Patent Grant
11110039
The present invention relates to a light-curable dental impression material. Moreover, the present invention relates to a use of the light-curable dental impression material of the present invention for the preparation of a dental impression.
Dental impression materials are known. Dental impression materials are commonly available as reactive multi-component materials provided in packages including two compartments or two separate containers that keep the components isolated from each other during storage. Once the components are mixed, a chemical reaction is initiated that turns the mixed composition into a hardened mass during the setting time. Moreover, the working time and the setting time of conventional dental impression materials are limited and depend on the rate of the curing reaction. Therefore, storage stability of a dental impression material depends on the separation of reactive components and necessitates mixing prior to use which needs to be done chairside immediately prior to use so that the dental impression may be completed during the working time of usually only a few minutes.
Devices have been developed for the automatic mixing and dispensing of multi-component dental impression materials in order to provide high precision with regard to the homogeneity of the mixture, and the ratio of the two components to be mixed. Accordingly, the components of the dental impression material are simultaneously supplied from separate material chambers to a mixer during application of the dental impression material, which mixes and then dispenses a mixed paste. The paste may be supplied from the mixer directly onto a dental impression tray for immediate placement in a patient's mouth.
Once the material components have come into contact with each other in the mixing chamber, the mixture of the material in the mixing chamber can only be stored for a short time because the mixed material will soon set inside the mixing chamber unless dispensed and used. Therefore, the dental practitioner may have to remove and replace mixers several times each day.
Dental impression materials may be silicone impression material curable in an addition or condensation reaction whereby addition silicones are most popular. Although conventional addition silicone impression materials provide good detail reproduction, excellent dimensional stability, little shrinkage on set, addition silicones are inherently hydrophobic and as such require moisture control for optimal use. Finally, addition silicones have only a poor tear resistance.
Dental impression material based on cross-linking polysiloxanes are known. For example, U.S. Pat. No. 5,849,812 describes an addition-curing polyether dental impression material comprising (a) at least one polyether which has at least two optionally substituted vinyl and/or allyl end-groups, (b) an SiH component, (c) at least one platinum catalyst, (d) optional additives, and (e) organopolysiloxane with at least two alkenyl groups.
U.S. Pat. No. 5,137,448 discloses a dental impression composition that is polymerizable by having an initiator activated by actinic light within the visible light range of 360 to 600 nanometers, which contains a compound having at least two terminal acrylate unsaturations and an organosilicone containing backbone.
It is the problem of the present invention to provide a dental impression material which is highly tolerant to moisture, which has adjustable working and setting times, and which has excellent tear resistance while providing at the same time good detail reproduction without adhesion to core build-up materials or composite restorations, excellent dimensional stability, and reduced shrinkage on set, and which may be provided as a single composition which does not need mixing prior to use.
Moreover, it is the problem of the present invention to provide a use of the dental impression material of the present invention.
The present invention provides a light-curable dental impression material comprising:
(a) a polymerizable polysiloxane resin composition comprising compounds of the following formula (I):
E-(L1-Z)n-L2-E (I)
When m is greater than 1, then L3, L4, X1, X2, Y1 and Y2 may each be independently the same or different as defined above such that the repeating unit
of the divalent group formula (II) may be same or different.
It is to be understood that the divalent group of formula (II) may include an oligomer or polymer chain of the same repeating unit or alternate oligomer or polymer chains of different repeating units and/or random polymer chains of different repeating units. Further, m of formula (II) may encompass i and j of specific embodiments of the compound of formula (I) as shown herein.
Further, the present invention provides a use of the light-curable dental impression material of the present invention for the preparation of a dental impression.
The present invention is based on the recognition that a specific composition of radically polymerizable polysiloxane compounds according to formula (I) may be used in a filled light-curable dental impression material given that such compounds contain at least one monovalent group E having a polymerizable carbon-carbon double bond, and at least one polysiloxane group so that the compounds have a low dynamic viscosity and may be cured in a radical polymerization reaction resulting in a cured material having limited adhesion to hard and soft tooth structure, core build-up materials or composite restorations.
The curing by radical polymerization allows to provide a convenient one component light-curable dental impression material which has high storage stability and which does not require mixing prior to use. Accordingly, the light-curable dental impression material may be provided as a ready-to-use dental tray. At the same time, the light-curable dental impression material provides, when cured, excellent tear resistance, good detail reproduction, excellent dimensional stability, and no shrinkage on set.
The terms “polymerization” and “polymerizable” relates to the combining or the capability to combine by covalent bonding of a large number of smaller molecules, such as monomers, to form larger molecules, that is, macromolecules or polymers. The monomers may be combined to form only linear macromolecules or they may be combined to form three-dimensional macromolecules, commonly referred to as crosslinked polymers. For example, monofunctional monomers form linear polymers, whereas monomers having at least two functional groups form crosslinked polymers also known as networks.
The term “C2-20 alkylene group” according to the present invention represents a divalent C2-20 hydrocarbon linker group. In particular, the linker group may be a hydrocarbon group which may be aliphatic and/or aromatic. Moreover, the linker group may be a straight-chain, branched and/or cyclic a hydrocarbon group. A C2-20 hydrocarbon linker group may contain 1 to 8 heteroatoms selected from oxygen, nitrogen and sulphur, which divalent organic residue may be substituted with one or more substituents selected from the group consisting of a C1-4 alkoxy groups, a hydroxyl group, a thiol group, and a C6-14 aryl group. The C2-20 alkylene group may be a linear or branched group. The hydrocarbon group may be substituted by 1 to 6 C1-4 alkyl groups. Specific examples of the alkyl groups are methylene, ethylene, n-propylene, i-propylene, n-butylene, i-butylene or tert.-butylene. In a preferred embodiment, the hydrocarbon group may contain 1 to 5 oxygen atoms in the hydrocarbon group in the form of aliphatic or aromatic ether bonds, keto groups, carboxylic acid groups, or hydroxyl groups. In case of an aliphatic group, the C2-20 alkylene group may be a straight chain or branched alkylene group or a cycloalkylene group. In case of an aromatic group, the C2-20 alkylene group may be an arylene group or a C3-14 heteroarylene group. Specifically, it may be a divalent substituted or unsubstituted C2-20 alkylene group, substituted or unsubstituted C6-14 arylene group, substituted or unsubstituted C3-20 cycloalkylene group, substituted or unsubstituted C7-20 arylenealkylenearylene group. Furthermore, the C2-20 alkylene group represents a saturated aliphatic C2-20 hydrocarbon chain which may contain 2 to 4 oxygen atoms or nitrogen atoms, and which may be substituted by 1 to 6 C1-4 alkyl groups, or the C2-20 alkylene group may be a substituted or unsubstituted C7-20 arylenealkylenearylene group which may be substituted by 1 to 6 C1-4 alkyl groups.
“Actinic radiation” is any electromagnetic radiation that is capable of producing photochemical action and can have a wavelength of at least 150 nm and up to and including 1250 nm, and typically at least 300 nm and up to and including 750 nm.
The term “electron donor” as used herein means a compound capable of contributing electrons in a photochemical process. Suitable examples include organic compounds having heteroatoms with electron lone pairs, for example amine compounds.
The present invention provides a light-curable dental impression material. The light-curable dental impression material is preferably a one-pack composition packaged in a syringe or provided on a ready-to-use dental impression tray. Alternatively, the light-curable dental impression material of the present invention may also be a two-pack composition, in particular when formulated as a dual cure composition containing an additional redox initiator system.
When packaged in a syringe or provided on a ready-to-use dental impression tray, the composition must be shielded from actinic light during storage.
The light-curable dental impression material of the present invention comprises a polymerizable polysiloxane resin composition comprising compounds of the formula (I) having a polymerizable moiety in combination with a polysiloxane moiety. The polymerizable polysiloxane resin composition comprises compounds of the formula (I) which are macromonomers. The macromonomers may be obtained by reacting a first reactant and a second reactant in a specific stoichiometric ratio so that an excess with regard to the molar amount of reactive groups of the second reactant is present, and using a third reactant in a specific ratio to end-cap any excess reactive end-groups.
The reaction of the first reactant and the second reactant is preferably an addition polymerization. However, a polycondensation is also possible.
The end-capping reaction of the third reactant with excess functional groups of the second reactant is preferably also an addition polymerization. However, a polycondensation is again possible.
In case of a polyaddition reaction, the formation of a urethane bond is preferred. Alternatively, the formation of urea or S-thiocarbamate linkages by the reaction of the first and second reactants is also possible. Accordingly, the first reactant may be a diol, or alternatively a diamine or a dithiol, and the second reactant may be a diisocyanate.
In case of polyfunctional reactants such as trifunctional reactants, branching may be introduced into the macromonomer. According to the present invention, it is possible to use a di-or polyalcohol as the first reactant and a di- or polyisocyanate as the second reactant whereby an isocyanate-terminated polyurethane prepolymer is formed which is endcapped with a monofunctional third reactant such as an alcohol as shown in
However, according to the present invention, it is also possible to use a di-or polyisocyanate as the first reactant and a di- or polyalcohol as the second reactant whereby a hydroxyl-terminated prepolymer is formed which is end-capped with a monofunctional third reactant such as an isocyanate. Alternatively, it is possible to use a di-or polyisocyanate as the first reactant and a di- or polyamine or di- or polythiol as the second reactant whereby an amine or thiol-terminated prepolymer is formed which is end-capped with a monofunctional third reactant such as an isocyanate.
The first, second and third reactants may be mixtures of two or more different compounds. Any of the first, second and third reactants may contain one or more polysiloxane moieties. Preferably, the third component introduces a radical polymerizable moiety into the macromonomer.
According to a preferred embodiment, the light-curable dental impression material of the present invention further comprises additional polymerizable compounds, notably compounds which are compounds of formula (I), but lack any polysiloxane moiety. Specifically, the light-curable dental impression material of the present invention preferably comprises additional polymerizable macromonomers. The polymerizable macromonomers may be obtained by reacting a fourth reactant and a fifth reactant in a specific stoichiometric ratio so that an excess with regard to the molar amount of reactive groups of the fifth reactant is present, and using a sixth reactant in a specific ratio to end-cap any excess reactive end-groups.
The reaction of the fourth reactant and the fifth reactant is preferably an addition polymerization. However, a polycondensation is also possible. The end-capping reaction of the sixth reactant with excess functional groups of the fifth reactant is preferably also an addition polymerization. However, a polycondensation is again possible.
