Patent Application
20230380944
The present invention relates to a coloring solution for dental ceramics. Specifically, the invention relates to a dental ceramic coloring solution suited for use in the fabrication of dental prostheses machined with a dental CAD/CAM system, for example, such as inlays, onlays, veneers, crowns, bridges, abutment teeth, dental posts, dentures, denture bases, and implant parts (fixtures, abutments).
Traditionally, metal has been used for a range of dental products, including, for example, dental prostheses (such as veneer crowns, dental caps, crowns, and post crowns), orthodontic products, and products for dental implants. However, metals lack aesthetic quality because of the colors that are distinctively different from the color of natural teeth, and can cause allergic reaction when released from these products. These issues involving the use of metal have been addressed by dental products that use a ceramic material such as aluminum oxide (alumina) or zirconium oxide (zirconia) as an alternative material of metal. Particularly, zirconia excels in strength, and has relatively good aesthetics, and this, combined in particular with the currently declining price of zirconia, has created a high demand for this material.
In recent years, there has been increasing use of a CAD/CAM system that makes use of a computer for designing and a milling machine for machining to form the final shape of a dental prosthesis, or to fabricate a prosthesis for large implants. For aesthetic values, the CAD/CAM system typically uses ceramics as a material of a mill blank to be milled. Particularly, recent years have seen increased use of ceramics that satisfy aesthetic requirements by reproducing the color of natural teeth with different shades of color vertically arranged in a thickness direction. However, for shades that are difficult to reproduce, a ceramic that has been worked into a shape of a dental prosthesis is colored by coating dental porcelain over a ceramic surface to satisfy high aesthetic requirements.
However, color coating with dental porcelain requires expertise and great technique. Specifically, high skills are required for coloring with dental porcelain because dental porcelain needs to be built up to develop colors with high aesthetics while reproducing the shape and structure of natural teeth with precision.
In a common technique used to circumvent the issues involved in the use of dental porcelain, a method is available that colors a dental prosthesis by applying a dental ceramic coloring solution to a dental ceramic to achieve even better aesthetics, instead of the skillful coloring with dental porcelain.
The use of dental ceramic coloring solutions is expected to increase, particularly in response to the continuously growing demand for ceramic materials and the associated increase in individual demand for better aesthetics.
Meanwhile, there is a need to improve the strength of zirconia because a dental ceramic, even when it is zirconia, cannot match the strength of conventional metals, despite that zirconia is superior to other ceramic materials in terms of strength. This is particularly the case with zirconia containing a stabilizer to improve translucency because the strength tends to decrease in such zirconia as the amount of stabilizer increases.
Techniques are available that improve zirconia strength. For example, Patent Literature 1 discloses one or more colorants comprising rare earth element metals or ions being present in the solution in an amount of at least about 0.05 mol/L (solvent), and transition metals or ions being present in the solution in an amount of about 0.00001 to about 0.05 mol/L (solvent). However, for example, coloring of zirconia with a colorant containing erbium is problematic because erbium also acts as a zirconia stabilizer, and causes a decrease of zirconia properties, such as strength, depending on the type of metal ion. With such a coloring solution, it is also not possible to improve the strength of a zirconia sintered body.
It is an object of the present invention to provide a dental ceramic coloring solution with which the desired shade can be imparted to a dental ceramic while improving the strength of the dental ceramic.
The present inventors conducted intensive studies to find a solution to the foregoing issues, and found that the above problems can be solved with a dental ceramic coloring solution that comprises a Zr component in addition to the coloring component. The present invention was completed after further studies.
Specifically, the present invention includes the following.
A dental ceramic coloring solution of the present invention can impart the desired shade to a dental ceramic while improving the strength of the dental ceramic. Generally, a dental ceramic containing zirconia as a main component and containing yttria as a stabilizer undergoes a transparency change with the fractions of these components. Typically, the transparency decreases with increase of zirconia fraction and decrease of yttria fraction. It is therefore assumed that the transparency decreases when a coloring component containing a zirconium component is applied to dental zirconia. However, with a coloring solution of the present invention, the strength of a dental ceramic can be improved while reducing a transparency change.
The present invention is a coloring solution for coloring a dental ceramic, comprising a coloring component, a solvent, and a Zr component.
Coloring Component
The coloring component contained in a coloring solution of the present invention is described first.
A coloring component in the present invention is a component that colors a ceramic sintered body when a ceramic pre-sintered body or unfired body is sintered after the application of the coloring solution. The coloring component is not particularly limited, and may be ions or complexes. Metal ions, in particular, are more preferred.
Ions and complexes of the coloring component used in the present invention are described below. Ions and complexes of the coloring component comprise one or more colorative cations. Here, “colorative” means having significant absorption in the human visible spectrum (for example, 380 to 790 nm wavelengths). In the present invention, a colorative cation develops a color after being fired. The ions and complexes of the present invention can dissolve colorative cations, and, by dissolving colorative cations, can coat a ceramic pre-sintered body or unfired body, and color a ceramic sintered body after firing.
The colorative cation is preferably an ion of at least one component selected from the group consisting of Al, K, Cr, Fe, Na, V, Y, Gd, La, Yb, Tm, Ni, Mn, Co, Nd, Pr, Cu, Tb, and Er, more preferably an ion of at least one component selected from the group consisting of Al, K, Cr, Fe, Na, V, Ni, Mn, Co, and Er, even more preferably an ion of at least two components selected from the group consisting of Al, K, Cr, Fe, Na, V, Ni, Mn, Co, and Er. The ion solution may contain only one of these cations, or may contain two or more of these cations in combination.
The colorative cation may be added in the solvent (described later) in the forms of salts containing cations, such as above, and anions. Examples of the anions include OAc−, NO3−, NO2−, CO32-, HCO3−, ONC−, SCN−, SO42-, SO32-, glutarate, lactate, gluconate, propionate, butyrate, glucuronate, benzoate, phenolate, halide anions (fluorides, chlorides, bromides), and acetate. Ac means acetyl group.
