CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application 63/376,415, filed September 20, 2022, the entire disclosure of which is hereby incorporated by reference.

BACKGROUND

Fabrication of dental restorations often requires extensive labor and time and the proficiency of highly skilled technicians. Many state-of-the-art dental restorations are underpinned by a sense of artistry that can typically only be achieved manually. In particular, to preserve aesthetics of the dental restorations the color and shade of the artificial tooth, crow n, bridge, or other dental structure must be matched to the color/shade of the surrounding teeth. This process requires careful estimate of the color/shade, followed by manufacturing the dental structure in the required color/shade and without microstructural inhomogeneities that may affect strength and reliability of the dental structure.

Some conventional technologies attempt to use computer assisted design/manufacturing (CAD/CAM) processes and equipment. In these conventional processes, a three-dimensional image of a tooth is first acquired. This image is displayed on a computer screen, and a dental technician may select a tooth from a plurality of tooth forms and shades stored in the computer to best fit the tooth to be restored. The selected tooth is projected onto the tooth to be restored until an optimum positioning and fit of the dental restoration is achieved. The digital data is supplied to a numerically controlled milling machine cuts a blank of the dental material into the dental restoration design based on the data supplied. However, in many instances such approach does not produce a dental structure of required precision or of required color/shade match, therefore forcing dental technicians to again resort to a manual adjustment of the form, fit and color of the dental structure for a particular use case. Accordingly, systems and methods are needed for improved color/shade matching and manufacturing of dental structures. SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter.

Briefly, the inventive technology is directed to preparing a material for dental structure having a predetermined custom shade and color (also referred to as a "shade" or “color/shade” for simplicity). In some embodiments, the target shade may be captured off the existing tooth by a digital camera. The acquired digital image may be processed to determine the target color, shade, hue, etc. (collectively, “shade” or “color/shade”) of the dental structure using commercially available or custom software. In operation, the custom mixing system mixes input components of the dental structures into a final (target) mixture using a pre-determined ratio of the components that is automatically determined based on the acquired digital image. In some embodiments, just three different components of the input material suffice to produce a wide variety of target shades for the dental structures.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of the inventive technology will become more readily appreciated as the same are understood with reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

FIGURE 1 is a schematic diagram of a color/shade measurement system in accordance with an embodiment of the present technology;

FIGURE 2 is a partially schematic side view of a system for manufacturing dental structure in accordance with an embodiment of the present technology;

FIGURE 3A is a partially schematic side view of a system for manufacturing dental structure in accordance with an embodiment of the present technology;

FIGURE 3B is a schematic view of an in-mouth injection matrix in accordance with an embodiment of the present technology;

FIGURE 3C is a partially schematic side view of a system for manufacturing dental structure in accordance with an embodiment of the present technology; and

FIGURE 4 is a flowchart describing a method for manufacturing dental structure in accordance with an embodiment of the present technology. DETAILED DESCRIPTION

While several embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the claimed subject matter.

Figure 1 is a schematic diagram of a color/shade measurement system in accordance with an embodiment of the present technology. The system 100 may be used to determine representative color and/or shade of a target tooth 10. In some embodiments a source of light 20 (e.g., an LED, a laser, a laser diode, a discharge lamp, etc.) emits light toward the target tooth 10, or, in particular, tooth enamel layer 15. The incoming light may be reflected toward a lens 30, and further toward a light sensor 35 (e.g., a digital camera) that captures an image of the target tooth. The captured image contains the color/shade information that can be transmitted to a controller 40 (e.g., a computer) through a wireless or wired communication 37. The color/shade information becomes an input to the process of manufacturing a customized material for a dental structure, as explained in more detail with respect to Figure 2 below.

Figure 2 is a partially schematic side view of a system 200 for manufacturing dental structure in accordance with an embodiment of the present technology. In operation, a custom shade mixing system 200 receives information corresponding to the desired color and/or shade of the dental structure. In some embodiments, the information corresponding to the desired color and/or shade of the dental structure can be received by a receiver 116, which may be a wireless or a wired receiver, of a mixing gun 110. The custom shade mixing system 200 is capable of producing the target color/shade based on a proper ratio of the input materials 119. In some embodiments, a controller 140 (e.g., a computer, processor, computer storage, etc.) 140 is configured for determining proper ratios of the input materials 119.

The inventor has found that in many practical applications a mixture of three input components 119 serves well to achieve a target color/shade of the dental structure. As a non-limiting illustrative example, the target color/shade of the dental structure may be achievable by, say, 30% of a first input material, 50% of a second input material, and a 20% of a third input material. Other combinations of input materials are also possible in different embodiments.