In case of a polyaddition reaction, the formation of a urethane bond is preferred. Alternatively, the formation of urea or S-thiocarbamate linkages by the reaction of the fourth and fifth reactants is also possible. Accordingly, the fourth reactant may be a diol, or alternatively a diamine or a dithiol, and the second reactant may be a diisocyanate.
In case of polyfunctional reactants, branching may be introduced into the macromonomer. According to the present invention, it is possible to use a di-or polyalcohol as the fourth reactant and a di- or polyisocyanate as the fifth reactant whereby an isocyanate-terminated prepolymer is formed which is endcapped with a monofunctional sixth reactant such as an alcohol as shown in
However, according to the present invention, it is also possible to use a di-or polyisocyanate as the fourth reactant and a di- or polyalcohol as the fifth reactant whereby a hydroxyl-terminated polyurethane prepolymer is formed which is end-capped with a monofunctional sixth reactant such as an isocyanate. Alternatively, it is possible to use a di-or polyisocyanate as the fourth reactant and a di- or polyamine or di- or polythiol as the second reactant whereby an amine or thiol-terminated polyurea or poly-S-thiocarbamate prepolymer is formed which is end-capped with a monofunctional third reactant such as an isocyanate.
The fourth, fifth and sixth reactants may be mixtures of two or more different compounds. None of the first, second and third reactants may contain any polysiloxane moiety in case of the additional polymerizable macromonomers. Reactants which do not contain any polysiloxane moiety used for preparing a polymerizable polysiloxane resin composition comprising compounds of the formula (I) may be used for preparing the additional polymerizable macromonomers. Preferably, the sixth component introduces a radical polymerizable moiety into the additional polymerizable macromonomer.
The Polymerizable Polysiloxane Resin Composition
The light-curable dental impression material of the present invention comprises a polymerizable polysiloxane resin composition comprising compounds of the following formula (I):
E-(L1-Z)n-L2-E (I)
According to a preferred embodiment, the polymerizable polysiloxane resin composition has a total siloxane content in a range of from 10 to 40% wt/wt, more preferably in a range of from 15 to 35% wt/wt. The total siloxane content of the polymerizable polysiloxane resin composition may be determined by 29Si-NMR.
In a compound of formula (I), E which may be the same or different, independently represent a monovalent group selected from a group containing a polymerizable carbon-carbon double bond, a group containing a polysiloxane moiety, a C2-20 alkoxy group, a C2-20 thioalkyl group, and a RNH group, wherein R is a C2-20 alkyl group.
According to a preferred embodiment, E is a group containing a polymerizable carbon-carbon double bond, preferably a (meth)acryloyl group, a (meth)acrylamide group or an allyl (meth)acrylamide group, more preferably a (meth)acryloyl group.
According to preferred embodiment, the monovalent groups E contain (meth)acrylate groups so that the total (meth)acrylate content of the polymerizable polysiloxane resin composition is in a range of from 0.20 to 0.50 mmol/g, more preferably from 0.25 to 0.45 mmol/g. The total (meth)acrylate content of the polymerizable polysiloxane resin composition is determined by using 1H-NMR.
According to a preferred embodiment, E is a group according to the following formula (IV):
wherein
Preferably, R1 represents a C1-4 alkyl group, more preferably a methyl group.
According to a first embodiment, X3 preferably represents an oxygen atom or a sulfur atom, more preferably an oxygen atom. According to a second embodiment, X3 preferably represents a group NR2, wherein R2 is a hydrogen atom, C1-12 alkyl group, or an allyl group.
Preferably, X4 represents an oxygen atom or a sulfur atom, more preferably an oxygen atom.
L5 is a divalent hydrocarbon linker group or polysiloxane containing linker group. A polysiloxane containing linker group may be a polysiloxane group or contain one or more hydrocarbon fragments in the main chain. Preferably, L5 is a linear or branched C2-3 alkylene group.
According to a preferred embodiment, the group -[L5-X4]- is selected from the following groups:
Preferably, a is an integer of from 1 to 10.
According to a preferred embodiment, E is a polysiloxane group of the following formula (V):
wherein
According to a preferred embodiment, R4 is a straight chain, optionally substituted C1-12 alkyl group, preferably it is a straight chain optionally substituted C1-6 alkyl group.
According to a preferred embodiment, R4 is a branched, optionally substituted C1-12 alkyl group, preferably it is a branched, optionally substituted C1-6 alkyl group.
According to a preferred embodiment, R4 is a cyclic, optionally substituted C1-12 alkyl group, preferably it is a cyclic, optionally substituted C1-6 alkyl group.
More preferably, R4 is a methyl group.
Preferably, X5 represents an oxygen atom or a sulfur atom, more preferably an oxygen atom.
Preferably, b is an integer of from 1 to 1000, more preferable it is an integer of from 1 to 100, and even more preferably it is an integer of from 1 to 10.
Preferably, c is 1.
According to a preferred embodiment, E is a linear optionally substituted C2-20 alkoxy group.
According to a preferred embodiment, E is a branched optionally substituted C2-20 alkoxy group.
Preferably, E is a linear optionally substituted C2-15 alkoxy group, more preferably it is a linear unsubstituted C2-15 alkoxy group, and even more preferably it is a linear unsubstituted C12 alkoxy group.
According to a preferred embodiment, E is a linear optionally substituted C2-20 thioalkyl group.
According to a preferred embodiment, E is a branched optionally substituted C2-20 thioalkyl group.
Preferably, E is a linear optionally substituted C2-15 thioalkyl group, more preferably it is a linear unsubstituted C2-15 thioalkyl group.
According to a preferred embodiment, E is a RNH group, wherein R is a C2-20 alkyl group.
Preferably, R is a linear optionally substituted C2-20 alkyl group.
Preferably, R is a branched optionally substituted C2-20 alkyl group.
Preferably, R is a linear optionally substituted C2-15 alkyl group, more preferably it is a linear unsubstituted C2-15 alkyl group, and even more preferably it is a linear unsubstituted C2-6 alkyl group.
In a compound of formula (I), L1 represents a divalent group of the following formula (II):
wherein
When m is greater than 1, then L3, L4, X1, X2, Y1 and Y2 may each be independently the same or different as defined above such that the repeating unit
of the divalent group formula (II) may be same or different.
It is to be understood that the divalent group of formula (II) may include an oligomer or polymer chain of the same repeating unit or alternate oligomer or polymer chains of different repeating units and/or random polymer chains of different repeating units. Further, m of formula (II) may encompass i and j of specific embodiments of the compound of formula (I) as shown herein.
According to a preferred embodiment, L3 represents a C2-20 alkylene group as defined above which may contain up to 10 heteroatoms in the main chain, which are selected from oxygen, sulfur or NR#, wherein R# represents a hydrogen atom or a straight chain, branched or cyclic C1-6 alkyl group.
According to a preferred embodiment, L3 represents a group according to the following formula (VI):
wherein
Ra1 and Ra2
Preferably, L3 is selected from the following groups:
According to a preferred embodiment, L3 represents a group according to the following formula (VII):
wherein
Rb1, Rb2, Rb3 and Rb4
Preferably, L6 is a linear or branched C2-3 alkylene group.
According to a preferred embodiment, the group -[L6-X5]- is selected from the following groups:
According to a preferred embodiment, L3 represents a group according to the following formula (VIII):
wherein
R6
L3 may also be a polysiloxane group of the following formula (VIIIa), (VIIIb), or (VIIIc)
wherein
R1# is an alkylene having 1 to 8 carbon atoms;
R2# is an alkyl having from 1 to 4 carbon atoms;
R4# is an alkyl, alkoxy or a cycloalkyl group;
y# is an integer from 5 to 20.
According to a preferred embodiment, R6 is a straight chain, optionally substituted C1-12 alkyl group, preferably it is a straight chain optionally substituted C1-6 alkyl group.
According to a preferred embodiment, R6 is a branched, optionally substituted C1-12 alkyl group, preferably it is a branched, optionally substituted C1-6 alkyl group.
According to a preferred embodiment, R6 is a cyclic, optionally substituted C1-12 alkyl group, preferably it is a cyclic, optionally substituted C1-6 alkyl group.
More preferably, R6 is a methyl group.
Preferably, X7 represents an oxygen atom.
Preferably, L7 and L8 which may be the same or different, independently represent a linear or branched C2-3 alkylene group.
More preferably, L7 and L8 which may be the same or different, independently are selected from the following groups:
h is an integer of from 1 to 40, preferably, h is an integer of from 1 to 20, more preferably it is an integer of from 1 to 10.
Preferably, t is 1.
According to a preferred embodiment, L4 may represent any group as defined according to L3.
According to a preferred embodiment, L4 represents a group according to the following formula (IX):
wherein
E and L1 are defined as above;
L9 is a divalent hydrocarbon linker group, preferably a C2-20 alkylene group;
X9 when more than one X9 is present the X9 groups may be the same or different, independently represent an oxygen atom, a sulfur atom and a group NRN2, wherein RN2 is a hydrogen atom or a C1-4 alkyl group;
u is an integer of from 1 to 4.
Preferably, X9 is an oxygen atom or a sulfur atom, more preferably it is an oxygen atom.
Preferably, u is 1 or 2, more preferably it is 2.
According to a preferred embodiment, the group according to formula (IX) is selected from the following groups:
In a group of formula (II), X1 and X2 which may be the same or different, and when more than one X1, and X2 is present, the X1, and X2 may be the same or different, independently represent an oxygen atom, a sulfur atom and a group NR′, wherein R′ is a hydrogen atom or a C1-4 alkyl group. Preferably, X1 and X2 represent an oxygen atom.
In a group of formula (II), Y1 and Y2 which may be the same or different, and when more than one Y1, and Y2 is present, the Y1, and Y2 may be the same or different, independently represent an oxygen atom, a sulfur atom and a group NR′, wherein R′ is a hydrogen atom or a C1-4 alkyl group. Preferably, Y1 and Y2 represent a group NR′, wherein R′ is a hydrogen atom or a C1-4 alkyl group. More preferably, Y1 and Y2 represent a group NR′, wherein R′ is a hydrogen atom.
In a group of formula (II), m represents 0 or an integer of from 1 to 40.
In a preferred embodiment m is 0.
In a preferred embodiment m is an integer of from 1 to 10.
Preferably, m is 1 or 2.
In a compound of formula (I), Z represents any group as defined according to L3.