A certain preferred embodiment is, for example, a coloring solution in which the coloring component comprises a Ni component. The Ni component can reproduce a reddish brown shade, and can provide the desired standard dental shade by combining yellow to dull brown. For example, the L* value in (L*,a*,b*) of L*a*b*color system may decrease when a coloring solution containing a Ni component is used. In other instances, the a* value may increase when a coloring solution containing a Ni component is used. In other cases, the b* value may decrease when a coloring solution containing a Ni component is used. The nickel compound may be a bivalent, trivalent, or tetravalent compound. Preferred are divalent nickel compounds. Examples of the Ni component include nickel(II) hydroxide, nickel(II) chloride hydrate (hexahydrate), nickel(II) nitrate hydrate (hexahydrate), nickel(II) sulfate hydrate (hexahydrate), and nickel(II) acetate hydrate (tetrahydrate). The Ni component may be used alone, or two or more thereof may be used in combination.
Another preferred embodiment is, for example, a coloring solution in which the coloring component comprises a Cr component. The Cr component can reproduce a grayish green shade, and can provide the desired standard dental shade by combining yellow to dull green. The chrome compound may be a trivalent or tetravalent compound. Preferred are trivalent chrome compounds. For example, the L* value in (L*,a*,b*) of L*a*b*color system may decrease when a coloring solution containing a Cr component is used. In other instances, the a* value may increase when a coloring solution containing a Cr component is used. In other cases, the b* value may decrease when a coloring solution containing a Cr component is used. Examples of the Cr component include chromium(III) chloride, chromium(III) chloride hydrate (hexahydrate), chromium(III) nitrate hydrate (nonahydrate), chromium(III) sulfate hydrate (n-hydrate), and chromium(III) acetate hydrate (monohydrate). In view of good solubility in water and in organic solvent, preferred are chromium(III) nitrate hydrate (nonahydrate), chromium(III) chloride hydrate (hexahydrate), and chromium(III) acetate hydrate (monohydrate). The Cr component may be used alone, or two or more thereof may be used in combination.
A certain preferred embodiment of the present invention is, for example, a coloring solution in which the coloring component further comprises an Al component. The Al component comprises an Al ion or an Al complex, and can increase the red tint. The Al component may improve the strength of zirconia. The improved zirconia strength is probably due to the Al component being dispersed between zirconia crystals, and developing its high toughness characteristics on the binding force between crystals by improving the intercrystalline binding force with an increased specific surface area of bonding between crystals.
Ions or complexes of Al may be added in the coloring solution in the form of salts containing cations and anions of Al, or in the form of complexes containing Al and its ligands. Examples of the anions or ligands include OAc−, NO3−, NO2−, CO32-, HCO3−, ONC−, SCN−, SO42-, SO32-, glutarate, lactate, gluconate, propionate, butyrate, glucuronate, benzoate, phenolate, halide anions (fluorides, chlorides, bromides), and acetate.
Specific examples of compounds as Al components include aluminum ethoxide, aluminum butoxide, aluminum propoxide, barium aluminate, magnesium aluminate, lithium aluminate, aluminum benzoate, aluminum chloride hydrate (aluminum chloride hexahydrate), aluminum oleate, aluminum perchlorate hydrate (such as aluminum perchlorate trihydrate, and aluminum perchlorate hexahydrate), aluminum citrate hydrate (aluminum citrate monohydrate), aluminum gluconate, lithium tetrachloroaluminate, lithium aluminum chloride, aluminum oxide, aluminum selenate hydrate, aluminum oxalate hydrate, aluminum tartrate hydrate, aluminum metazirconate, aluminum octanoate hydroxide, aluminum stearate, aluminum titanate, aluminum lactate, aluminum palmitate, lithium tetrahydridoaluminate, lithium aluminum hydride, aluminum iodide, aluminum laurate, aluminum butyrate, aluminum nitrate hydrate (such as aluminum nitrate nonahydrate), aluminum sulfide, and aluminum cesium sulfate hydrate. In view of solubility, preferred are aluminum chloride hydrate, aluminum perchlorate hydrate, aluminum oxalate hydrate, and aluminum nitrate hydrate. These AI components may be used alone, or two or more thereof may be used in an appropriate combination.
A coloring solution of the present invention may comprise a V (vanadium) component to impart a yellow-tinged shade to a dental ceramic. A certain preferred embodiment of the present invention is, for example, a coloring solution in which the coloring component further comprises a V component.
Ions or complexes of V may be added in the coloring solution in the form of salts containing cations and anions of V, or in the form of complexes containing V and ligands. Examples of the anions or ligands include OAc−, NO3−, NO2−, CO32-, HCO3−, ONC−, SCN−, SO42-, SO32-, glutarate, lactate, gluconate, propionate, butyrate, glucuronate, benzoate, phenolate, halide anions (fluorides, chlorides, bromides), and acetate.
In view of stability and ease of handling, the vanadium compound is preferably a vanadium compound with a valency of +IV and/or +V, more preferably an oxidovanadium compound.
Specific examples of compounds as V components include vanadium acetylacetonate, vanadyl acetylacetonate, vanadyl stearate, vanadium naphthenate, vanadium benzoylacetonate, vanadyl oxalate, bis(maltolato)oxovanadium(IV), oxobis(1-phenyl-1,3-butanedionate)vanadium, vanadium(V) oxytriisopropoxide, vanadium(V) trichloride oxide, vanadium(IV) dichloride oxide, vanadium(III) chloride hydrate (hexahydrate), vanadium(III) chloride anhydrous, vanadium disilicide, vanadium(III) oxide, vanadium(IV) oxide, vanadium(V) oxide, iron tetrapolyvanadate, vanadyl(IV) sulfate hydrate, vanadium(III) bromide, vanadyl oxalate (oxalic acid oxovanadium(IV) salt), vanadyl(IV) acetate (VO[OC(O)CH3]2), vanadyl(V) nitrate (VO(NO3)3), vanadyl glycolate, vanadium hydride, vanadium selenide, vanadium carbide (VC), vanadium nitride (VN), potassium divanadate, potassium vanadate, potassium metavanadate (KVO3), sodium metavanadate (NaVO3), sodium divanadate (Na4V2O7), sodium vanadate (Na3VO4), sodium vanadate hydrate, lithium metavanadate (LiVO3), rubidium divanadate (Rb4V2O7), rubidium metavanadate (RbVO3), rubidium vanadate (Rb3VO4), vanadium diboride, vanadium boride (VB), and vanadium(III) sulfide (V2S3). In view of good stability and good ease of handling of the coloring solution, preferred are vanadyl oxalate, vanadyl nitrate, and vanadyl acetate. The vanadium component may be used alone, or two or more thereof may be used in combination.
