GB2476969A

GB2476969A - Dental implant comprising a plurality of channels

Info

Publication number: GB2476969A
Application number: GB1000674A
Authority: GB
Inventors: Eliezer Bar Shalom
Original assignee: AB Dental Devices Ltd
Current assignee: AB Dental Devices Ltd
Priority date: 2010-01-18
Filing date: 2010-01-18
Publication date: 2011-07-20
Also published as: GB201017709D0; WO2011086529A1; GB2477010A; GB201000674D0

Abstract

A method for making a dental implant is disclosed. A layer of powder is supplied and a sintering laser beam is applied, which melts a portion of the powder. This is repeated to form a dental implant 100 comprising channels 122 or pores. The channels 122 are configured to promote bone in-growth and contribute to the positional stability of the implant 100 in the bone 130. The channels 122 may have a cross-sectional area between 10-800 microns and a depth of between 10-500 microns and form a lattice. The powder may be a ceramic or a metal, such as titanium. The laser can be applied in the presence of an inert gas and can be controlled by a controller with a processor. An apparatus is disclosed comprising a surface, at least one pore and at least one cross-sectional portion. Multiple channels 122 pass through the cross-sectional portion.

Description

DENTAL IMPLANT

B ACKGROUND

1. TECHNICAL FIELD

[0001] The present invention relates to the field of dental implants and more particularly, to a dental implant having "through channels".

2. DISCUSSION OF RELATED ART [0002] To replace natural teeth, one or more metal dental implants of various fonns are inserted into a bore in the bone of the jaw, and following integration with the bone, prosthetic teeth are attached.

[0003] To achieve bony integration and greater implant stability the surface of the implant is treated to form a rough surface.

[0004] A variety of methods have been developed to attain a sufficiently porous surface to promote bone integration and implant stability. One method comprises plasma spraying of metal onto the metallic surface of the implant in a mariner that provides a surface into which bone will grow.

[00051 Another method comprises applying titanium powder which is subjected to high temperature, causing the powder to melt and fuse with the underlying implant structure, thereby forming pores into which bone will grow.

[0006] Related existing art: EP 1764061 Al (Mangano, Carlo) which teaches pores on a surface of the implant that receive ingrowth of bone from the recipient.

BRIEF SUMMARY

[0007] Embodiments of the present invention provide a method for making a dental implant. One method comprises supplying a layer of powder; applying a sintering laser beam that melts a portion of the powder, and repeating the above steps to form a dental implant with channels passing through at least a portion of the implant. According to an aspect of the present invention, the channels are configured to provide promote ingrowth of bone and contribute to positional stability of the implant in a bone in which the implant is to be implanted.

[00081 According to some embodiments of the invention, the pores have a square cross-sectional area of between about 70 and 800 microns.

[0009] According to some embodiments of the invention, the pores have a depth of between about 10 and 100 microns.

[00101 According to some embodiments of the invention, the channels have a square area of between about 70 and 800 microns.

[0011] According to some embodiments of the invention, the powder comprises a metal or ceramic powder.

[00121 According to some embodiments of the invention, the powder comprises a titanium powder.

[0013] According to some embodiments of the invention, the layers of powder and sintering laser are applied in the presence of an inert gas.

[00141 According to some embodiments of the invention, the layers of powder are deposited in thicknesses of between about 1 and 100 microns.

[00151 According to some embodiments of the invention, the layers of powder are deposited along planes perpendicular to the longitudinal axis of the implant.

[00161 According to some embodimeiits of the invention, the laser beam is controlled by a controller having a computer processing unit that includes a software module that provides digital three-dimensional instructions.

[00171 According to an aspect of the present invention, there is provided a dental implant comprising a surface having at least one pore and at least one cross- sectional portion including multiple channels which pass through the cross-sectional portions.

[00181 According to some embodiments of the invention, the pores have square cross-sectional area of between about 70 and 800 microns.

[00191 According to some embodiments of the invention, the pores have a depth of between about 10 and 100 microns.