In a preferred embodiment, Z represents any group as defined according to L4.
Preferably, Z represents a group according to formula (IX).
In a compound of formula (I), L2 represents any group as defined according to L3 or L4. Preferably, L2 represents any group as defined according to L3.
Preferably, L2 is selected from the following groups:
In a preferred embodiment, L2 represents a single bond.
In a compound of formula (I), n represents 0 or an integer of from 1 to 4.
In a preferred embodiment, n is >0.
In a preferred embodiment, n is 0 and L2 is a divalent group of formula (II), wherein m is 0.
In a preferred embodiment, n=0 and L2 represents a divalent group of the formula (II), wherein
L3 is a divalent C1-12 hydrocarbon group or a polysiloxane group;
L4 which may be the same or different when more than one L4 is present, independently represents a divalent linker group which may be substituted with up to four substituents of the formula (III), wherein L1 and E are as defined above;
X1 and X2 are oxygen atoms,
Y1 and Y2 are NH groups, and
m is an integer of from 1 to 40.
In a preferred embodiment, n is >0 and L2 represents a divalent group of the formula (II), wherein
L3 is a divalent C1-12 hydrocarbon group or a polysiloxane group; L4 which may be the same or different when more than one L4 is present, independently represents a divalent linker group which may be substituted with up to four substituents of the formula (III), wherein L1 and E are as defined above;
X1 and X2 are oxygen atoms,
Y1 and Y2 are NH groups, and
m is an integer of from 1 to 40.
According to a preferred embodiment, L1 and L2 independently represent a divalent group of the formula (II), wherein
L3 is a divalent C1-12 hydrocarbon group or a polysiloxane group;
L4 which may be the same or different when more than one L4 is present, independently represents a divalent linker group which may be substituted with up to four substituents of the formula (III), wherein L1 and E are as defined above;
X1 and X2 are oxygen atoms,
Y1 and Y2 are NH groups,
m is an integer of from 1 to 40; and
Z is a divalent C1-12 hydrocarbon group.
When m is greater than 1, then L3, L4, X1, X2, Y1 and Y2 may each be independently the same or different as defined above such that the repeating unit
of the divalent group formula (II) may be same or different.
It is to be understood that the divalent group of formula (II) may include an oligomer or polymer chain of the same repeating unit or alternate oligomer or polymer chains of different repeating units and/or random polymer chains of different repeating units. Further, m of formula (II) may encompass i and j of specific embodiments of the compound of formula (I) as shown below:
According to a specific embodiment, the compound of formula (I) is a compound of any one of the following formulae:
R# is an alkylene having from 2 to 25 carbon atoms;
R′# is H or CH3;
R″# is an alkylene having from 2 to 15 carbon atoms;
R1# is an alkylene having 1 to 8 carbon atoms;
R2# is an alkyl having from 1 to 4 carbon atoms;
R4# is an alkyl, alkoxy or a cycloalkyl group;
i and j are independently an integer from 1 to 20;
x# is an integer from 2 to 10;
y# is an integer from 5 to 20;
b# is an integer from 50 to 100; and
k is an integer from 5 to 15.
According to a preferred embodiment, the compound of formula (I) has a molecular weight of 100 to 10.000 Da, more preferably 300 to 2000 Da.
Preferably, a compound of formula (I) has a dynamic viscosity in the range of from 0.001 to 100 Pas, more preferably 0.1 to 10 Pas. The dynamic viscosity is a measure of the internal resistance of a fluid to flow. The dynamic viscosity can be measured with various types of viscometers and rheometers at a temperature of 25° C.
According to a preferred embodiment, wherein -L1-Z- represents a divalent group of the formula (II), which is obtainable by reacting a diisocyanate compound, a diol compound, and a polyol compound having at least three hydroxyl groups.
According to a preferred embodiment, L2 represents a divalent group of the formula (II), which is obtainable by reacting a diisocyanate compound and a diol compound.
According to a preferred embodiment, the polymerizable polysiloxane resin mixture is obtainable by reacting a mixture comprising:
(a) x equivalents of one or more di- or polyol compounds of the following formula (X):
HO-L4(OH)l (X)
(b) y equivalents of one or more compounds of the following formula (XI):
OCN-L3NCO (XI)
(c) z equivalents of one or more compounds of the following formula (XII):
wherein 0.05≤x/y≤0.66, and 2y−
wherein x, y, and z are the molar equivalents of components (a), (b) and (c)
and
wherein l is as defined in formula (X) and xl/x is the molar fraction of the compounds having a hydroxyl functionality of l+1.
The mixture contains x molar equivalents of component (a), y molar equivalents of component (b), and z molar equivalents of component (c).
The molar equivalents are adjusted so that 0.05≤x/y≤0.66, and 2y−fx≤z≤1.5(2y−fx), wherein f is the mean hydroxyl functionality of component (a) defined by the following formula:
wherein l is as defined in formula (X) and xl/x is the molar fraction of the compounds having an hydroxyl functionality of l+1.
Accordingly, the molar equivalents x of component (a) depend on the functionality of the one or more di- and/or polyhydroxyl compounds contained in component (a). According to a preferred embodiment, l is 1. When l is 1, then f is 2. According to a further preferred embodiment, the mixture contains one compound of formula (I), preferably wherein l is 1. As a result, compounds according to formula (I) are linear.
According to the present invention, the molar equivalent y is larger than the molar equivalent x in that 0.05≤x/y≤0.66. Given that y>x and depending on the molar ratio of r′=x/y, the polymerization degree (Pa) increases according to Pa=(1+r′)/(1−r′). In case x/y>0.66, the viscosity of the polymerizable composition may become excessively large so that large amounts of a solvent or reactive diluent are required for providing a light-curable dental impression material of the present invention. In case x/y<0.05, the polymerizable composition contains an excess of reaction products between component (b) and component (c) whereby the mechanical properties of the light-curable dental impression material of the present invention are deteriorated.
The mixture contains z molar equivalents of a one or more and chain terminating compounds (c). The amount of z is selected according to the present invention so that 2y−fx≤z≤1.5(2y−fx), wherein f is the mean hydroxyl functionality of component (a) defined above. Preferably, z is 2y−fx. In case x<2y−fx, then the content of end groups in the macromers contained in the polymerizable mixture of the present invention may be reduced which is not preferable in view of the mechanical properties of the dental composite of the present invention. In case z>1.5(2y−fx), the excess of chain terminating compounds may compete with the reaction of component (a) and component (b) and interfere with the macromer formation.
The average molecular weight
In the above formula
According to an alternative embodiment, the polymerizable polysiloxane resin mixture is obtainable by reacting a mixture comprising:
(a′) x equivalents of one or more di- or polyisocyanate compounds of the following formula (X′):
OCN-L4′(NCO)l′ (X′)
wherein 0.05≤x/y≤0.66, and 2y−
wherein x, y, and z are the molar equivalents of components (a′), (b′) and (c′)
and
wherein l is l′ as defined in formula (X′) and x1/x is the molar fraction of the compounds having an isocyanate functionality of l′+1.
The mixture contains x molar equivalents of component (a′), y molar equivalents of component (b′), and z molar equivalents of component (c′).
The molar equivalents are adjusted so that 0.05≤x/y≤0.66, and 2y−fx≤z≤1.5(2y−fx), wherein f is the mean isocyanate functionality of component (a) defined by the following formula:
wherein l is as defined in formula (X) and xl/x is the molar fraction of the compounds having an hydroxyl functionality of l+1.
Accordingly, the molar equivalents x of component (a) depend on the functionality of the one or more di- and/or polyhydroxyl compounds contained in component (a). According to a preferred embodiment, l is 1. When l is 1, then f is 2. According to a further preferred embodiment, the mixture contains one compound of formula (I), preferably wherein l is 1. As a result, compounds according to formula (I) are linear.
According to the present invention, the molar equivalent y is larger than the molar equivalent x in that 0.05≤x/y≤0.66. Given that y>x and depending on the molar ratio of r′=x/y, the polymerization degree (Pa) increases according to Pa=(1+r′)/(1−r′). In case x/y>0.66, the viscosity of the polymerizable composition may become excessively large so that large amounts of a solvent or reactive diluent are required for providing a light-curable dental impression material of the present invention. In case x/y<0.05, the polymerizable composition contains an excess of reaction products between component (b) and component (c) whereby the mechanical properties of the light-curable dental impression material of the present invention are deteriorated.
The mixture contains z molar equivalents of a one or more and chain terminating compounds (c). The amount of z is selected according to the present invention so that 2y−fx≤z≤1.5(2y−fx), wherein f is the mean isocyanate functionality of component (a) defined above. Preferably, z is 2y−fx. In case x<2y−fx, then the content of end groups in the macromers contained in the polymerizable mixture of the present invention may be reduced which is not preferable in view of the mechanical properties of the dental composite of the present invention. In case z>1.5(2y−f x), the excess of chain terminating compounds may compete with the reaction of component (a) and component (b) and interfere with the macromer formation.
The average molecular weight
In the above formula
Preferably, the light-curable dental impression material comprises 2 to 95 percent by weight, based on the total weight of the light-curable dental impression material, of a polymerizable polysiloxane resin composition comprising compounds of formula (I). More preferably, the light-curable dental impression material comprises 4 to 20 percent by weight, based on the total weight of the light-curable dental impression material, of compounds of formula (I).
Additionally, the light-curable dental impression material may preferably comprise up to 75 percent by weight, based on the total weight of the light-curable dental impression material, of polymerizable compounds of formula (I), but lack any polysiloxane moiety. Preferably, the light-curable dental impression material may comprises 10 to 50 percent by weight, based on the total weight of the light-curable dental impression material, of such polymerizable compounds of formula (I) lacking any polysiloxane moiety.
In the preparation of the polymerizable compounds of formula (I), coupling agents may be used. Examples of suitable coupling agents are bismuth compounds such as bismuth 2-ethyl hexanoate (K-KAT 348), tin compounds such as dibutyl tin dioctanoate, and tertiary amines such as 1,4-diazabicyclo[2.2.2]octane (DABCO).
The Filler
The light-curable dental impression material of the present invention comprises a filler. The filler is a particulate filler which has preferably a mean particle size in the range of from 0.05 to 75 μm as measured, for example, by electron microscopy or by using a conventional laser diffraction particle sizing method as embodied by a MALVERN Mastersizer S or MALVERN Mastersizer 3000 apparatus. The particulate filler may be a multimodal particulate filler representing a mixture of two or more particulate fractions having different average particle sizes. The particulate reactive filler may also be a mixture of particles of different chemical composition.