A coloring solution of the present invention may comprise a Co component. A certain preferred embodiment of the present invention is, for example, a coloring solution in which the coloring component further comprises a Co component.
Ions or complexes of Co may be added in the coloring solution in the form of salts containing cations and anions of Co, or in the form of complexes containing Co and its ligands. Examples of the anions or ligands include OAc−, NO3−, NO2−, CO32, HCO3−, ONC−, SCN−, SO42−, SO32-, glutarate, lactate, gluconate, propionate, butyrate, glucuronate, benzoate, phenolate, halide anions (fluorides, chlorides, bromides), and acetate.
Specific examples of compounds as Co components include bis(acetylacetonate)diaqua cobalt(II), tris(acetylacetonate)cobalt(III), cobalt(II) amidosulfate hydrate, cobalt(II) benzoate, cis-tetraamminedichlorocobalt(III) chloride, pentaamminechlorocobalt(III) chloride, hexaamminecobalt(III) chloride, hexaamminecobalt(III) nitrate, ammonium diamminetetranitrocobaltate(III), triammine trinitro cobalt(III), tetraamminedinitrocobalt(III) chloride, potassium diamminetetranitrocobaltate(III), cobalt(II) chloride hydrate (for example, cobalt(II) chloride hexahydrate), cobalt(II) chloride, cobalt(III) chloride, cobalt(II) octanoate, cobalt(II) oleate, cobalt(II) perchlorate hydrate (cobalt(II) perchlorate hexahydrate), cobalt(II) fluoride hydrate (cobalt(II) fluoride dihydrate, cobalt(II) fluoride trihydrate, cobalt(II) fluoride tetrahydrate), dicobalt octacarbonyl (Co2(CO)8), cobalt(II) formate hydrate, cobalt(II) citrate hydrate, cobalt disilicide, cobalt(II) acetate, cobalt(II) acetate hydrate (cobalt(II) acetate tetrahydrate), cobalt(II) oxide, cobalt(III) oxide, tricobalt tetroxide (Co3(CO)4), potassium hexacyanocobaltate(III), cobalt(II) bromide, cobalt(II) bromide hydrate, cobalt(II) oxalate hydrate (for example, such as cobalt(II) oxalate dihydrate, and cobalt(II) oxalate tetrahydrate), cobalt resinate, cobalt(II) nitrate hydrate (cobalt(II) nitrate trihydrate, cobalt(II) nitrate hexahydrate), cobalt(II) metazirconate, cobalt(II) hydroxide, cobalt(III) hydroxide, cobalt(II) stearate, cobalt(II) selenate, cobalt(II) selenate hexahydrate, cobalt(II) tungstate tetrahydrate, cobalt(II) carbonate hydroxide, ammonium tetrakis(thiocyanate)cobaltate(II) hydrate, cobalt(II) thiocyanate, cobalt(II) metatitanate, potassium hexanitrocobaltate(III), sodium hexanitrocobaltate(III), hexaamminecobalt(III) sulfate, pentacobalt diboride, cobalt(II) molybdate hydrate, cobalt(II) iodide hydrate, cobalt(II) laurate, cobalt(II) sulfide, cobalt(II) sulfate hydrate, cobalt(II) phosphide, and cobalt(II) phosphate hydrate. In view of solubility and chromogenicity, preferred are cobalt(II) chloride hydrate, cobalt(II) perchlorate hydrate, cobalt(II) fluoride hydrate, cobalt(II) nitrate hydrate, cobalt(II) oxalate hydrate, and cobalt(II) acetate hydrate. The Co component may be used alone, or two or more thereof may be used in an appropriate combination.
A coloring solution of the present invention may comprise an Er component. A certain preferred embodiment of the present invention is, for example, a coloring solution in which the coloring component further comprises an Er component.
Ions or complexes of Er may be added in the coloring solution in the form of salts containing cations and anions of Er, or in the form of complexes containing Er and its ligands. Examples of the anions or ligands include OAc−, NO3−, NO2−, CO32-, HCO3−, ONC−, SCN−, SO42-, SO32-, glutarate, lactate, gluconate, propionate, butyrate, glucuronate, benzoate, phenolate, halide anions (fluorides, chlorides, bromides), and acetate.
Specific examples of compounds as Er components include trivalent erbium compounds such as tris(acetylacetonate)erbium hydrate, erbium chloride hydrate (erbium chloride hexahydrate), erbium perchlorate hydrate, erbium acetate hydrate (erbium acetate tetrahydrate), erbium oxide, erbium oxalate hydrate, erbium nitrate hydrate, erbium stearate, erbium fluoride, erbium tetraboride, erbium iodide hydrate, erbium sulfide, and erbium sulfate hydrate. In view of solubility and chromogenicity, preferred are erbium chloride hydrate, erbium perchlorate hydrate, erbium nitrate hydrate, erbium oxalate hydrate, and erbium acetate hydrate. The Er component may be used alone, or two or more thereof may be used in an appropriate combination.
A coloring solution of the present invention may comprise a Mn component. A certain preferred embodiment of the present invention is, for example, a coloring solution in which the coloring component further comprises a Mn component.
Ions or complexes of Mn may be added in the coloring solution in the form of salts containing cations and anions of Mn, or in the form of complexes containing Mn and its ligands. Examples of the anions or ligands include OAc−, NO3−, NO2−, CO32, HCO3−, ONC−, SCN−, SO42-, SO32-, glutarate, lactate, gluconate, propionate, butyrate, glucuronate, benzoate, phenolate, halide anions (fluorides, chlorides, bromides), and acetate.
Specific examples of compounds as Mn components include manganese(II) chloride hydrate (tetrahydrate), manganese(II) nitrate hydrate (hexahydrate), manganese(II) acetate hydrate (tetrahydrate), manganese(II) sulfate hydrate (for example, pentahydrate). The Mn component may be used alone, or two or more thereof may be used in an appropriate combination.
Zr Component
The following describes the Zr component contained in a coloring solution of the present invention. The Zr component comprises a Zr ion or a Zr complex, and improves the ceramic strength by being present with the coloring component.
