactured using a ceramic injection molding method or a metal injection molding method in dependence of the material chosen for the inner body. It will be appreciated that when the inner body is made of ceramic the outer body is made of metal and vice-versa.

[0015] According to the present invention the ceramic body (either when outer or inner body) may be manufactured by ceramic injection molding firstly, the metal outer/inner body being directly formed via metal injection molding on or in the shaped ceramic body.

[0016] Preferably the ceramic body manufactured by ceramic injection molding is pre-sintered to a given shape before the metal is injected in the mold containing the ceramic body. Thereafter, the complete product including pre-sintered ceramic body and metal body is sintered.

[0017] Thus, the present invention provides preferably for a process for manufacturing dental devices, in particular endosseous dental implants comprising the steps of: manufacturing a ceramic body by means of ceramic injection molding; and manufacturing the metal body directly on or inside the ceramic body via metal injection molding.

[0018] It is believed that the adhesion and/or the interaction between the two bodies is improved by the combination of ceramic and metal injection molding used to manufacture the respective bodies.

[0019] In fact, if the metal is heated over the ceramic body it interacts with the ceramic body to ensure a better adhesion. Possible micro-movements between the outer and the inner bodies are then avoided because the two bodies perfectly fit and there is no micro gap therebetween.

[0031] Ceramic injection molding (CIM) and metal injection molding (MIM) are well known technologies in the art of molding. Similar to plastic injection molding, a molten polymer (called binder) plus ceramic (CIM) or metal (MIM) powder paste are injected into a mold. The volume of the part is restricted to small components. The binder material is removed by either solvent extraction or controlled heating to above the volatilization temperatures and the so called green body is sintered.

[0032] Both CIM and MIM consist essentially of the following steps:

[0033] powder manufacture;

[0034] mixing or blending;

[0035] injection molding; and

[0036] preferably sintering.

[0037] According to the knowledge of the present inventors, the two technologies have never been utilized together in order to form any kind of devices in general or dental devices and dental implants, respectively, in particular made up with ceramic and metal components/bodies.

[0038] The present invention will be exemplified disclosing an endosseous dental implant which is envisaged as the currently preferred embodiment thereof. However, it should be understood that the basic principles of the present invention (which includes the combination of metal injection molding and ceramic injection molding techniques) may be applied to other medical/dental devices like for instance dental prosthesis or to prosthetic parts in general. Also, it is believed that the basic principles of the invention are applicable to other non-medical devices.

[0039] The endosseous dental implant of the present invention, as shown in a schematic representation of FIG. 1, comprises a metal implanting part or outer body 1 which is to be implanted in bone tissue and a ceramic inner body 2 comprising a core 3, a collar 4 and a hollow 5. As well known in the relevant art, the metal implanting part or outer body 1 may be preferably provided with an external thread structure 6. Furthermore, the section of the outer body 1 in contact with the bone tissue may be treated to give it a special surface morphology or chemical properties preferably by sandblasting and/or acid-etching (for instance by the SLA—Sand-blasted, Large grit, Acid-etched—surface treatment method). Also titanium plasma spraying thereof is intended to be within the scope of the invention. Preferably sandblasting is performed with glass beads or Al₂O₃ grits or TiO₂ grits. The surface of the implant in contact with the gingival tissue may be advantageously polished, but other surface treatments to improve soft tissue attachment are possible. In addition, surface modification at the soft tissue and/or bone tissue apposition surface can be done by growth factor adsorption, and/or peptide adsorption, and/or protein adsorption, and/or amino acid adsorption. The SLA-interface may be designed advantageously to follow the outline of the tissue and is not necessarily identical to the interface between the inner body 2 and the outer body 1.

[0040] The inner shape/profile of the implanting part 1 (outer body) is complementary to the outer profile of the inner body 2.

[0041] Preferably, according to the invention, the inner profile of the implanting part or the outer body 1 is a rounded profile to decrease tension between the inner and the outer bodies. This complementary rounded profile is particularly advantageous as the present inner and outer bodies are manufactured by means of CIM and MIM, respectively.

[0042] The metal implanting part or the outer body 1 is made preferably of titanium or a titanium alloy or any other comparable materials. The inner body 2 is preferably an aluminum or zirconium or magnesium based ceramic material such as aluminum oxide, zirconium oxide or magnesium oxide or combinations thereof. Preferably, the ceramic material is electrically insulating.