The required ratios of the input materials 119 may be forwarded by actuators 118 (e g., stepper motors, micromotors, etc.) through dispensing channels 120 into their respective plungers 122. The actuators 118 may be powered off a battery 114 (e.g., a single use battery, or a rechargeable battery that is charged through a charging element 112). In operation, the plungers 122 may forward the input materials 119 (in required ratios that are controlled by the actuators 118) toward cartridges 126. In some embodiments, the cartridges 126 may be replaceable cartridges that are prefilled with their respective input materials. In some embodiments, action of the plungers 122 is limited by the stopper 124.

From the cartridges 126, properly dosed materials 119 are forwarded to an adapter 128 and further through a funnel (or other material-aggregating element) 130. Next, the mixture of materials 119 enters a mixing tip 132 where the materials are mixed into a relatively homogenous mix of dental material that is characterized with a relatively uniform color/shade.

In some embodiments, the mixing tip 132 may be disposable, and anew mixing tip may be used for each target dental structure. The mixture of dental material that leaves the mixing tip 132 may be collected by a dish 180. In some embodiments, the dish 180 may be shaped as a mold for the target dental structure in order to, at least partially, simplify the subsequent steps of producing the required shape of the dental structure.

Figure 3A is a partially schematic side view of a system 200 for manufacturing dental structure in accordance with an embodiment of the present technology. In some embodiments, the mixing gun 110 may be utilized to mix input materials 119 and to apply the mixture directly into the patient’s mouth using an injection matrix 212. A user may find the injection matrix 212 to be preferable when a plurality of dental structures requires similar treatment. In some embodiments, the injection matrix 212 may be formed using a conventional wax-up method, in which a silicone impression is taken of the patient's existing dental structure 202. The desired shape of the dental structure may then be crafted into a fillable mold 204 formed within the injection matrix 212 around the existing dental structure 202. In other embodiments, this design process may be accomplished digitally with the aid of specialty software.

In some embodiments, matching a dental structure to surrounding dental structures may require the user to develop the structure’s appearance in layers. As such, a user may create multiple injection matrices 212 to accommodate the creation of multiple dental structure layers within a single dental structure. For example, a first injection matrix 212 having a first design may be created for an inner dentin layer of a tooth, a second injection matrix 212 having a second design may be created to further define a tooth’s apparent characteristics or features, and a third injection matrix 212 have a third design may be created for an outer enamel layer.

Figure 3B is a schematic view of an in-mouth injection matrix 212 in accordance with an embodiment of the present technology'. In some embodiments, the injection matrix 212 may feature one or more injection holes 206 to facilitate the application of the input materials 119. In some embodiments, user may place the mixing tip 132 of the mixing gun 1 10, in the desired injection hole 206 and apply the mixture to the existing dental structure as described above. In some embodiments, there may be a plurality of injection holes 206 for each dental structure receiving treatment to facilitate the application and flow of the mixture from the mixing gun 110 into the fillable mold 204.

Figure 3C is a partially schematic side view of a system for manufacturing dental structure in accordance with an embodiment of the present technology'. In some embodiments, the mixing gun 110 may be utilized to mix input materials 119 and apply the mixture to a fillable mold 210 for placement in the patient’s mouth at a later time. A user may find a mold 212 to be preferable when the user only wishes to conduct work on a single dental structure (e.g., a crown or a dental bridge). In some embodiments, the mold is formed using an impression made of the patient’s existing teeth to ensure that the dental structure will fit amongst the patient’s other teeth, around the existing damaged tooth 202, and extend from the patient’s gums 208 a length such that ensures a desirable uniform appearance without limiting utility. In other embodiments, this design process may be accomplished digitally with the aid of specialty' software.

In some embodiments, matching a dental structure to surrounding dental structures may require the user to develop the structure’s appearance in layers. As such, a user may create multiple molds 210 to accommodate the creation of multiple dental structure layers within a single dental structure. For example, a first mold 210 having a first design may be created for an inner dentin layer of a tooth, a second mold 210 having a second design maybe created to further define a tooth’s apparent characteristics or features, and a third mold 210 have a third design may be created for an outer enamel layer.

Figure 4 is a flowchart describing a method for manufacturing dental structure in accordance with an embodiment of the present technology ⁷ . In some embodiments, the method may include additional steps or may be practiced without all steps illustrated in the flow chart. In some embodiments, the order of the steps listed may be changed. The method begins at block 300, during which the user develops a specific treatment plan that meets the patient’s particular dental needs. The user then proceeds to block 302, during which the user forms a dental mold for the patient based on their existing tooth 202 or other dental structure. This mold may take many forms including, but not limited to, a fillable mold 204 within an injection matrix 212 or a separately fillable mold 210 for a bridge or crown. In some embodiments, the user may determine that a plurality of molds are required to adequately administer care. This mold may be shaped in a variety of ways including, but not limited to, conventional or digital wax-up, as described with respect to Figure 3A above.