The ceramic strength improves by applying a dental ceramic coloring solution containing a Zr component. Though the reason for this remains unclear, the present inventors have proposed the following explanation. Specifically, a likely explanation involved in the improvement of ceramic strength is that, when a dental ceramic coloring solution of the present invention is applied to, for example, a dental zirconia pre-sintered body, the Zr component that has penetrated the pre-sintered body reacts with the zirconia stabilizer in a tetragonal phase upon being fired, and remains in the zirconia sintered body as partially stabilized zirconia. Another possible explanation for the improved strength is the establishment of a uniform zirconia crystal structure as a result of the penetration of the Zr component reducing an excessive crystal granulation due to the stabilizer, or reducing the transformation into a cubic crystal system.
Ions or complexes of Zr may be added in the coloring solution in the form of salts containing cations and anions of Zr, or in the form of complexes containing Zr and its ligands. Examples of the anions or ligands include OAc−, NO3−, NO2−, CO32-, HCO3−, ONC−, SCN−, SO42-, SO32-, glutarate, lactate, gluconate, propionate, butyrate, glucuronate, benzoate, phenolate, halide anions (fluorides, chlorides, bromides), and acetate.
Specific examples of compounds added to contain the foregoing ions or complexes in a coloring solution of the present invention include zirconium(IV) chloride oxide hydrate, zirconium(IV) sulfide, zirconium(IV) tetrakis(acetylacetonate), zirconium(IV) chloride, zirconium(IV) octanoate, zirconium(IV) oleate oxide, dichlorobis(η5-cyclopentadienyl)zirconium(IV), zirconium(IV) acetate oxide, zirconium(IV) oxide hydrate, zirconium(IV) stearate oxide, zirconium(IV) nitrate oxide hydrate, zirconium(IV) n-butoxide, zirconium(II) hydride, zirconium(IV) carbide, dizirconium carbonate trioxide hydrate, zirconium nitride, ammonium hexafluorozirconate(IV), zirconium(IV) iodide, zirconium(IV) laurate oxide (Zr(C11H23COO)2O), zirconium(IV) sulfate hydrate, and zirconium(IV) dihydrogen phosphate oxide. In view of the ability to further improve the dental ceramic strength, preferred are zirconium(IV) chloride oxide hydrate, zirconium(IV) chloride, zirconium(IV) acetate oxide, zirconium(IV) oxide hydrate, and zirconium(IV) nitrate oxide hydrate, more preferably zirconium chloride oxide hydrate. The Zr component may be used alone, or two or more thereof may be used in an appropriate combination.
In view of improving the strength of a dental ceramic, the content of the Zr component in the coloring solution is preferably 0.0650 to 0.900 mol/L, more preferably 0.0800 to 0.850 mol/L, even more preferably 0.0900 to 0.800 mol/L in terms of a Zr ion in the whole solution. When the content of the Zr component is 0.0650 mol/L or more, it is possible to produce the effect to improve the strength of a dental ceramic. When the content of the Zr component is 0.900 mol/L or less, the strength can improve without decreasing the aesthetics of the dental ceramic. The content of the Zr component can be measured using a technique, for example, such as inductively coupled plasma (ICP) emission spectral analysis, or X-ray fluorescence analysis.
Preferably, a coloring solution of the present invention comprises water and/or an organic solvent as solvent. Water and/or an organic solvent allow the Zr component and the coloring component to dissolve, and improve the penetration of the coloring solution into a dental ceramic. The solvent content in the coloring solution is preferably 45 to 99 mass %, more preferably 60 to 98.5 mass %, even more preferably 75 to 98 mass %.
It is required that water be essentially free of impurities that are detrimental to the effects of the present invention. Preferably, water is purified water, distilled water, ion-exchange water, or deionized water. The content of water in the coloring solution is preferably 45 to 99 mass %, more preferably 60 to 98.5 mass %, even more preferably 75 to 98 mass %.
The organic solvent has a solubility parameter (hereinafter, “SP value”) of preferably 17.7 (MPa)1/2 or more, more preferably 18.0 (MPa)1/2 or more. With an SP value of 17.7 (MPa)1/2 or more, sufficient solubility can be provided for the coloring component, and the coloring solution can sufficiently penetrate a dental ceramic, achieving sufficient coloring, and further improvement of dental ceramic strength.
The SP value is represented by the square root of intermolecular attraction force, that is, cohesive energy density (CED). CED describes the amount of energy needed to evaporate 1 mL of a liquid.
The SP value can be calculated by the Fedors method, using the following formula (A).
SP value=(CED value)1/2=(E/V)1/2 Formula (A)
In the formula (A), E represents the molecular cohesive energy (J/mol), and V represents the molecular volume (cm3/mol). Of the various methods available for the calculation of SP value, the present invention employs the commonly used Fedors method.
The method of calculation, and various data for molecular cohesive energy E and molecular volume V can be found in Research on Coatings, Vol. 152, Published October, 2010, pp. 41 to 46 (Study on Solubility Parameter of Paint Additives by Shinichi Ueda, Tomoo Yamada, and Masami Sugishima).
Preferred as organic solvent are alcohols, glycols, triols, and ketones, and a mixture selected from combinations of these. Specific examples include:
These organic solvents may be used alone, or two or more thereof may be used in an appropriate combination. The organic solvent may be used as a thickener (described later) to adjust viscosity.
The organic solvent content in a coloring solution of the present invention is preferably 45 to 99 mass %, more preferably 60 to 98.5 mass %, even more preferably 75 to 98 mass %.
A coloring solution of the present invention may comprise a complexing agent to such an extent that it does not hinder the effects of the present invention. Adding a complexing agent may be beneficial in improving the storage stability of the coloring solution, accelerating the dissolution process of the salts added to the coloring solution, and/or increasing the amount of salts that can dissolve in the coloring solution.
The complexing agent can typically form complexes with the metal ions present in the coloring solution. The complexes formed must be soluble in solvent. For example, the complexing agent may be used in at least a stoichiometric proportion in relation to the molar quantity of the ions contained in the coloring solution. Desirable results can be obtained when the mole ratio of the complexing agent is about 1 or about 2, or about 3 or more relative to the cations in the coloring solution.
Examples of the complexing agent include N,N-di(2-hydroxyethyl)glycine, acetylacetonate, crown ether, cryptands, ethylenediaminetriacetate and salts thereof, ethylenediaminetetraacetate and salts thereof, nitrilotriacetate and salts thereof, citric acid and salts thereof, triethylenetetramine, porphin, polyacrylate, polyaspargate, acidic peptides, phthalocyanine, salicylate, glycinate, lactate, propylenediamine, ascorbate, oxalic acid and salts thereof, and a mixture of these. The complexing agent may be used alone, or two or more thereof may be used in an appropriate combination.