Preferably, the photocurable dental impression material comprises 10 to 60 percent by weight, more preferably 20 to 50 percent by weight, based on the total weight of the dental impression material of a filler.
The specific type of filler is not particularly limited. In order to achieve a usable depth of cure, preferred are fillers with a refractive index comparable to the one of the polymerisable resin mixture. Accordingly, any toxicologically acceptable inorganic, especially hydrophobic fillers may be employed such as silicas, aluminas, magnesias, titanias, inorganic salts, metallic oxides and glasses.
The filler may be a mixtures of different fillers such as silicone dioxides including crystalline forms, in particular particulate quartz, amorphous silicon dioxides, in particular diatomaceous earth, and silanated fumed silica.
The viscosity and thixotropicity of the uncured as well as the physical properties of the cured compositions may be controlled by varying the sizes and surface areas of the filler.
The filler may be surface treated with one or more silanating agents. Preferred silanating agents include those having at least one polymerizable double bond and at least one group that easily hydrolyses with water. Examples of such agents include 3-methacryloxypropyltrimethoxysilane, 3-methacryloxypropyldimethoxy-monochlorosilane, 3-methacryloxypropyldichloromonomethoxysilane, methacryloxypropyltri-chlorosilane, 3-methacryloxypropyldichloromonomethyl-silane, 3-methacryloxypropylmonochlorodimethylsilane, and mixtures thereof.
Preferred filler are fumed silica, quartz, cristobalite, calcium silicate, diatomaceous earth, zirconium silicate, montmorillonite such as bentonite, zeolite, including molecular sieves such as sodium aluminium silicate, metal oxide powder such as aluminium or zinc oxide or their mixed oxides, barium sulphate, calcium carbonate, plaster, and glass powder.
Preferably, the light-curable dental impression material comprises 5 to 50 percent by weight, based on the total weight of the light-curable dental impression material, of a particulate filler. More preferably, the filler is contained in an amount of from 10 to 45 percent by weight based on the total weight of the light-curable dental impression material.
The Photoinitiator.
The light-curable dental impression material of the present invention comprises a photoinitiator. The photoinitiator generates free radicals upon exposure to actinic light. Free radicals may be typically produced by either of two pathways:
(1) a photoinitiator compound undergoes excitation by energy absorption with subsequent decomposition of the compound into one or more radicals (Norrish type I), or
(2) a photoinitiator compound undergoes excitation and the excited photoinitiator compound interacts with a second compound by either energy transfer or a redox reaction to form free radicals from any of the compounds (Norrish type II).
According to the present invention any compound or system capable of initiating the polymerization of the mixture of polymerizable silicone compounds according to the present invention may be used.
For example, a suitable photoinitiator system may be in the form of a binary or tertiary system. A binary systems may include a photoinitiator and an electron donor compound, and a tertiary system may include an iodonium, sulfonium or phosphonium salt, a photoinitiator, and an electron donor compound, as for example described in U.S. Pat. No. 5,545,676.
Suitable photoinitiators are monoketones and diketones that absorb some light within a range of about 400 nm to about 520 nm (preferably, about 450 nm to about 500 nm). Particularly suitable compounds include alpha diketones that have some light absorption within a range of about 400 nm to about 520 nm (even more preferably, about 450 to about 500 nm). Examples include camphor quinone, benzil, furil, 3,3,6,6-tetramethylcyclo-hexanedione, phenanthraquinone, 1-phenyl-1,2-propanedione and other 1-aryl-2-alkyl-1,2-ethanediones, and cyclic alpha diketones.
Moreover, suitable photoinitiators are compounds of the following formula (III) as disclosed in EP 3231413 A1 and EP 3153150 A1:
In a compound of formula (XIII), M is Ge or Si.
Moreover, in a compounds of formula (XIII), R7, R8 and R9 may be the same or different, independently represent an organic group. Preferably, R7 and R8 independently from each other represent a substituted or unsubstituted hydrocarbyl or hydrocarbylcarbonyl group, and R9 represents a substituted or unsubstituted hydrocarbyl group. The hydrocarbyl group may be an alkyl group, a cycloalkyl group, a cycloalkylalkyl group, an arylalkyl group or an aryl group. An alkyl group may be linear C1-20 or branched C3-20 alkyl group, typically a linear C1-8 or branched C3-8 alkyl group. Examples for C1-16 alkyl groups can include linear or branched alkyl groups having 1 to 6 carbon atoms, preferably 1 to 4 carbon atoms, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl and n-hexyl. A cycloalkyl group may be a C3-20 cycloalkyl group, typically a C3-8 cycloalkyl group. Examples of the cycloalkyl group can include those having 3 to 6 carbon atoms, for example, cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.
A cycloalkylalkyl group may have 4 to 20 carbon atoms and may include a combination of a linear or branched alkyl group having 1 to 6 carbon atoms and a cycloalkyl group having 3 to 14 carbon atoms. Examples of the cycloalkylalkyl(-) group can for example, include methylcyclopropyl, methylcyclobutyl, methylcyclopentyl, methylcyclohexyl, ethylcyclopropyl, ethylcyclobutyl, ethylcyclopentyl, ethylcyclohexyl, propylcyclopropyl, propylcyclobutyl, propylcyclopentyl, propylcyclohexyl. An arylalkyl group may be a C7-20 arylalkyl group, typically a combination of a linear or branched alkyl group having 1 to 6 carbon atoms and an aryl group having 6 to 10 carbon atoms. Specific examples of an arylalkyl group are a benzyl group or a phenylethyl group. An aryl group can include aryl groups having 6 to 10 carbon atoms. Examples of the aryl group are phenyl and naphtyl.
The hydrocarbylcarbonyl groups of R7 and R8 represent acyl groups (Rorg-(C═O)—) in which the organic residue Rorg is a hydrocarbyl residue as defined above.
Compound of formula (XIII) may contain one or two hydrocarbylcarbonyl groups, that is either one of R7 and R8 is a hydrocarbylcarbonyl group, or both R7 and R8 are hydrocarbylcarbonyl groups. Preferably, compound of formula (XIII) contains one hydrocarbylcarbonyl group. Preferably, the hydrocarbylcarbonyl group is an arylcarbonyl group, more preferably a benzoyl group. Preferably, R7 and R8 are independently selected from the group consisting of alinear C1-6 or branched C3-6 alkyl group, and a phenyl or benzoyl group which may optionally be substituted by one to three substitutents selected from halogen atoms, a nitro group, a C1-4 alkoxy group and a —NRxRy group wherein Rx and Ry independently from each other represent a C1-4 alkyl group, and R9 is a linear or branched C3-6 alkyl group or a phenyl group. Most preferably, R7 and R8 are independently selected from the group of a linear C1-4 or branched C3 or C4 alkyl group, and a phenyl or benzoyl group which may optionally be substituted with one substituent selected from the group consisting of selected from a halogen atom, a nitro group, a C1-4 alkoxy group and a —NRxRy group wherein Rx and Ry independently from each other represent a C1-4 alkyl group, and R9 is a linear C1-4 or branched C3 or C4 alkyl group.
Moreover, in a compounds of formula (XIII), R10 represents a hydrogen atom, an organic or organometallic group, provided that when R10 is a hydrogen atom, the initiator system further comprises a sensitizer compound having a light absorption maximum in the range from 300 to 600 nm.
According to a first preferred embodiment, R10 represents a group of the following formula (XIV):
wherein R11
(i) is a group of the following formula (XV):
wherein
M, R7, R8 and R9 have the same meaning as defined above for formula (XIII), whereby the compound of formula (XIII) may be symmetrical or unsymmetrical; or
(ii) is a group of the following formula (XVI):
wherein
X represents a single bond, an oxygen atom or a group NRX1, wherein RX1 represents a substituted or unsubstituted hydrocarbyl group;
R* represents a substituted or unsubstituted hydrocarbyl group, a trihydrocarbylsilyl group, a mono(hydrocarbylcarbonyl)dihydrocarbylsilyl group or a di(hydrocarbylcarbonyl)monohydrocarbylsilyl group; or
(iii) when M is Si, R11 may be a substituted or unsubstituted hydrocarbyl group.
For R* of formula (XVI) being a trihydrocarbylsilylgroup, a mono(hydrocarbylcarbonyl)-dihydrocarbylsilyl group or a di(hydrocarbylcarbonyl)monohydrocarbylsilyl group, each of the hydrocarbyl and hydrocarbylcarbonyl groups has the same meaning as defined for R7, R8 and R9 and is independently selected therefrom.
In formula (XVI), RX1 has the same meaning as defined for R9 and is independently selected therefrom.
According to a second preferred embodiment, R10 represents a hydrogen atom. Accordingly, the initiator system further comprises a sensitizer compound. The sensitizer compound is preferably an alpha-diketone sensitizer compound having a light absorption maximum in the range from 300 to 500 nm. The alpha-diketone sensitizer is capable of absorbing visible light and forming a photoexcitation complex with a hydrogen donating compound of formula (XIII). The alpha-diketone photoinitiator compound may be selected from camphorquinone, 1,2-diphenylethane-1,2-dione (benzil), 1,2-cyclohexanedione, 2,3-pentanedione, 2,3-hexanedione, 3,4-hexanedione, 2,3-heptanedione, 3,4-heptanedione glyoxal, biacetyl, 3,3,6,6-tetramethylcyclohexanedione, 3,3,7,7-tetramethyl-1,2-cycloheptanedione, 3,3,8,8-tetramethyl-1,2-cyclooctanedione; 3,3,18,18-tetramethyl-1,2-cyclooctadecanedione; dipivaloyl; furil, hydroxybenzil, 2,3-butanedione, 2,3-octanedione, 4,5-octanedione, and 1-phenyl-1,2-propanedione. Camphorquinone is the most preferred alpha-diketone photoinitiator. According to a preferred embodiment, the light-curable dental impression material contains the alpha-diketone sensitizer in an amount from 0.01 to 5 percent by weight, based on the total weight of composition.
Preferably, in the compounds of formula (XIII), M is Si.