[00201 According to some embodiments of the invention, the channels have a square area of between about 70 and 800 microns.

[0021] According to some embodiments of the invention, the implant comprises a metal or ceramic.

[0022] According to some embodiments of the invention, the metal or ceramic comprises titanium.

[23] These, additional, and/or other aspects and/or advantages of the present invention are: set forth in the detailed description which follows; possibly inferable from the detailed description; andlor learnable by practice of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[00241 The present invention will be more readily understood from the detailed description of embodiments thereof made in conjunction with the accompanying drawings of which: Figure 1 shows a dental implant having "through channels", according to some embodiments of the invention; Figure 2 shows the dental implant shown in Figure 1 in partial cross section, according to some embodiments of the invention; and Figure 3 shows a cross-sectional portion of the dental implant shown in Figure 1, according to some embodiments of the invention; and Figure 4 shows a schematic drawing of an existing art manufacturing device configured for producing the dental implant of Figures 1 and 2.

DETAILED DESCRIPTION

[00251 Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is applicable to other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

[0026] Figures 1 and 2 show a dental implant 100 having channels 122 therethrough. Dental implant 100 additionally includes threads 124 and a prosthetic head 116.

[0027] Prosthetic head 116, as seen partial cross section in Figure 2, includes an abutment receptacle 114 configured for supporting an abutment (not shown).

Abutment receptacle 114 optionally comprises an octagonal cross-sectional shape which receives an abutment having an octagonal shape.

[0028 Alternatively, the cross-sectional shape of abutment receptacle 114 is triangular, square configured for receiving projections of similar shapes from the corresponding abutments. In still other options, the cross-sectional shape of abutment receptacle 114 is a five or six point star design.

[0029 Additionally, receptacle 114 comprises a cylinder having a round cross sectional cross section, and the walls of the cylinder are optionally threaded to receive a threaded screw.

[0030 In still further embodiments, receptacle 114 comprises a peg that extends above dental implant 100 and is configured to pass into an appropriately shaped receptacle in an abutment and/or prosthetic. The many options for connecting dental implant 100 to abutments and/or prosthetics are well known to those familiar with the industry.

[0031] As seen in Figures 2 and 3, channels 122 pass through the thickness of implant 100 into a core 118 which is hollow. Channels 122 are optionally cylindrical and have a round cross-sectio to those familiar with the industry n shape. Optionally abutment receptacle 114 includes channels 122.

[0032] Alternatively, channels 122 have a polygon cross-sectional shape. The many options for creating cylindrical channels 122 are well known to those familiar with the industry.

[0033] Channels 122 optionally form a lattice structure as seen in figure 2. The configuration of the lattice structure may be as a ladder configuration however the lattice structure of channels 122 may include angled channels 122 for example that 45° to the vertical channels shown. The many forms that channels 122 can form to create optimal infusion of bone 130 can be easily understood to those familiar with the industry.

[0034 Core 118 optionally includes an octagonal cross-sectional shape which is optionally contiguous with abutment receptacle 114. In some embodiments, the cross-sectional shape of core 118 is triangular, square, or hexagonal. In still other embodiments, the cross-sectional shape of core 118 is a five or six point star design.

[0035] Following implantation, channels 122 are optimally filled with bone. Bone ingrowth into channels 122 of dental implant 100 contributes to positional stability of dental implant 100 in bone 130 in which the implant is implanted. The stability results in even distribution of mastication forces between implant 100 and bone 130.

[0036] The inventors have discovered that as a result of the bone ingrowth into channels 122, a greater long-term stability is possibly created for implant 100 within bone 130, than when implant 100 includes only pores taught in the above-noted prior art of EP 1764061 Al (Mangano, Carlo).

[0037] Further the inventors have discovered that distance between multiple dental implants 100 may possibly be reduced from a standard amount of approximately 2 millimeters to about 1 millimeter.

[0038] In embodiments, channels 122 have a cross-sectional square area of between 70 and 800 microns and a depth of between about 10 and 100 microns.