The content of the complexing agent in a coloring solution of the present invention is not particularly limited, as long as the present invention can exhibit its effects. For example, it is preferable to contain the complexing agent in an amount sufficient to dissolve the cations in the solution, or to prevent precipitation of the cations. Specifically, the content of the complexing agent in the coloring solution is preferably 0.01 mass % or more, more preferably 0.05 mass % or more, even more preferably 0.10 mass % or more. There is no specific upper limit for the content of the complexing agent. However, the content of the complexing agent is preferably 50 mass % or less, more preferably 20 mass % or less, even more preferably 10 mass % or less. The complexing agent may fail to fully dissolve the cations when used in excessively small amounts, whereas the excess portion of the complexing agent itself may remain without dissolving when the complexing agent is used in excessively large amounts.
A coloring solution of the present invention has a pH of preferably 0 to 9, more preferably 1 to 7, even more preferably 2 to 6. The cations may start precipitating from the solution when the pH falls outside of these ranges. For example, the pH is preferably 0 to 9 when the coloring solution is an aqueous solution. The pH is preferably 0 to 6 when the coloring solution does not contain a complexing agent, and is preferably 3 to 9 when the coloring solution contains a complexing agent. The pH can be measured with a commercially available pH meter (for example, a compact pH meter LAQUAtwin manufactured by Horiba Ltd.).
Preferably, a coloring solution of the present invention has an appropriate viscosity so that the solution, in addition to being applied to a ceramic surface in necessary amounts, can move into the pores of a ceramic unfired body or a ceramic pre-sintered body. The appropriate viscosity is, for example, preferably 0.1 to 10,000 mPa, more preferably 0.5 to 6,000 mPa, even more preferably 1 to 3,000 mPa at 20° C. When the viscosity is too high, it may not be possible to contain the coloring solution in the pores of a ceramic unfired body or a ceramic pre-sintered body. The viscosity can be measured at 25° C. with a Brookfield viscometer, though the method of viscosity measurement is not particularly limited.
In order to achieve the appropriate viscosity, a coloring solution of the present invention may comprise one or more thickeners to such an extent that it does not hinder the effects of the present invention.
The thickener may be selected from the above organic solvents to adjust viscosity, or may be selected from the following thickeners. Examples of thickeners other than the organic solvents include:
The content of the thickener in a coloring solution of the present invention is preferably 0.01 to 10 mass %, more preferably 0.1 to 8 mass %, even more preferably 0.2 to 5 mass %.
A coloring solution of the present invention may comprise other additives, provided that it does not hinder the effects of the present invention.
Examples of the additives include stabilizers (for example, methoxyphenol, hydroquinone, Topanol A (2,4-dimethyl-6-tert-butylphenol (excluding a stabilizer capable of reducing a phase transformation of zirconia)), and a mixture of these), buffers (for example, acetate, amino buffer, and a mixture of these), preservatives (for example, sorbic acid, benzoic acid, and a mixture of these), and a mixture of these. The additives may be used alone, or two or more thereof may be used in combination.
The content of the additive in a coloring solution of the present invention may be, for example, 0.01 to 10 mass %, 0.05 to 5 mass %, or 0.1 to 3 mass %.
In a coloring solution of the present invention, the coloring component may comprise a colorant that becomes decolored after zirconia is fired. The colorant that becomes decolored after zirconia is fired is not particularly limited, as long as it is decolored after firing zirconia, and can provide a satisfactory color difference before and after firing. The colorant may be, for example, an organic dye.
The organic dye is not particularly limited, as long as it is an organic dye having a chromophore, and that dissolves in the coloring solution. Preferably, the organic dye is an aromatic organic dye, that is, an organic dye containing one or more aromatic groups that may be substituted. More preferably, the organic dye is an aromatic organic dye having an auxochrome, in addition to a chromophore. The chromophore is not particularly limited, as long as it is a group of atoms that confer color by binding to an aromatic ring. Examples include a nitro group, an azo group, a ketimide group (>C═N—), a carbonyl group, a carbon-carbon double bond, a carbon-carbon triple bond, a carbon-nitrogen multiple bond, a thiocarbonyl group, a nitroso group, and an azoxy group. The organic dye may contain one of such groups of atoms alone, or may contain two or more groups of atoms in an appropriate combination. Examples of the auxochrome include a hydroxyl group, an amino group, a carboxyl group, a sulfone group, and a halogen atom. The organic dye may contain one of such auxochromes alone, or may contain two or more auxochromes in an appropriate combination.
The organic dye is preferably a food dye, more preferably a food dye that dissolves in the coloring solution, because the colorant that becomes decolored after firing zirconia must be harmless and nontoxic to humans. Examples of such food dyes include:
Preferred are organic dyes containing two or more aromatic groups and having a ketimide group or an azo group as a chromophore, for example, such as yellow 4 (tartrazine), yellow 5 (sunset yellow FCF), red 2 (amaranth), red 102 (new coccin), blue 1 (brilliant blue FCF), green 3 (fast green FCF), and isobetanin. Because the colorant (A) can be changed depending on the content of the stabilizer in a zirconia pre-sintered body to which a coloring solution of the present invention is applied, a certain preferred embodiment is, for example, a zirconia coloring solution in which the colorant (A) is an organic dye containing two or more aromatic groups, and having a ketimide group or an azo group as a chromophore, and a sulfone group as an auxochrome. In the present specification, “aromatic group” includes an aromatic group whose ring structure consists solely of carbon atoms, and a heteroaromatic group whose ring structure contains elements other than carbon (e.g., oxygen, nitrogen). The colorant that becomes decolored after firing zirconia may be used alone, or two or more thereof may be used in an appropriate combination. The colorant that becomes decolored after firing zirconia may produce different color intensities depending on the pH of the coloring solution, and may take different compound structures for different pH values. However, the pH of the zirconia coloring solution is not particularly limited, as long as the present invention can exhibit its effects. A pH value may be selected that provides an appropriate color intensity, according to the type of the colorant that becomes decolored after firing zirconia.