For example, compounds of formula (XIII) wherein R11 has the formula (XV) and which are symmetrical may be have the following structural formulae:
For example, compounds of formula (XIII) wherein R11 represents a group of formula (XVI) wherein X is a bond, an oxygen atom or a NRX1 group, and R* represents a substituted or unsubstituted hydrocarbyl group may have the following structural formulae:
For example, compounds of formula (XIII) wherein R represents a group of formula (XVI) wherein R* represents a trihydrocarbylsilyl group have the following structural formulae:
For example, compounds of formula (XIII) wherein M is Si and R11 represents a substituted or unsubstituted hydrocarbyl group may have the following structural formulae:
Preferably, compound of formula (XIII) is selected from the group consisting of:
wherein compounds of formula (XIII) with M=Si are particularly preferred.
More preferably, compound of formula (XIII) is selected from the group consisting of:
wherein it is particularly preferred that M=Si.
Most preferably, compound of formula (XIII) is tert-butyl (tert-butyldimethylsilyl)glyoxylate) (DKSi).
A suitable photoinitiator system may also include phosphine oxides typically having a functional wavelength range of about 380 nm to about 1200 nm. Examples of phosphine oxide free radical initiators with a functional wavelength range of about 380 nm to about 450 nm include acyl and bisacyl phosphine oxides such as those described in U.S. Pat. No. 4,298,738, U.S. Pat. No. 4,324,744 U.S. Pat. No. 4,385,109 and EP 0 173 567. Specific examples of the acylphosphine oxides include 2,4,6-trimethylbenzoyldiphenylphosphine oxide, bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, dibenzoylphenylphosphine oxide, bis(2,6-dimethoxybenzoyl)phenylphosphine oxide, tris(2,4-dimethylbenzoyl)phosphine oxide, tris(2-methoxybenzoyl)phosphine oxide, 2,6-dimethoxybenzoyldiphenylphosphine oxide, 2,6-dichlorobenzoyldiphenylphosphine oxide, 2,3,5,6-tetramethylbenzoyldiphenylphosphine oxide, benzoyl-bis(2,6-dimethylphenyl)phosphonate, and 2,4,6-trimethylbenzoylethoxyphenylphosphine oxide. Commercially available phosphine oxide photoinitiators capable of free-radical initiation when irradiated at wavelength ranges of greater than about 380 nm to about 450 nm include bis(2,4,6-trimethylbenzoyl)phenyl phosphine oxide (IRGACURE 819), bis(2,6-dimethoxybenzoyl)-(2,4,4-trimethylpentyl) phosphine oxide (CGI 403), a 25:75 mixture, by weight, of bis(2,6-dimethoxybenzoyl)-2,4,4-trimethylpentyl phosphine oxide and 2-hydroxy-2-methyl-1-phenylpropan-1-one (IRGACURE 1700), a 1:1 mixture, by weight, of bis(2,4,6-trimethylbenzoyl)phenyl phosphine oxide and 2-hydroxy-2-methyl-1-phenylpropane-1-one (DAROCUR 4265), and ethyl 2,4,6-trimethylbenzylphenyl phosphinate (LUCIRIN LR8893X). Typically, the phosphine oxide initiator is present in the composition in catalytically effective amounts, such as from 0.01 percent by weight to 5.0 percent by weight, based on the total weight of the composition.
Suitable electron donor compounds include substituted amines, e.g., ethyl dimethylaminobenzoate and/or dimethylamino benzonitrile.
Tertiary amine reducing agents may be used in combination with an acylphosphine oxide Examples of suitable aromatic tertiary amine include N,N-dimethylaniline, N,N-dimethyl-p-toluidine, N,N-dimethyl-m-toluidine,
N,N-dimethyl-3,5-dimethylaniline, N,N-dimethyl-3,4-dimethylaniline, N,N-dimethyl-4-ethylaniline, N,N-dimethyl-4-isopropylaniline, N,N-dimethyl-4-t-butylaniline, N,N-dimethyl-3,5-di-t-butylaniline, N,N-bis(2-hydroxyethyl)-3,5-dimethylaniline, N,N-bis(2-hydroxyethyl)-p-toluidine, N,N-bis(2-hydroxyethyl)-3,4-dimethylaniline, N,N-bis(2-hydroxyethyl)-4-ethylaniline, N,N-bis(2-hydroxyethyl)-4-isopropylaniline, N,N-bis(2-hydroxyethyl)-4-t-butylaniline, N,N-bis(2-hydroxyethyl)-3,5-di-isopropylaniline, N,N-bis(2-hydroxyethyl)-3,5-di-t-butylaniline, 4-N,N-dimethylaminobenzoic acid ethyl ester, 4-N,N-dimethylaminobenzoic acid methyl ester, 4-N,N-dimethylaminobenzoic acid n-butoxyethyl ester, 4-N,N-dimethylaminobenzoic acid 2-(methacryloyloxy) ethyl ester, 4-N, N-dimethylaminobenzophenone ethyl 4-(N,N-dimethylamino)benzoate and N,N-dimethylaminoethyl methacrylate. Examples of an aliphatic tertiary amine include trimethylamine, triethylamine, N-methyldiethanolamine, N-ethyldiethanolamine, N-n-butyldiethanolamine, N-lauryldiethanolamine, triethanolamine, 2-(dimethylamino) ethyl methacrylate, N-methyldiethanolamine dimethacrylate, N-ethyldiethanolamine dimethacrylate, triethanolamine monomethacrylate, triethanolamine dimethacrylate, and triethanolamine trimethacrylate.
One or more amine reducing agents may be present in the composition in an amount from 0.01 percent by weight to 5.0 percent by weight, based on the total weight of the composition.
According to a further preferred embodiment, the photo initiator further comprises an iodonium compound of the following formula (XVII):
R12-l+-R13A− (XVII)
wherein
R12 and R13
which are independent from each other, represent an organic moiety, and
A− is an anion;
For example, diaryl iodonium salt may be selected from (4-methylphenyl)[4-(2-methylpropyl) phenyl] iodonium hexafluoroantimonate, include (4-methylphenyl)[4-(2-methylpropyl) phenyl] iodonium tetrafluoroborate, diphenyliodonium (DPI) tetrafluoroborate, di(4-methylphenyl)iodonium (Me2-DPI) tetrafluoroborate, phenyl-4-methylphenyliodonium tetrafluoroborate, di(4-heptylphenyl)iodonium tetrafluoroborate, di(3-nitrophenyl)iodonium hexafluorophosphate, di(4-chlorophenyl)iodonium hexafluorophosphate, di(naphthyl)iodonium tetrafluoroborate, di(4-trifluoromethylphenyl)iodonium tetrafluoroborate, DPI hexafluorophosphate, Met-DPI hexafluorophosphate; DPI hexafluoroarsenate, di(4-phenoxyphenyl)iodonium tetrafluoroborat, phenyl-2-thienyliodoniurn hexafluorophosphate, 3,5-dimethylpyrazolyl-4-phenyliodonium hexafluorophosphate, DPI hexafluoroantimonate, 2,2′-DPI tetrafluoroborate, di(2,4-dichlorophenyl)iodonium hexafluorophosphate, di(4-bromophenyl)iodonium hexafluorophosphate, di(4-methoxyphenylpiodonium hexafluorophosphate, di(3-carboxyphenyl)iodonium hexafluorophosphate, di(3-methoxycarbonylphenyl)iodonium hexafluorophosphate, di(3-methoxysulfonylphenyl)iodonium hexafluorophosphate, di(4-acetamidophenyl)iodonium hexafluorophosphate, di(2-benzothienyl)iodonium hexafluorophosphate, and DPI hexafluorophosphate.
Particularly preferred iodonium compounds include diphenyliodonium (DPI) hexafluorophosphate, di(4-methyl phenyl)iodonium (Me2-DPI) hexafluorophosphate, diaryliodonium hexafluoroantimonate, (4-methylphenyl)[4-(2-methylpropyl) phenyl] iodonium hexafluoroantimonate, (4-methylphenyl)[4-(2-methylpropyl)phenyl]iodonium hexafluorophosphate (Irgacure® 250, commercial product available from BASF SE), (4-methylphenyl)[4-(2-methylpropyl) phenyl] iodonium tetrafluoroborate, 4-octyloxyphenyl phenyliodonium hexafluoroantimonate, 4-(2-hydroxytetradecyloxyphenyl)phenyliodonium hexafluoroantimonate, and 4-isopropyl-4′-methyldiphenyliodonium borate.
According to a particularly preferred embodiment, the iodonium compound is DPI hexafluorophosphate and/or 4-isopropyl-4′-methyldiphenyliodonium tetrakis(pentafluorophenyl) borate.
According to a further preferred embodiment, the photo initiator further comprises a sulfonium compound of the following formula (XVIII):
R14R15R16S+A− (XVIII)
wherein
R14, R15 and R16
which are independent from each other, represent an organic moiety or wherein any two of R14, R15 and R16 form a cyclic structure together with the sulfur atom to which they are bound, and
A− is an anion.
A preferred triaryl sulfonium salt is S-(phenyl)thianthrenium hexafluorophosphate:
According to a further preferred embodiment, the photo initiator further comprises a phosphonium compound of the following formula (XIX):
R17R18R19R20P30 A− (XIX)
wherein
R17, R18, R19, and R20
which are independent from each other, represent an organic moiety, and
A− is an anion.
Particularly preferred phosphonium salts are the tetraalkyl phosphonium salts tetrakis-(hydroxymethyl)-phosphonium (THP) salt or a tetrakis-(hydroxymethyl)-phosphonium hydroxide (THPOH) salt, wherein the anion of the tetraalkyl phosphonium salt is selected from the group consisting of formate, acetate, phosphate, sulphate, fluoride, chloride, bromide and iodide.
According to a preferred embodiment, the light-curable dental impression material comprises 0.01 to 5 percent by weight, alternatively 0.1 to 5 percent by weight, more preferably 1 to 4 percent by weight, based on the total weight of the light-curable dental impression material, of a photoinitiator.
Optional Polymerizable (Meth)Acrylates or (Meth)Acrylamides
The light-curable dental impression material of the present invention may further comprise with up to 20 percent by weight based on the total weight of the composition of polymerizable (meth)acrylates or (meth)acrylamides.