[0039 In embodiments, channels 122 have a square area of between about 70 and 800 microns.

[0O As shown in a schematic drawing in Figure 4, implant 100 is produced in a production unit ii including an atmosphere-controlled chamber 12 in which implant 100 is formed.

[O1] Layers of a powder 18 are optionally deposited with a thickness of between about 1 and 100 microns on a vertical platform 14 along a cylinder 19 utilizing a dispenser iii that optimally moves across vertical platform 14.

[0042] Each time a layer of powder 18 is deposited, a striker arm 13 of a laser gen-erates a laser beam 140 that is directed by a reflector 142 towards the layer of powder 18 which was just deposited.

[0043] Powder 18 struck by laser beam 140 melts and solidifies to form an implant portion 16 having a thicknesses of between about 1 and 100 microns as noted above.

[0044] In embodiments plaffomi 14 is moved downward as implant 100, consisting of one or more implant portions 16, is formed.

[0045] Laser beam 140 is controlled by a controller 15 to form channels 122.

Controller 15 typically includes a computer processing unit (CPU) 146 that includes a software module 144 that provides digital three dimensional instructions that control movement of, inter alia, laser beam 140, reflector 142 and downward motion 148. In alternative embodiments, for example where production unit 11 does not include downward movement in direction 148, software module 144 provides digital three dimensional instructions that control movement of, inter alia, laser beam 140 and reflector 142.

[O61 As implant 100 is formed, reserve powder 17 around implant 100 can be recovered for a subsequent manufacturing process.

[O7 Layers of powder 18 optionally have a thickness of between about 1 and microns. Powder 18 optionally comprises medical grade 2 or 4 titanium powder or ceramic titanium powder. The grains within each layer of powder 18 optionally are between about 10 and 200 nanometers in dimensioii. However, the thickness of the layers of powder 18 as well as the grains within the layer may vary according to a variety of factors including improvements in existing art.

[0048] In embodiments, layers of powder 18 are sintered by laser beam 140 so that implant 100 acquires a generally cylindrical form.

[0049] During manufacture of implant 100, chamber 12 is filled with an inert gas 150, for example argon, at a controlled atmospheric pressure so as to reduce potential impurities in implant 100.

[00501 To clean implant 100 of any remaining powder 18, implant 100 is optionally introduced into a bath of distilled water or organic acids, aiid subjected to ultrasound treatment.

[0051 Referring to figures 1, 2 and 3, the inventors have discovered that dental implant 100 becomes affixed in place by the ingrowth of bone 130 into channels 122.

[00521 Additionally, the inventors have discovered that implant 100 provides greater long-term stability than the implant taught in EP 1764061 Al (Mangano, Carlo) which oniy includes pores on the surface of the iniplant.

[0053] It is to be understood that the details set forth herein do not construe a limitation to an application of the invention.

[0054] Furthermore, it is to be understood that the invention can be carried out or practiced in various ways and that the invention can be implemented in embodiments other than the ones outlined in the description above.

[00551 It is to be understood that the terms "including", "comprising", "consisting", and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers; or groups thereof, and that the terms are to be construed as specifying components, features, steps or integers.

E0056J If the specification or claims refer to "an additional" element, that does not preclude there being more than one of the additional element.

[00571 It is to be understood that where the claims or specification refer to "a" or "an" element, such reference is not be construed that there is only one of that elenient.

[00581 It is to be understood that where the specification states that a component, feature, structure, or characteristic "may", "might", "can" or "could" be included, that particular component, feature, structure, or characteristic is not required to be included.

[00591 Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, the invention is not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described.

[0060] Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks.

[0061] The term "method" may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques, and procedures by practitioners of the art to which the invention belongs.

[00621 The descriptions, examples, methods, and materials presented in the claims and the specification are not to be construed as limiting but rather as illustrative only.

[0063] Meanings of technical and scientific terms used herein are to be commonly understood as by one of ordinary skill in the art to which the invention belongs, unless otherwise defined.