The content of the colorant that becomes decolored after firing zirconia is not particularly limited, as long as the liquid component can produce color. Preferably, the content of the colorant that becomes decolored after firing zirconia is 0.009 to 3.0 mass %, more preferably 0.09 to 1.6 mass %, even more preferably 0.2 to 1.4 mass %, particularly preferably 0.25 to 1.2 mass % relative to the mass of the whole coloring solution.
A certain embodiment is, for example, a coloring solution in which the coloring component is essentially free of a colorant that becomes decolored after firing zirconia. By “essentially free of a colorant that becomes decolored after firing zirconia”, it means that the content of the colorant that becomes decolored after firing zirconia is preferably less than 0.009 mass %, more preferably less than 0.001 mass %, even more preferably less than 0.0001 mass % relative to the mass of the whole coloring solution. The content of the colorant that becomes decolored after firing zirconia may be 0 mass %.
A ceramic colored with a coloring solution of the present invention is not particularly limited, as long as it contains ceramic. Examples include those containing, for example, zirconia (zirconium oxide or ZrO2 as it is also called), alumina (aluminum oxide or Al2O3 as it is also called), feldspar glass, disilicate glass, or porcelain. Preferred as dental ceramics are those containing zirconia and/or alumina, more preferably those containing zirconia as a main component. In the case of a dental ceramic containing zirconia as a main component, the zirconia content is more preferably 65 mass % or more, particularly preferably 75 mass % or more, most preferably 85 mass % or more.
A dental ceramic colored with a coloring solution of the present invention may be an unfired body or a pre-sintered body, provided that it is not sintered. However, in view of penetration of the coloring solution, a zirconia pre-sintered body is preferred in the case of a dental ceramic containing zirconia as a main component.
Another embodiment of the present invention is, for example, a dental ceramic (a colored ceramic pre-sintered body or a colored unfired body) supporting a coloring component and a Zr component on a surface of the dental ceramic. The content of the coloring component and the Zr component is not particularly limited, as long as the present invention can exhibit its effects. For example, the content of the coloring component and the Zr component can be appropriately adjusted by adjusting the applied amount of a coloring solution of the present invention, according to, for example, the desired color intensity to be obtained after sintering. The coloring component and the Zr component can be adjustably supported not only on the outermost surface but in the surface of a ceramic pre-sintered body or unfired body because the coloring component and the Zr component can penetrate into a ceramic pre-sintered body or unfired body by capillary action through spaces that are in communication with outside, following application of, for example, a coloring solution of the present invention. By “support”, it generally means a state of adhesion to a support. In the present invention, “support” refers to a state of adhesion to a ceramic by means of, for example, adsorption.
With a dental ceramic of the present invention, the desired shade needed for dental use can be imparted after firing while improving the strength.
More preferably, the ceramic pre-sintered body or unfired body comprises zirconia as a main component, as noted above. Below is a description of zirconia. In the present invention, a pre-sintered body after coloring is called “colored ceramic pre-sintered body” to distinguish it from “ceramic pre-sintered body”, a simplified term used herein to refer to a pre-sintered body before coloring with the coloring solution. A coloring solution of the present invention can also be used to color a zirconia unfired body. In this case, a zirconia sintered body is produced without producing a pre-sintered body. In situations assuming such sintered bodies, the conditions in the descriptions given below in conjunction with zirconia pre-sintered bodies are equally applicable as preferred embodiments of the zirconia unfired body.
The following describes a zirconia pre-sintered body of the present invention. The zirconia pre-sintered body refers to a material containing zirconia (ZrO2: zirconium oxide) as a main component, and in which zirconia has pre-sintered after the material was molded according to the dental product to be produced. For example, “zirconia pre-sintered body” means a block formed while zirconia particles (powder) are not fully sintered. The main component may be 50 mass % or more. The zirconia content in a zirconia pre-sintered body according to the present invention is preferably 60 mass % or more, more preferably 70 mass % or more, even more preferably 80 mass % or more. For example, for applications as dental prostheses or dental implant products, the zirconia pre-sintered body can be prepared by, for example, pre-sintering a disc or a block obtained by press forming a zirconia powder using a known technique. The zirconia pre-sintered body has a density of preferably 2.7 g/cm3 or more. The zirconia pre-sintered body has a density of preferably 4.0 g/cm3 or less, more preferably 3.8 g/cm3 or less, even more preferably 3.6 g/cm3 or less. Molding can be performed with ease when the density is confined in these ranges. The density of the pre-sintered body can be calculated as, for example, a ratio of the mass of the pre-sintered body to the volume of the pre-sintered body. The zirconia pre-sintered body has a three-point flexural strength of preferably 15 to 70 MPa, more preferably 18 to 60 MPa, even more preferably 20 to 50 MPa. The flexural strength can be measured following ISO 6872:2015 except for the specimen size, using a specimen measuring 5 mm×10 mm×50 mm in size. For surface finishing, the specimen surfaces, including chamfered surfaces (45° chamfers at the corners of specimen), are finished longitudinally with #600 sandpaper. The specimen is disposed in such an orientation that its widest face is perpendicular to the vertical direction (loading direction). In the flexure test, measurements are made at a span of 30 mm with a crosshead speed of 0.5 mm/min.
It is preferable that the zirconia in the zirconia pre-sintered body and in a zirconia powder and a molded body of zirconia powder be predominantly monoclinic in crystal system. In the present invention, “being predominantly monoclinic in crystal system” means that the fraction fm of the monoclinic crystal system of zirconia calculated from the formula (1) below is 50% or more relative to the total amount of all the crystal systems (monoclinic, tetragonal, and cubic) of zirconia. In the zirconia pre-sintered body and in a zirconia powder and a molded body of zirconia powder, the fraction fm of the monoclinic crystal system of zirconia calculated from the formula (1) below is preferably 55% or more, more preferably 60% or more, even more preferably 70% or more, yet more preferably 75% or more, particularly preferably 80% or more, still more preferably 85% or more, most preferably 90% or more relative to the total amount of the monoclinic, tetragonal, and cubic crystal systems. The fraction fm of monoclinic crystal system can be calculated from the formula (1) below, using peaks in an X-ray diffraction (XRD) pattern by CuKα radiation. The predominant crystal system possibly contributes to elevating the shrinkage temperature in firing the zirconia pre-sintered body, and reducing the firing time.
In a zirconia pre-sintered body of the present invention, the peaks for tetragonal and cubic crystal systems may be essentially undetectable. That is, the fraction fm of the monoclinic crystal system may be 100%.