The (meth)acrylate compounds may be selected from methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, isopropyl acrylate, isopropyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate (HEMA), hydroxypropyl acrylate, hydroxypropyl methacrylate, tetrahydrofurfuryl acrylate, tetrahydrofurfuryl methacrylate, glycidyl acrylate, glycidyl methacrylate, bisphenol A glycerolate dimethacrylat (“bis-GMA”, CAS-No. 1565-94-2), 4,4,6,16 (or 4,6,6,16)-tetramethyl-10,15-dioxo-11,14-dioxa-2,9-diazaheptadec-16-enoicacid 2-[(2-methyl-1-oxo-2-propen-1-yl)oxy]ethyl ester (CAS no. 72869-86-4)_(UDMA), glycerol mono-and di- acrylate such as 1,3-glycerol dimethacrylate (GDM), glycerol mono-and dimethacrylate, ethyleneglycol diacrylate, ethyleneglycol dimethacrylate, polyethyleneglycol diacrylate (where the number of repeating ethylene oxide units vary from 2 to 30), polyethyleneglycol dimethacrylate (where the number of repeating ethylene oxide units vary from 2 to 30 especially triethylene glycol dimethacrylate (“TEGDMA”), neopentyl glycol diacrylate, neopentylglycol dimethacrylate, trimethylolpropane triacrylate, trimethylol propane trimethacrylate, mono-, di-, tri-, and tetra- acrylates and methacrylates of pentaerythritol and dipentaerythritol, 1,3-butanediol diacrylate, 1,3-butanediol dimethacrylate, 1,4-butanedioldiacrylate, 1,4-butanediol dimethacrylate, 1,6-hexane diol diacrylate, 1,6-hexanediol dimethacrylate, di-2-methacryloyloxethyl hexamethylene dicarbamate, di-2-methacryloyloxyethyl trimethylhexanethylene dicarbamate, di-2-methacryloyl oxyethyl dimethylbenzene dicarbamate, methylene-bis-2-methacryloxyethyl-4-cyclohexyl carbamate, di-2-methacryloxyethyl-dimethylcyclohexane dicarbamate, methylene-bis-2-methacryloxyethyl-4-cyclohexyl carbamate, di-1-methyl-2-methacryloxyethyl-trimethyl-hexamethylene dicarbamate, di-1-methyl-2-methacryloxyethyl-dimethylbenzene dicarbamate, di-1-methyl-2-methacryloxyethyl-dimethylcyclohexane dicarbamate, methylene-bis-1-methyl-2-methacryloxyethyl-4-cyclohexyl carbamate, di-1-chloromethyl-2-methacryloxyethyl-hexamethylene dicarbamate, di-1-chloromethyl-2-methacryloxyethyl-trimethylhexamethylene dicarbamate, di-1-chloromethyl-2-methacryloxyethyl-dimethylbenzene dicarbamate, di-1- chloromethyl-2-methacryloxyethyl-dimethylcyclohexane dicarbamate, methylene-bis-2-methacryloxyethyl-4-cyclohexyl carbamate, di-1-methyl-2-methacryloxyethyl-hexamethylene dicarbamate, di-1-methyl-2-methacryloxyethyl-trimethylhexamethylene dicarbamate, di-1-methyl-2-methacryloxyethyl-dimethylbenzene dicarbamate, di-1-methyl-2-metha-cryloxyethyl-dimethylcyclohexane dicarbamate, methylene-bis-1-methyl-2-methacryloxyethyl-4-cyclohexyl carbamate, di-1-chloromethyl-2-methacryloxyethyl-hexamethylene dicarbamate, di-1-chloromethyl-2-methacryloxyethyl-trimethylhexamethylene dicarbamate, di-1-chloromethyl-2-methacryloxyethyl-dimethylbenzene dicarbamate, di-1-chloromethyl-2-methacryloxyethyl-dimethylcyclohexane dicarbamate, methylene-bis-1-chloromethyl-2-methacryloxyethyl-4-cyclohexyl carbamate, 2,2′-bis(4-methacryloxyphenyl)propane, 2,2′bis(4-acryloxyphenyl)propane, 2,2′-bis[4(2-hydroxy-3-methacryloxy-phenyl)]propane, 2,2′-bis[4(2-hydroxy-3-acryloxy-phenyl)propane, 2,2′-bis(4-methacryloxyethoxyphenyl)propane, 2,Z-bis(4-acryloxyethoxyphenyl)propane, 2,2′-bis(4-methacryloxypropoxyphenyl)propane, 2,2′-bis(4-acryloxypropoxyphenyl)propane, 2,2′-bis(4-methacryloxydiethoxyphenyl)propane, 2,2′-bis(4-acryloxydiethoxyphenyl)propane, 2,2′-bis[3(4-phenoxy)-2-hydroxypropane-1-methacrylate]propane, and 2,2′-bis[3(4-phenoxy)-2-hydroxypropane-1-acrylatelpropane.
Preferred (meth)acrylamides may be selected from the following compounds.
Most preferred are the bis-(meth)acrylamides:
N,N′-diallyl-1,4- bisacrylamido-(2E)-but-2-en (BAABE) having the structural formula
and
N,N′-diethyl-1,3-bisacrylamido-propan (BADEP) having the structural formula
Further Components
Optionally, the light-curable dental impression material of the present invention may further comprise stabilizer(s), plasticizers, dyes/pigments and/or flavorants/sweeteners. Moreover, the light-curable dental impression material of the present invention may further comprise cationically polymerizable monomers.
The term “stabilizer” as used herein means any compound capable of preventing polymerizable compounds contained in the light-curable dental impression material from spontaneous polymerization during storage. However, the stabilizer does not disturb or prevent intended polymerisation curing of the light-curable dental impression material during application.
For example, the stabilizer may be a conventional stabilizer selected from the group consisting of hydroquinone, hydroquinone monomethylether, tert-butyl-hydroquinone, tert-butylhydroxyanisol, propyl gallate and 2,6-di-tert-butyl-p-cresol. From these conventional stabilizers, 2,6-di-tert-butyl-p-cresol is preferred. Furthermore, anaerobic stabilizers such TEMPO, phenothiazine, galvanoxyl radical may be used.
The light-curable dental impression material according to the invention may contain the stabilizer in an amount of 0.001 to 1 percent by weight, preferably 0.005 to 0.8 percent by weight based on the total weight of the composition. When the amount of the stabilizer is below the above indicated lower limit of 0.001, then storage stability of the light-curable dental impression material might be insufficient, since the amount of stabilizer is too small to provide a stabilizing effect. However, when the amount of stabilizer is above the maximum threshold of 1 percent by weight, then the applicability of the light-curable dental impression material might be negatively affected, since higher amounts of stabilizer may disturb or even substantially prevent intended polymerization curing of the light-curable dental impression material during application.
The light-curable dental impression material according to the invention may contain one or more plasticizers so as to improve the softness of impression material upon curing, reduce the affinity between cured impression and dental substrate, and enhance clean removal of the impression from dental substrate. Suitable plasticizers are nontoxic in the oral environment and may include, for example, mineral oils, vegetable oils, hydrogenated vegetable oils, silicone oils, phthalate derivatives such as dibutyl phthalate, diethyl phthalate and dioctyl phthalate, fatty alcohols, fatty (meth)acrylates, glycerin, glycerides, and other macromolecules such as polyethylene glycols, polypropylene glycols, polytetrahydrofurans, polyvinyl alcohols, polyether-modified polysiloxanes, xathan gum, cellulosepolyalkylene glycols and hydrocarbon waxes including their halogenated and/or hydrogenated derivatives.
The light-curable dental impression material may comprise 0.1 to 20 wt. % plasticizer, optionally 1 to 10 wt. % plasticizer, based on the total weight of the composition.
The dyes and pigments are selected in such a way that they render color to the light-curable dental impression material while imparting no or low absorption and scattering of the actinic light as measured by, for example, UV-Vis spectroscopy.
Suitable dyes and pigments are soluble in the polymerizable resin matrix, or have a mean particle size in the range of from 0.05 to 75 μm as measured, for example, by electron microscopy or by using a conventional laser diffraction particle sizing method. In some embodiments, thermochromic pigments including leuco dyes and thermochromic liquid crystals are used that, upon heating at physiological temperatures, change from high-absorbance color to low-absorbance color within the wave length range of actinic light.
The light-curable dental impression material may comprise 1 ppm to 10% of dyes and/or pigments by weight, optionally 4 ppm to 5% by weight, based on the total weight of the composition.
According to a specific embodiment, the light-curable dental impression material according to the invention may include additional cationic polymerizable resins including a compound having one or more cationic polymerizable groups according to the following formula (XX).
wherein
Preferably, K represents a vinyl ether group, a vinyl ester group, a vinyl siloxane group, an epoxide group, an oxetane group and a furane group.
More preferably, K represents a vinyl ether group and a vinyl ester group, most preferably K represents a vinyl ether group.
Preferably, R21 represents an o-valent C1-30 hydrocarbyl groups which may contain 1-15 heteroatoms selected from O, S, Si, and which may be substituted by 1-15 substituents selected from C1-4 alkyl groups, C4-10 aryl groups, C4-9 heteroaryl groups, halogen atoms, C1-4 alkoxy groups, ester groups, thioether groups, silyl groups, and siloxane groups.
The hydrocarbyl group may be an alkyl group, a cycloalkyl group, a cycloalkylalkyl group, an arylalkyl group or an aryl group.
An alkyl group may be straight-chain or branched C1-30 alkyl group, typically a C1-6 alkyl group. Examples for a C1-6 alkyl group can include linear or branched alkyl groups having 1 to 6 carbon atoms, preferably 1 to 4 carbon atoms, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl and n-hexyl.
A cycloalkyl group may be a C3-20 cycloalkyl group, typically a C3-8 cycloalkyl group. Examples of the cycloalkyl group can include those having 3 to 6 carbon atoms, for example, cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.
A cycloalkylalkyl group may have 4 to 20 carbon atoms and may include a combination of a linear or branched alkyl group having 1 to 6 carbon atoms and a cycloalkyl group having 3 to 14 carbon atoms. Examples of the cycloalkylalkyl group can for example, include methylcyclopropyl, methylcyclobutyl, methylcyclopentyl, methylcyclohexyl, ethylcyclopropyl, ethylcyclobutyl, ethylcyclopentyl, ethylcyclohexyl, propylcyclopropyl, propylcyclobutyl, propylcyclopentyl, propylcyclohexyl.
An arylalkyl group may be a C7-20 arylalkyl group, typically a combination of a linear or branched alkyl group having 1 to 6 carbon atoms and an aryl group having 6 to 10 carbon atoms. Specific examples of an arylalkyl group are a benzyl group or a phenylethyl group.
An aryl group can include aryl groups having 6 to 10 carbon atoms. Examples of the aryl group are phenyl and naphthyl.