[0064J The present invention may be implemented in the testing or practice with methods and materials equivalent or similar to those described herein.

[0065 Any publications, including patents, patent applications and articles, referenced or mentioned in this specification are herein incorporated in their entirety into the specification, to the same extent as if each individual publication was specifically and individually indicated to be incorporated herein. In addition, citation or identification of any reference in the description of some embodiments of the invention shall not be construed as an admission that such reference is available as prior art to the present invention.

E0066J While the invention has been described with respect to a limited number of embodiments, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of some of the preferred embodiments. Other possible variations, modifications, and applications are also within the scope of the invention. Accordingly, the scope of the invention should not be limited by what has thus far been described, but by the appended claims and their legal equivalents.

Claims

CLAIMSWhat is claimed is: 1. A method for making a dental implant, the method comprising: a. supplying a layer of powder; b. applying a laser beam that melts a portion of the powder; c. repeating step a and step b to form a dental implant with channels passing through at least a portion of the implant, d. such that the channels are configured to provide promote ingrowth of bone and contiibute to positional stability of the implant in a bone in which the implant is to be implanted.
2. The method according to claim 1, wherein the laser applies a sintering beam.
3. The method according to claim 1, wherein the pores have a cross-sectional areas of between about 10 and 800 microns.
4. The method according to claim 2, wherein the pores have a depth of between about 10 and 500 microns.
5. The method according to claim 3, wherein the pores form a lattice.
6. The method according to claim 1, wherein the powder comprises a metal or ceramic powder.
7. The method according to claim 4, wherein the powder comprises a titanium powder.
8. The method according to claim 1 in which the layers of powder and sintering laser are applied in the presence of an inert gas.
9. The method according to claim 1, wherein the layers of powder are deposited in thicknesses of between about 1 and 100 microns.
10. The method according to claim 1, wherein the layers of powder are de-posited along planes perpendicular to the longitudinal axis of the implant.
ii. The method according to claim 1, wherein the laser beam is controlled by a controller having a computer processing unit that includes a software module which provides digital three dimensional instructions.
12. A dental implant having a surface including at least one pore and at least one cross-sectional portion including multiple channels which pass through the cross-sectional portions.
13. The implant according to claim 10, wherein the pores have cross-sectional area of between about 10 and 800 microns.
14. The implant according to claim 11, wherein the pores have a depth of between about 10 and 500 microns.
15. The implant according to claim 12, wherein the pores form a lattice.
16. The implant according to claim 10, wherein the implant comprises a metal or ceramic.
17. The implant according to claim 4 wherein the metal or ceramic comprises titathum.Amendments to the Claims have been filed as follows CLAIMS: What is claimed is: 1. A dental implant having a core, an inner thread for connecting an abutment to the implant and an outer thread for connecting the dental implant to a jaw bone, characterized in that the core is at least partially porous and is ananged to enhance bone growth into the implant, and in that the dental implant is produced layer by layer by laser sintering, wherein the bone growth into the implant enhances implant stability and allows for close implantation of neighbouring implants.2. The dental implant according to claim 1, wherein the porous part of the core comprises a lattice of interconnected channels extending therethrough.3. The dental implant according to claim 2, wherein the channels have a diameter between 0.1 and 1 millimeter.4. The dental implant according to any claims 1 to 3, wherein the dental implant comprises titanium or titanium alloys. CoQ 5. A method comprising: defining a spatial structure of a dental implant with a porous core, to yield enhanced bone growth into the dental implant upon implantation; and producing, simultaneously, by layer-wise laser sintering, a plurality of dental implants according to the defined spatial structure, wherein the enhanced bone growth into the implant core enhances implant stability and allows for close implantation of neighbouring implants.6. The method according to claim 5, further comprising defining the spatial structure of the porous core such as to comprise a lattice of interconnected channels.7. The method of claim 4, wherein the spatial structure is defined according to specified implantation requirements.