In formula (1), Im(111) and Im(11-1) represent the peak intensities of the (111) plane and (11-1) plane, respectively, of the monoclinic crystal system of zirconia, Im(111) represents the peak intensity of the (111) plane of the tetragonal crystal system of zirconia, and Ic(111) represents the peak intensity of the (111) plane of the cubic crystal system of zirconia.
Preferably, a zirconia pre-sintered body of the present invention comprises a stabilizer capable of reducing a phase transformation of zirconia. For example, a stabilizer capable of reducing a phase transformation of zirconia is preferably contained in zirconia before pre-sintering.
Examples of the stabilizer capable of reducing a phase transformation of zirconia include oxides such as yttrium oxide (Y2O3; hereinafter “yttria”), calcium oxide (CaO), magnesium oxide (MgO), yttria, cerium oxide (CeO2), scandium oxide (Sc2O3), niobium oxide (Nb2O5), lanthanum oxide (La2O3), erbium oxide (Er2O3), praseodymium oxide (Pr6O11), samarium oxide (Sm2O3), europium oxide (Eu2O3), and thulium oxide (Tm2O3). Preferred is yttria. These may be used alone, or two or more thereof may be used in combination. In a certain preferred embodiment of the coloring solution, a dental ceramic to be colored contains zirconia as a main component, and yttria as a stabilizer, and the stabilizer consists essentially of yttria. In such a preferred embodiment, “stabilizer consisting essentially of yttria” means that the content of stabilizers other than yttria is less than 0.1 mol %, preferably 0.05 mol % or less, more preferably 0.01 mol % or less, even more preferably 0.001 mol % or less in total 100 mol % of zirconia and stabilizer.
When a stabilizer is contained, the stabilizer content is preferably 0.1 to 18 mol %, more preferably 1 to 15 mol %, even more preferably 1.5 to 10 mol % in total 100 mol % of zirconia and stabilizer.
A zirconia pre-sintered body of the present invention may optionally comprise, for example, a colorant (including a pigment, a composite pigment, and a fluorescent agent), alumina (Al2O3), titanium oxide (TiO2), or silica (SiO2). These components may be used alone, or two or more thereof may be used as a mixture. Examples of the pigment include an oxide of at least one component selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Zn, Y, Zr, Sn, Sb, Bi, Ce, Pr, Sm, Eu, Gd, Tb, and Er. Examples of the composite pigment include (Zr,V)O2, Fe(Fe,Cr)2O4, (Ni,Co,Fe)(Fe,Cr)2O4·ZrSiO4, and (Co,Zn)Al2O4. Examples of the fluorescent agent include Y2SiO5:Ce, Y2SiO5:Tb, (Y,Gd,Eu)BO3, Y2O3:Eu, YAG:Ce, ZnGa2O4:Zn, and BaMgAI10017:Eu.
A typical method of production of a zirconia pre-sintered body of the present invention is as follows. First, granules are prepared that comprise a zirconia raw material containing a stabilizer (preferably, zirconia particles that are predominantly monoclinic in crystal system), and the granules are pressed into a shape such as a block or a disc. Optionally, the molded body is subjected to CIP (Cold Isostatic Pressing). The applied pressure is, for example, 50 to 500 MPa. This is followed by pre-sintering. Pre-sintering can produce a zirconia pre-sintered body by gradually increasing temperature from room temperature to 800 to 1,200° C., and retaining this temperature for about 1 to 6 hours. The resulting zirconia pre-sintered body can then be milled with a known device, according to the final dental product. For example, when the dental product is a dental prosthesis, the zirconia pre-sintered body is milled into a shape of a dental cap with a CAD/CAM or other device.
The zirconia pre-sintered body may be a commercially available product. Examples of such commercially available products include Noritake KATANA® zirconia (Model: Disc UTML, Disc STML, Disc ML, Disc HT, Disc LT, all manufactured by Kuraray Noritake Dental Inc.).
A method of production of a colored zirconia pre-sintered body of the present invention comprises the step of containing the zirconia coloring solution in a zirconia pre-sintered body after milling. The zirconia coloring solution may be contained by, for example, being applied to the zirconia pre-sintered body with a brush or the like, dipping the zirconia pre-sintered body in a container containing the coloring solution, or spraying the coloring solution to the zirconia pre-sintered body with a sprayer or the like. Known tools and devices can be used. When a zirconia sintered body is produced directly from an unfired body without the pre-sintering step, the zirconia coloring solution may be contained in the zirconia unfired body after milling.
The present invention also encompasses a zirconia sintered body obtained by sintering the colored zirconia pre-sintered body. A method of production of the zirconia sintered body comprises the step of firing the colored zirconia pre-sintered body. The firing temperature (highest temperature in firing) can be appropriately selected according to the type of zirconia, and is not particularly limited as long as the coloring component can develop color. However, the firing temperature is preferably 1,350° C. or more, more preferably 1,450° C. or more, even more preferably 1,500° C. or more. The upper limit of firing temperature is not particularly limited, and is, for example, preferably 1,600° C. or less. The zirconia sintered body encompasses not only sintered bodies after sintering of molded zirconia particles under ordinary pressure or no applied pressure, but sintered bodies compacted by a high-temperature pressing process such as HIP (Hot Isostatic Pressing).
The stabilizer content in a zirconia sintered body of the present invention can be measured, for example, by inductively coupled plasma (ICP) emission spectral analysis or X-ray fluorescence analysis.
Preferably, the zirconia sintered body has at least one of partially stabilized zirconia and fully stabilized zirconia as the matrix phase. In the zirconia sintered body, the predominant crystalline phase of zirconia is at least one of the tetragonal crystal system and the cubic crystal system. The zirconia sintered body may have both the tetragonal crystal system and the cubic crystal system. Preferably, the zirconia sintered body is essentially free of a monoclinic crystal system. Zirconia that is partially stabilized by addition of a stabilizer is called partially stabilized zirconia (PSZ), whereas zirconia that is fully stabilized is called fully stabilized zirconia.
The present invention encompasses dental products formed from the zirconia sintered body. Examples of the dental products include dental prostheses, orthodontic products, and dental implant products. The dental prostheses can be used as, for example, zirconia inlays, onlays, laminate veneers, or crowns.
In the foregoing embodiments, aspects such as the type and content of each component can be changed as appropriate, and changes such as additions and deletions can be made in any of the components. In the foregoing embodiments, the composition and property values of the coloring solution can be varied and combined as appropriate.