The hydrocarbylcarbonyl groups of R21 represent acyl groups (R22-(C═O)—) in which the organic residue R22 is a hydrocarbyl residue as defined above.
Preferably, the hydrocarbylcarbonyl group is an arylcarbonyl group, more preferably a benzoyl group.
Preferably, R21 is selected from the group consisting of a straight chain or branched C1-6 alkyl group, and a phenyl or benzoyl group which may optionally be substituted by one to three substitutents selected from halogen atoms, C1-4 alkoxy groups.
Preferably, o is between 1 and 4, more preferably o is 2.
More preferably, the reactive diluent is a compound of the formula (XXI)
wherein
R23 and R26
In a preferable embodiment, X′ represents an oxygen atom, R24 represents a hydrogen atom, or a methyl group, R25 represents a hydrogen atom, R23 and R26 represent vinyl groups, more preferable X′ represents an oxygen atom, R24 and R25 represent a hydrogen atom, R23 and R26 represent vinyl groups.
A particular suitable reactive diluent is ethylene glycol vinyl ether.
The present invention also provides the use of the light-curable dental impression material according to the present invention for the preparation of a dental impression.
It was found that the acid residues in the raw material Silmer OH Di-10 (a hydroxyl-terminated siloxane) have a significant negative impact on the performance of the formulated composition from the polymerizable resin B derived from hydroxyl-terminated siloxanes. Due to the inconsistent quality of off the shelf/impure hydroxyl-terminated siloxane from the same manufacturer and/or different manufacturers, efforts were made to identify the root causes of such inconsistent quality of off the shelf/impure raw materials. Once the active impurities were identified, an effective process was developed to remove/clean up those active impurities in order to ensure good quality of hydroxyl-terminated siloxanes as well as performance of formulated composition from the polymerizable resin B derived from such treated hydroxyl-terminated siloxanes.
“off the shelf” and “impure” are used interchangeably.
The active impurities that were identified include allyl alcohol, aldehydes and acids, along with additional unidentified compounds. Generally high acid values of 0.25-0.55 mgKOH/g were found from such off the shelf hydroxyl-terminated siloxanes (Silmer OH Di-10 from Siltech or DMS-C16 from Gelest), which was designated as low quality hydroxyl-terminated siloxanes. It was also found that some off the shelf materials could readily turn into low quality hydroxyl-terminated siloxanes with increasing acid value, due to normal aging at room temperature.
Solid acid-absorbent materials were used to treat low quality hydroxyl-terminated siloxanes in order to ensure good quality of hydroxyl-terminated siloxanes.
In an embodiment, a light curable dental impression material having improved shore hardness and improved tear strength may be provided. The impression material comprises a polymerizable polysiloxane resin mixture obtained by a process comprising steps of:
to form the polymerizable polysiloxane resin mixture.
In one embodiment of the light curable dental impression material, the polymerizable polysiloxane resin composition comprises compounds of the following formula (I):
E-(L1-Z)n-L2-E (I)
In certain embodiment of the light curable dental impression material; L2 and/or L3 and/or L4 independently represent a polysiloxane group of the following formula (VIIIa)
wherein
R1# is an alkylene having 1 to 8 carbon atoms;
R2# is an alkyl having from 1 to 4 carbon atoms; and
y# is an integer from 5 to 20;
In one embodiment of the light curable dental impression material; the L4″ is a group formula (VII):
wherein
Rb1, Rb2, Rb3 and Rb4; which is a same or different, independently represent a hydrogen atom, a C1-6 linear or branched alkyl group, a C4-10 aryl group, a polymerizable double bond containing organic residue, a group of the following formula [-X′″L′″]mRb5, wherein X′″ represents O, S, or NRb6 wherein Rb6 represents a hydrogen atom, an organic residue containing a polymerizable double bond, a linear or branched C1-6 alkyl group, or a C4-10 aryl group, L′″ represents a C1-6 linear or branched alkyl group, a C4-10 aryl group, or a SiRb72 group wherein Rb7 which is a same or different, independently represent an organic residue containing a polymerizable double bond or a C1-4 alkyl group, m is an integer from 1 to 20, and Rb5 is an organic residue containing a polymerizable double bond, a C1-4 alkyl group or a C4-10 aryl group; X5 and X6 which is a same or different, and when more than one X5 or X6, are present, the X5 and X6 is the same or different, independently represent an oxygen atom, a sulfur atom and a group NRN, wherein RN is a hydrogen atom or a C1-4 alkyl group;
L6 is a divalent hydrocarbon linker group;
e is an integer of from 1 to 10;
f is an integer of from 1 to 100; and
g is 0 or 1;
According to a preferred embodiment, the group -[L6-X5]- is selected from the following groups:
In an embodiment of the light curable dental impression material, L3 is selected from the following groups:
In one aspect, a process is provided for preparing a polymerizable polysiloxane resin mixture. The process includes the following steps:
(a) treating an impure diol compound of formula (Xa)
HO-L4(OH) (Xa)
with a solid acid absorbent material to obtain purified compound of formula (Xa).
(b) reacting a mixture comprising:
(i) x equivalents of purified compound of formula (Xa) and one or more di or polyol compounds of the following formula
HO-L4″(OH)l″ (X)
(ii) y equivalents of one or more compounds of a following formula (XI):
OCN-L3NCO (XI)
(iii) z equivalents of one or more compounds of a following formula (XII):
Examples of solid acid-absorbent materials may include activated basic alumina oxide (Al2O3), molecular sieve (MS), weak basic ion-exchange resin such as Amberlyst A21 or combination thereof. Activated basic alumina oxide (Al2O3) and molecular sieve (MS) were used to treat low quality hydroxyl-terminated siloxanes such as silmer monomers with acid value of 0.234-0.297 mgKOH/g (lot#11801005 and lot# 11804022). There was not only significant reduction in total acid value from 0.234-0.297 mgKOH/g to 0.056 mgKOH/g but also increased pH (as evident from Table 15, 16 and 17). More importantly, the polymerizable urethane-polyether-siloxane copolymer could offer significantly enhanced mechanical properties, such as Shore A Harness and Tear Strength, respectively, in its formulated compositions (as depicted in
The solid acid-absorbent material is added in an amount of from 1-10% wt/wt based on total weight of the off the shelf/impure hydroxyl-terminated siloxanes; alternatively from 1-5% based on total weight of the off the shelf hydroxyl-terminated siloxanes. 5-10%, wt/wt of such basic Al2O3 were found to work well. Molecular sieve is optional to reduce total moisture during such treatment. It was also demonstrated weak basic ion-exchange resin, Amberlyst A21, also work well to remove acidic impurities from low quality hydroxyl-terminated siloxane to allow them to regain good mechanical properties. Such effectiveness is evident by reduced low acid value (<0.06 mgKOH/g) to achieve higher pH (>4.0); complete removal of allyl alcohol; regained high reactivity in urethane reactions with increased exothermic temperature; consistent results of good mechanical properties for formulated TRON Pastes from Resin B derived from such pretreated Silmer monomers.
The present invention will now be further illustrated based on the following examples.
Siloxane-Modified Genesis Resin (
The following raw materials were used.
Dry air was purged through a 1000 mL resin reaction kettle and the jack temperature was set at 500C. Trimethyl hexamethylene diisocyanate (TMDI)(121.7 g, 0.58 mol) was added to the reaction kettle, followed by addition of Voranol-220-028 (466.8 g, 0.12 mol), and then Silmer monomer (284.0 g, 0.29 mol), and 0.31 g of urethane catalyst (K-Kat®348, a Bismuth Carboxylate from King Industries) into the reaction system. The reaction was kept for additional 2-3 hours. Then sample was taken for analysis by FTIR and NMR to make sure all of hydroxyl group got reacted prior to proceeding to the next step. PEGMA (116.6 g, 0.32 mol) was added slowly to the reaction system for 30 min. The reaction was maintained at 50° C. for another 2 hours. Then 1-dodecanol (118.2 g, 0.10 mol) was added slowly into the system. The reaction was kept at 50° C. overnight, then butylated hydroxy toluene (BHT) (0.4 g) was added to the system prior to discharge. Sampling was made for FTIR and NMR. The resin was placed in 45° C. to clear out all the trapped air bubbles. Viscosity of 11 Pa.s @25° C. resulted with MA content as 0.32 mmol/g and siloxane content as 28.2% wt/wt.
In a similar manner as described in Preparation Example 1, further siloxane-modified polyether-urethane dimethacrylate macromonomers were prepared.
The composition and properties of macromonomers of Preparative Examples 1 to 14 are as shown in the following Tables 1 and 2
PEGMA-modified Genesis Resin as Additional Polymerizable Macromonomers (
The following raw materials were used.
Dry air was purged through a 1000 mL resin reaction kettle and the jack temperature was set at 50° C. Trimethyl hexamethylene diisocyanate (TMDI) (105.35 g, 0.50 mol) was added to the reaction kettle, followed by addition of Voranol 220-056 (400.4 g, 0.20 mol, Voranol 220-028 (400.6 g, 0.10 mol) and 0.304 g of urethane catalyst (K-Kat®348, a Bismuth Carboxylate from King Industries) into the reaction system. The reaction was kept for additional 2-3 hours. Then sample was taken for analysis by FTIR and NMR to make sure all of hydroxyl group got reacted prior to proceeding to the next step. PEGMA (161.9 g, 0.45 mol) was added slowly to the reaction system for 60 min. The reaction was kept at 50° C. overnight, then 0.4 g of BHT was added to the system prior to discharge. Sampling was made for FTIR and NMR. The resin was placed in 45° C. to clear out all the trapped air bubbles. Viscosity of 24 Pa.s @25° C. was resulted with MA content as 0.42 mmol/g.
In a similar manner as described in Reference Example 15, further PEGMA-modified polyether-urethane dimethacrylate macromonomers were prepared.
The composition and properties of macromonomers of Reference Examples 15 to 39 are as shown in the following Tables 3 and 4
The effect of the molecular weight of carbinols on the appearance of the siloxane-modified macromonomers was investigated. The results are summarized in Table 5.