[0043] The inner body 2 comprises the core 3 which lies inside the outer body 1. The outer profile of the inner body 2 has, as explained, a rounded profile which is complementary to the inner profile of the outer body 1, such that the rounded profile alleviates the tension between the outer body 1 and the inner body 2. The profile may also advantageously be adapted for locking against relative rotation of the two bodies. Thus, the profile includes an anti-rotation feature.

[0044] Further the inner body 2 is provided with the collar 4 which is located at the distal end thereof. The collar 4 is, in the implanted state, basically in contact with the soft tissue, such that to avoid direct contact of the metal outer body 1 with the soft tissue.

[0045] As shown in FIGS. 2 through 8 the dental implant may optionally be provided with a titanium inner sleeve 7 which provides for a fixing to an abutment, cap, crown etc. (not shown), wherein the titanium inner sleeve 7 is located in the hollow 5 defined at the collar 4 of the inner body 2. Otherwise the dental implant of FIGS. 2 through 8 incorporates the features described in connection with FIG. 1.

[0046] Preferably, the inner sleeve 7 of the FIG. 2 is provided in a known manner with a thread 8 and anti-rotation means 8′ (for instance of polygonal, octagonal or any other suitable shape) for fixing the abutment, cap, crown etc (not shown). The inner sleeve 7 is snap coupled to the inner body 2 with corresponding means indicated at reference numeral 9. A gap 10 may be formed at the interface between the sleeve 7 and the lower section of the hollow 5 of the inner body 2.

[0047] As indicated in FIGS. 4 through 8 the snap coupling 9 between the inner body 2 and the sleeve 7 may be left out and instead a press fitting, an adhesive coupling, lock engagement, warm shrinking may be provided. Also it is conceivable according to the present invention to provide combinations of two or more of snap coupling, press fitting, adhesive coupling, lock engagement and warm shrinking between the sleeve and the inner body 2. Furthermore, the sleeve 7 may also be provided by means of a MIM process if it is made of metal or by a CIM process if ceramics are used. The vertical length of the hollow 5 may vary according to the length of the thread 8 of the sleeve 7 and the anti-rotation means 9′ may be omitted.

[0048] As shown in FIGS. 9 and 10 the dental device according to the present invention may be designed as an one-piece device including the outer body 1 and the inner body 2, the inner body 2 forming at an upper section thereof an abutment 11. The one-piece dental device of FIG. 10 is formed in a similar manner to the implant of FIGS. 2 through 8 with a titanium inner sleeve 7, the titanium inner sleeve 7 being located in the hollow 5 defined at the abutment 11 of the inner body 2. Otherwise the dental device of FIGS. 9 and 10 incorporates the features described in connection with FIG. 1 and therefore such features will not be repeated. Also the inner sleeve 7 may be designed in the same manner as the inner sleeve described in connection with FIGS. 2 through 8.

[0049] The dental implants or dental devices of the present invention, as shown in FIGS. 1 through 10, are manufactured by means of a combination of a CIM/MIM method which process is part of the present invention.

[0050] The manufacturing of the ceramic inner body 2 is accomplished according to a CIM method by injecting the powdered ceramics into shaped molds. The ceramic is provided as powdered material. It contains binder for better molding or forming; the binder is preferably removed after forming by burning it out prior to sintering. The shaped ceramic inner body is preferably subsequently pre-sintered.

[0051] The metal outer body 1 is then preferably formed/molded on the ceramic inner body 2. When the metal outer body 1 is made on the ceramic inner body 2, preferably the sintered ceramic inner body 2 is moved to another shaped mold wherein it undergoes the MIM process. Thereafter, the complete product including the CIM made inner body and the MIM made outer body is sintered in a final sintering step.

[0052] The pre-sintering step of the CIM inner body is intended to give the inner body a final shape, and therefore problems of different expansion coefficients of ceramics and metal during the final sintering step may be avoided.

[0053] It will be appreciated that according to the invention the inner body may be made of metal by a MIM process and the outer body of ceramic by a CIM process. In this case, preferably, the metal inner body is molded into the ceramic outer body. It will be further appreciated that when the metal inner body is molded inside the ceramic outer body the mold for the metal component may be construed inside the ceramic body. Same applies if the sleeve 7 is made by metal injection molding inside the inner body.

[0054] The metal body is formed/molded on a pre-formed ceramic body. Because of the process the two bodies are perfectly shaped.

[0055] The embodiments described are chosen to provide an illustration of principles of the invention and its practical application to enable thereby the person of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Therefore, the foregoing description is to be considered exemplary, rather than limiting, and the true scope and spirit of the invention is that described in the appended claims.

[0056] The disclosures in European Patent Application No. 04005302.7 from which this application claims priority are incorporated herein by reference.