The present invention encompasses embodiments combining the foregoing features, provided that the present invention can exhibit its effects with such combinations made in various forms within the technical scope of the present invention.
The following describes the present invention in greater detail by way of Examples. The present invention, however, is not limited by the following descriptions.
Coloring solutions were prepared for Examples and Comparative Examples, and their properties were evaluated, as follows. The results are presented in Tables 1 and 2.
Preparation of Coloring Solution
The components shown in Tables 1 and 2 were mixed at ordinary temperature in the amounts shown in Tables 1 and 2 to prepare coloring solutions. The molar concentration of the Zr component in the coloring solutions was measured by inductively coupled plasma (ICP) emission spectral analysis (SPS3500, manufactured by Hitachi High-Tech Science Corporation).
Production of Zirconia Pre-Sintered Body
The following describes the method of production of a zirconia pre-sintered body to which the coloring solution is applied.
First, a zirconia powder containing a stabilizer was prepared. A mixture was prepared by adding 9.9 mass % (5.5 mol %) of yttria as stabilizer to 90.1 mass % of a zirconia powder that is predominantly monoclinic in crystal system. The mixture was added to water to prepare a slurry, and the slurry was mixed and pulverized to an average particle diameter of 0.13 μm or less by wet pulverization with a ball mill. After pulverization, the slurry was dried with a spray dryer, and the resulting powder was fired at 950° C. for 2 hours to prepare a powder (primary powder). The average particle diameter can be determined by a laser diffraction scattering method. As a specific example of a laser diffraction scattering method, a 0.2% aqueous solution of sodium hexametaphosphate may be used as a dispersion medium for the measurement of average particle diameter by volume, using a laser diffraction particle size distribution analyzer (SALD-2300, manufactured by Shimadzu Corporation).
Water was added to the primary powder to prepare a slurry, and the slurry was mixed and pulverized to an average particle diameter of 0.13 μm or less by wet pulverization with a ball mill. After adding a binder to the pulverized slurry, the slurry was dried with a spray dryer to prepare a powder (secondary powder). The secondary powder was used as a raw material powder for the production of the zirconia pre-sintered body below.
The method of production of a zirconia pre-sintered body is as follows. The raw material powder (1.32 g) was filled into a die measuring 19 mm in diameter, and was pressed under a surface pressure of 57.5 kN for 20 seconds with a uniaxial pressing machine (primary press forming). The resulting primary press-molded body was then fired at 1,000° C. for 2 hours to prepare a zirconia pre-sintered body.
Measurement of Chromaticity of Sintered Body
The coloring solution prepared was applied to the zirconia pre-sintered body with a brush, and the zirconia pre-sintered body was fired into a zirconia sintered body under the firing conditions shown in Tables 1 and 2. The zirconia sintered body was ground into a circular disc measuring 15 mm in diameter and 1.2 mm in thickness, and was measured for chromaticity against a white background according to L*a*b*color system (JIS Z 8781-4:2013 Color Measurements—Part 4: CIE 1976 L*a*b* color space), using a spectrophotometer (Crystaleye; measurement mode: 7 band, LED light source) manufactured by Olympus Corporation under this trade name (n=3). Tables 1 and 2 show the mean values of measured values.
Measurement of Transparency of Sintered Body
The coloring solution prepared was applied to the zirconia pre-sintered body with a brush, and the zirconia pre-sintered body was fired into a sintered body under the firing conditions shown in Tables 1 and 2. The sintered body was ground into a circular disc measuring 15 mm in diameter and 1.2 mm in thickness, and was measured for chromaticity using a spectrophotometer (Crystaleye CE100-DC/JP, 7-band LED light source) manufactured by Olympus Corporation under this trade name. In the chromaticity measurement, the same specimen was measured for lightness (Lw*) against a white background, and lightness (Lb*) against a black background, using the same measurement device in the same measurement mode with the same light source. The difference (ΔL*=(Lw*)−(Lb*)) was then determined as transparency (ΔL*) (n=3). Tables 1 and 2 show the mean values of calculated values. The preferred transparency range is 3 to 20, more preferably 5 to 19, even more preferably 6 to 18.
Measurement of Biaxial Flexural Strength of Sintered Body
The coloring solution prepared was applied to the zirconia pre-sintered body with a brush, and the zirconia pre-sintered body was fired into a sintered body (15 mm in diameter, 1.2 mm in thickness) under the firing conditions shown in Tables 1 and 2. The sintered body was measured for biaxial flexural strength in compliance with JIS T 6526:2012 at a crosshead speed of 0.5 mm/min, using a desktop universal precision tester Autograph (AG-I 100 kN) manufactured by Shimadzu Corporation under this trade name (n=5). Tables 1 and 2 show the mean values of measured values.
Separately, the percentage change of biaxial flexural strength was calculated using the following formula, relative to the zirconia sintered body that was not colored with a coloring solution (Comparative Example 1).
Percentage change of biaxial flexural strength (%)={(biaxial flexural strength of sintered body fired after application of coloring solution—biaxial flexural strength of uncolored zirconia sintered body)/biaxial flexural strength of uncolored zirconia sintered body}×100
Examples 1 to 13 in which coloring solutions of the present invention were applied showed improvement of zirconia strength after firing, compared to Comparative Example 1 in which a coloring solution was not applied, and in Comparative Examples 2 and 3 in which a coloring solution containing no Zr component was applied. Particularly, a comparison between Examples 1 to 3 and Comparative Example 2, and a comparison between Examples 5 to 7 and Comparative Example 3 revealed that the presence or absence of the Zr component, or the content of Zr component makes hardly any difference in the chromaticity and transparency after firing, confirming that a coloring solution of the present invention has small influence on the shade imparted to zirconia, that is, the desired shade can be imparted to zirconia, while improving the strength of zirconia after firing.
A coloring solution of the present invention can impart the desired shade to a dental ceramic while improving the strength of the dental ceramic. This enables a coloring solution of the present invention to be suitably used as a coloring solution for coloring a dental ceramic. A dental ceramic coloring solution of the present invention is useful given an expected increase in the use of dental ceramic coloring solutions, particularly in response to the continuously growing demand for ceramic dental caps and the associated increase in individual demand for better aesthetics.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-168077 | Oct 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/036508 | 10/1/2021 | WO |