In block 304. the user illuminates a target tooth 10. As discussed above in reference to Figure 1, in some embodiments a source of light 20 (e.g., an LED, a laser, a laser diode, a discharge lamp, etc.) emits light toward the target tooth 10, or, in particular, tooth enamel layer 15. This facilitates future blocks including block 306, during which the user captures a digital image of the target tooth 10. The incoming light may be reflected toward a lens 30, and further toward a light sensor 35 (e.g., a digital camera) that captures an image of the target tooth. The captured image contains the color/shade information that can be transmitted to a controller 40 (e.g., a computer) through a wireless or wired communication 37. The color/shade information becomes an input to the process of manufacturing a customized material for a dental structure, as explained in subsequent blocks.

In block 308, the user determines the dental structure layer they will work on next. In some embodiments, users may determine that multiple layers (e.g., dentin, enamel, etc.) may be necessary to sufficiently capture or replicate a tooth’s apparent characteristics, features, or finish. In block 310, the user determines a target shade to be mixed and dispensed by the mixing gun 110 from the digital image of the target tooth 10. In block 312, the custom shade mixing system 200 receives information corresponding to the desired color and/or shade of the dental structure. In some embodiments, the information corresponding to the desired color and/or shade of the dental structure can be received by a receiver 116, which may be a wireless or a wired receiver, of a mixing gun 110. In block 314, the user determines the proper ratio of input materials 119 to produce the desired shade when mixed. In some embodiments, this block is performed by a controller 140 (e.g., a computer, processor, etc.).

In block 316, the required ratios of the input materials 119 are forw arded by actuators 118 (e g., stepper motors, micromotors, etc.) through dispensing channels 120 into their respective plungers 122. The plungers 122 then forward the input materials 119 (in required ratios that are controlled by the actuators 118) toward cartridges 126. In some embodiments, the cartridges 126 may be replaceable cartridges that are prefilled with their respective input materials. In some embodiments, action of the plungers 122 is limited by the stopper 124.

In block 318, the input materials 119 are forwarded from the cartridges 126 in the desired ratios to an adapter 128 and further through a funnel (or other material-aggregating element) 130. In block 320, the input materials 119 are dispensed through a mixing tip 132 in block 320 to form a relatively homogenous mixture in the target shade. The mixture is then applied into the formed mold. In some embodiments, this mixture is applied through injection holes 206 in an injection matrix 212 in the patient’s mouth. In other embodiments, this mixture is applied to a fillable mold 210 outside of the patient’s mouth for later insertion. In some embodiments, the mixing tip 132 may be disposable, and a new mixing tip may be used for each target dental structure. In some embodiments, the dispensed mixture is then cured under ultraviolet (UV) light.

Depending upon the patient’s treatment plan, the user is then presented may be presented with two choices in blocks 322 and 324. In block 322, the user may elect to apply a new target shade to the same layer. If so, the user returns to block 310 to determine the new target shade. If not, the user proceeds to block 324. in which they may elect to proceed to a new layer. If so, the user returns to block 308 to determine the next appropriate dental structure layer. If not, the user proceeds to block 328, in which the method ends. In some embodiments, the cured dental structure may then require additional cosmetic procedures (e.g.. shaping, polishing, etc.) dependent upon the patient's input and treatment plan.

Many embodiments of the technology described above may take the form of computer- or controller-executable instructions, including routines executed by a programmable computer or controller. Those skilled in the relevant art will appreciate that the technology can be practiced on computer/controller systems other than those shown and described above. The technology can be embodied in a special-purpose computer, controller or data processor that is specifically programmed, configured or constructed to perform one or more of the computer-executable instructions described above. Accordingly, the terms "‘computer” and “controller” as generally used herein refer to any data processor and can include Internet appliances and hand-held devices (including palmtop computers, wearable computers, cellular or mobile phones, multi -processor systems, processor-based or programmable consumer electronics, network computers, mini computers and the like).

The present application may also reference quantities and numbers. Unless specifically stated, such quantities and numbers are not to be considered restrictive, but exemplary of the possible quantities or numbers associated with the present application.

Also in this regard, the present application may use the term '‘plurality’ ⁷ to reference a quantity or number. In this regard, the term ‘'plurality” is meant to be any number that is more than one, for example, two, three, four, five, etc. The terms “about,” “approximately,” etc., mean plus or minus 5% of the stated value. From the foregoing, it will be appreciated that specific embodiments of the technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the disclosure. Moreover, while various advantages and features associated with certain embodiments have been described above in the context of those embodiments, other embodiments may also exhibit such advantages and/or features, and not all embodiments need necessarily exhibit such advantages and/or features to fall within the scope of the technology. Accordingly, the disclosure can encompass other embodiments not expressly shown or described herein.