Further additional polymerizable macromonomers in the form of trimethacrylated polyethers derived from Carpol triols were prepared as high molecular weight crosslinkers in accordance with the scheme shown in
Standard Genesis Resin with T-9 via TMDI to Voranol Process (T2V):
Dry air was purged through a 1000 mL resin reaction kettle and the jack temperature was set at 50° C. Voranol-220-056 (545.01 g, 0.2726 mol) and urethane catalyst (T-9) (0.12 g) was added to the reaction kettle. Thereafter, trimethyl hexamethylene diisocyanate (TMDI) (114.22 g, 0.5431 mol) was charged into an additional funnel and started adding slowly into the reaction system through 2 hours. Then sample was taken for analysis by FTIR and NMR. HEMA (28.6 g) was added to the reaction system in 30 min, then 34.47 g of 1,4-butanediol (BDO) was charged into the system in 30 min too. The reaction was kept for 1 hr at 50° C., TIM preblend (ICEM) (65.01 g) was added in 30 min and it was kept further for overnight reaction at 50° C., finally additional 13.7 g of HEMA was added into the system. The reaction was kept in mixing at 50° C. overnight. BHT (0.4 g) was added to the system prior to discharge. Sampling was made for FTIR and NMR. The resin was placed in 45° C. to clear out all the trapped air bubbles. Viscosity of 55 Pa.s@25° C. was resulted.
Standard Genesis Resin with K-KAT via TMDI to Voranol Process (T2V):
Dry air was purged through a 1000 mL resin reaction kettle and the jack temperature was set at 50° C. Voranol-220-056 (546.27 g, 0.2732 mol) and 0.14 g of urethane catalyst (K-Kat®348, a bismuth carboxylate from King Industries) was added to the reaction kettle. Then trimethylhexamethylene diisocyanate (TMDI) (114.65 g, 0.5452 mol) was charged into an additional funnel and started adding slowly into the reaction system through 2 hours. Then sample was taken for analysis by FTIR and NMR. HEMA (26.6 g) was added to the reaction system in 30 min, then 34.47 g of 1,4 butanediol (BDO) was charged into the system in 30 min too. The reaction was kept for 1 hr at 50° C. TIM preblend (ICEM) (64.86 g) was added in 30 min and the reaction was kept further for overnight reaction at 50° C., finally additional 13.06 g of HEMA was added into the system. The reaction was kept in mixing at 50° C. overnight. 0.4 g of BHT was added to the system prior to discharge. Sampling was made for FTIR and NMR. The resin was placed in 45° C. to clear out all the trapped air bubbles. Viscosity of 120 Pa.s @25° C. was resulted.
Modified Genesis Resin with K-KAT via Voranol to TMDI Process (V2T):
Dry air was purged through a 1000 mL resin reaction kettle and the jack temperature was set at 50° C. Trimethyl hexamethylene diisocyanate (TMDI) (154.73 g (0.7358 mol) and 0.15 g of urethane catalyst (K-Kat®348, a Bismuth Carboxylate from King Industries) was added to the reaction kettle. Thereafter, Voranol-220-056 (545.77 g, 0.273 mol) was charged into an additional funnel started adding slowly into into the reaction system through 2 hours. Then sample was taken for analysis by FTIR and NMR. HEMA (39.04 g, 0.300 mol) was added to the reaction system in 30 min, then 31.5 (0.35 mol) of 1,4 butanediol (BDO) was charged into the system in 30 min too. The reaction was kept in mixing at 50° C. overnight, then 0.4 g of BHT was added to the system prior to discharge. Sampling was made for FTIR and NMR. The resin was placed in 45° C. to clear out all the trapped air bubbles. Viscosity of 90 Pa.s @25° C. was resulted.
Modified Genesis Resin with K-KAT via All-in One Process (All-in-One):
Dry air was purged through a 1000 mL resin reaction kettle and the jack temperature was set at 50° C. Trimethyl hexamethylene diisocyanate (TMDI) (154.73 g (0.7358 mol), Voranol-220-056 (545.95 g, 0.273 mol), HEMA (64.71 g, 0.497 mol), of 1,4 Butanediol (BDO) (34.77, 0.3858 mol) and 0.27 g of urethane catalyst (K-Kat®348, a bismuth carboxylate from King Industries) was added to the reaction kettle. The reaction was kept in mixing at 50° C. overnight, then 0.4 g of BHT was added to the system prior to discharge. Sampling was made for FTIR and NMR. The resin was placed in 45° C. to clear out all the trapped air bubbles. Viscosity of 15 Pa.s @25° C. was resulted.
The composition and properties of the additional polymerizable macromonomers are summarized in Tables 7 to 10.
It was unexpectedly discovered that dosing certain amount (10-30% wt/wt) of Resin B with Resin A could effectively improve the mechanical properties (Shore A hardness and tear strength) from such formulated pastes for both light body and heavy body impression materials, see Table 14A. Further increase in load of Resin B in the mixture could not offer any such performance enhancement.
Combo Resins with 90/10 or 80/20 of Resin A comprising compounds of the formula (I) without any polysiloxane group and Resin B comprising compounds of the formula (I) according to the present invention, were also prepared by mixing all components of Resin A and Resin B in feed compositions (see Table 11) as part of composition approach to further reduce the reaction rate involved in hydroxyl-terminated siloxane monomer. Indeed moderate temperature raisings of 5° C. in 80/20 combo resin (ZZ2-4) and 9° C. in 90/10 combo resin (ZZ1-208) in comparison to 12° C. in Resin B only were found in such direct synthesis of Resin A and Resin B in 90/10 or 80/20 compositions.
Further, such Combo Resins were formulated (see Table 12) and pastes were made (Table 13) and evaluated (Table 14B), accordingly with the following test methods.
1. Depth of Cure and Shore A Hardness:
Impression material is extruded in a cylindrical mold with 20-mm height and 12-mm inner diameter, and cured from one side for 30 seconds using a blue LED light source with 60±5 mW/cm2 intensity and peak wave length at 460±10 nm. The Depth of Cure is determined by measuring the height of cured specimen after removing the uncured portion. The Shore A Hardness is measured by a durometer on the cross section of cured specimen at 10-mm depth of cure.
2. Compression set (Recovery) OLD Method:
Impression material is extruded in a cylindrical mold with 10-mm height and 8-mm inner diameter, and cured from one side for 20 seconds using a blue LED light source with 1000±100 mW/cm2 intensity and peak wave length at 460±10 nm. Counting from the time when light curing is completed, the height of the cured specimen is measured at 0′55″ (recorded as A). At 1′00″, the cured specimen is compressed by 30% (to a height of 7 mm) for 5 seconds, and then allowed to recover under no load. At 3′00″, the height of the specimen is measured again (recorded as B). The recovery is calculated as (1−(A−B)/10)×100%.
3. Compression Set (Recovery) NEW Method:
Impression material is extruded in a cylindrical mold with 20-mm height and 12.5-mm inner diameter, and cured from both sides for 90 seconds (45 seconds each side) using a blue LED light source with 60±5 mW/cm2 intensity and peak wave length at 460±10 nm. Counting from the time when light curing is completed, the height of the cured specimen is measured at 0′55″ (recorded as A). At 1′00″, the cured specimen is compressed by 30% (to a height of 14 mm) within 1 second, and the deforming force is slowly released over a period of 5 seconds, after which the cured specimen is allowed to recover under no load. At 3′00″, the height of the specimen is measured again (recorded as B). The recovery is calculated as (1−(A−B)/20)×100%.
4. Tear Strength OLD Method:
Impression material is extruded in a dog bone-shaped mold. The material is cured either for 30 seconds in a halogen light oven such as Triad 2000 (Dentsply Sirona), or for 45 seconds using a blue LED light source with 60±5 mW/cm2 intensity and peak wave length at 460±10 nm. Within 2 hours following curing completion, the specimen is subject to tensile elongation at a crosshead speed of 100 mm/min. The tear strength is determined as the tensile stress at break of the specimen.
5. Tear Strength NEW Method:
Impression material is extruded in a mold in compliance with Die C of ATSM D624—“Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers”. The material is cured for 45 seconds using a blue LED light source with 60±5 mW/cm2 intensity and peak wave length at 460±10 nm. Within 2 hours following curing completion, the specimen is subject to tensile elongation at a crosshead speed of 500 mm/min. The tear strength is determined as the ratio between the force at break and the thickness of the specimen at the notch.
The compositions of corresponding activated resins (AL02-170-2) and KR2-11 and the compositions of formulated pastes thereof (AL02-171 and AL02-172, respectively, are shown below. Although paste from 90/10 Combo Resin (ZZ2-208) could offer excellent tear strength, it got lower Shore A hardness in comparison to the paste based on physically blended Resin A and Resin B in same composition, AL02-171 vs AL02-132 in Table 14B.
To a 2000 mL flask equipped with mechanical agitator, 1625 g of purchased hydroxyl-terminated siloxane, Silmer OH Di-10 (total acid value as 0.297 mgKOH/g) was added, followed by addition of 168 g of activated basic alumina oxide (˜60 mesh). The content was mixed at room temperature for 4-8 h and then allowed to settle overnight, prior to decanting the top clear liquid for further filtration under reduced pressure to remove any solid particles. All clear liquid of 1476 g was collected (91% in yield). Samples were analyzed for total acid value and total moisture content analysis. 0.056 mgKOH/g for total acid value and 1006 ppm for moisture content were resulted.
Additional GC/MS was done for samples with similar treatment and it revealed no allyl alcohol could be detected, see Table 15 for the detailed compositions before & after pretreatment.
As shown in Table 15, treatment of Silmer/lot 11804022 or DMS/lot 3A-2388/aged with molecular sieve only could reduce total moisture content but failed to remove those acidic impurity and good mechanical performance of the formulated compositions from the resulting resin with such molecular sieve-treated Silmer monomer could not be reached. Thus the removal of the acidic impurity is critical to ensure adequate free-radical polymerization to construct the cross-linking network. Activated basic alumina oxide was found to be effective to achieve this goal. Other solid materials with weakly basic property should also work similarly in removing acidic impurities. As depicted in Table 15, we did confirm this by using a microporous ion-exchange resin with weakly basic groups (Amberlyst A21). With Amberlyst A21, an easier filtration process was achieved in comparison to using basic alumina oxide in Silmer treatment.
While the present disclosure has been described with reference to one or more embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims. In addition, all numerical values identified in the detailed description shall be interpreted as though the precise and approximate values are both expressly identified.
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| 18198048 | Oct 2018 | EP | regional |
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| Number | Date | Country | |
|---|---|---|---|
| 20190350817 A1 | Nov 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62673187 | May 2018 | US | |
| 62736772 | Sep 2018 | US |
