Abstract:
A method of using a dental filler is disclosed. The method may include securing a prosthetic to a dental implant, the prosthetic having an access channel therethrough. The method may also include filling a portion of the access channel by inserting a polytetrafluoroethylene dental plug into the access channel and compressing the polytetrafluoroethylene dental plug within the access channel.

Description:
BACKGROUND 
     Technical Field 
       [0001]    The present disclosure generally relates to systems, devices, and methods of filling and sealing access channels of abutments, crowns, bridges, and bars. More particularly, some embodiments herein relate to PTFE dental plugs and systems and methods of using such plugs in filling and sealing access channels of abutments, crowns, bridges, bars and natural teeth. 
       Description of the Related Art 
       [0002]    Dental implant supported restoration devices are used for the replacement of missing teeth. A dental implant supported restoration device includes a dental implant anchored in the bone and a prosthetic secured to the dental implant. Prosthetics, such as abutments, crowns, bridges and bars can be attached to the dental implants via a retaining screw. 
         [0003]    When attaching prosthetics to a dental implant using a screw, an access channel to allow insertion and stabilization of the prosthetic screw is formed in the prosthetic. The access channel is then sealed off from the oral environment with a seal to prevent collection of foreign debris and foreign bodies within the access channel and to minimize growth of microorganisms. 
         [0004]    Cotton has been used to fill access channels, but cotton is easily compressible, hydrophilic, organic, and porous, with many voids. Cotton fill material does not provide sufficient stiffness to support the seal, and leads to seal breakage which then results in fluid intrusion into the access channel and growth of microorganisms supported by the cotton within the access channel. 
         [0005]    Common plumber&#39;s tape has also been used to fill the access channel. Such thin tape material is folded or crumpled into the access channel, and when filling the access channel it is still compressible. The folded and crumpled nature of the tape, when used to fill access channels, still provides inadequate support for the access channel seal, and the folds and crumples in the tape can collect water and foreign debris that supports microorganism growth. Such tape also suffers from unknown degradation and transformation during sterilization and possible contamination, including incorporation of perfluorooctanoic acid. 
       BRIEF SUMMARY 
       [0006]    A method of using a dental filler is disclosed. The method may include securing a prosthetic to a dental implant, the prosthetic having an access channel therethrough. The method may also include filling a portion of the access channel by inserting a polytetrafluoroethylene dental plug into the access channel and compressing the polytetrafluoroethylene dental plug within the access channel. 
         [0007]    A dental filler system is disclosed. The dental filler system may include a polytetrafluoroethylene dental plug having a first length and a first diameter. The dental filler system may also include a dental prosthetic having an access channel formed therein, the access channel having a second diameter that is larger than the first diameter, having a fill length that is smaller than the first length, and being shaped to receive a fastener. 
         [0008]    A dental filler is disclosed. The dental filler may include a body of polytetrafluoroethylene material extending from a first end to a second end and having a first cross-sectional area at the first end and a second cross-sectional area at the second end. The body may a volumetric density between 0.15 and 2.15 g/cm 3  and a low crystallinity characterized by a crystalline to amorphous peak melt temperature between 320 and 340 degrees Celsius. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0009]      FIG. 1A  depicts a pre-cut length of PTFE plug according to one or more embodiments disclosed herein; 
           [0010]      FIG. 1B  depicts a cross section of the PTFE plug of  FIG. 1A  according to one or more embodiments disclosed herein; 
           [0011]      FIG. 2  depicts an implant supported one-piece restoration according to one or more embodiments disclosed herein; 
           [0012]      FIG. 3  depicts an exploded view of the implant supported one-piece restoration according to one or more embodiments disclosed herein; 
           [0013]      FIG. 4  depicts an abutment supported restoration according to one or more embodiments disclosed herein; 
           [0014]      FIG. 5  depicts an implant supported bar restoration according to one or more embodiments disclosed herein; 
           [0015]      FIG. 6  depicts a root canal treated tooth restoration according to one or more embodiments disclosed herein; 
           [0016]      FIG. 7  depicts an elongated PTFE fill material according to one or more embodiments disclosed herein; 
           [0017]      FIG. 8  depicts a tapered PTFE fill material according to one or more embodiments disclosed herein; 
           [0018]      FIG. 9A  depicts a PTFE fill material with a quadrilateral cross section according to one or more embodiments disclosed herein; 
           [0019]      FIG. 9B  depicts a cross section of the PTFE fill material with the quadrilateral cross section of  FIG. 8A  according to one or more embodiments disclosed herein; 
           [0020]      FIG. 10A  depicts a PTFE fill material with a triangular cross section according to one or more embodiments disclosed herein; 
           [0021]      FIG. 10B  depicts a cross section of the PTFE fill material with the triangular cross section of  FIG. 10A  according to one or more embodiments disclosed herein; 
           [0022]      FIG. 11A  depicts a PTFE fill material with an oval cross section according to one or more embodiments disclosed herein; and 
           [0023]      FIG. 11B  depicts a cross section of the PTFE fill material with the oval cross section of  FIG. 11A  according to one or more embodiments disclosed herein. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]      FIGS. 1A and 1B  show an embodiment of a PTFE access channel plug  100 . The PTFE access channel plug  100  shown in  FIG. 1A  includes a body  102  that extends between a first end  104  and a second end  106 . The body  102  may be made from material, including virgin PTFE (polytetrafluoroethylene) resin, that is perfluorooctanoic acid (PFOA) free. In some embodiments, the material that forms the body  102  is 100% virgin PTFE resin. In other embodiments, the material that forms the body  102  may be less than 100% virgin PTFE resin. 
         [0025]    PTFE is a synthetic fluoropolymer of tetrafluoroethylene, which has a high molecular weight and includes carbon and fluorine. The high bond strength between carbon and fluorine makes the material hydrophobic and nonreactive to most harsh chemicals. The PTFE plug  100  may have a volume density of between 0.15 g/cm 3  and 2.15 g/cm 3 , and more preferably between 0.15 g/cm 3  and 0.75 g/cm 3 . The PTFE plug  100  may also include single axis or bi-axially expanded PTFE. In some embodiments, the PTFE plug  100  may include a combination of one or more of single axis and bi-axially expanded PTFE. Expanded PTFE may have a volume density range between 0.2-1.4 g/cm 3  which correlates to an air volume between 90-35%. 
         [0026]    The volume density of the PTFE plug is one factor that determines how the PTFE plug compresses and fills the cavity or access channel. In some embodiments, volume densities of 0.25 g/cm 3 , 0.50 g/cm 3 , and 0.75 g/cm 3  may be used. 
         [0027]    The PTFE plug  100  may include PTFE material with a low crystallinity. For example, the PTFE material may have a differential scanning calorimetry reported at greater than 340° C. peak melt temperature. In some embodiments, the PTFE material may have a differential scanning calorimetry reported at between 320° C.−350° C. peak melt temperature. Low crystallinity PTFE material facilitates the creep and compressive abilities of the PTFE material in the PTFE plug  100 , which aids in filling voids and asymmetrical features within an access channel or cavity. 
         [0028]    In some embodiments, the PTFE material is either a porous PTFE material or a nonporous PTFE material. A porous PTFE material, particularly low density, porous PTFE material, provides more flexibility in filling cavities and access channels within a cavity or prosthetic, because the low density, porous PTFE material is more compressible and flexible, thus allowing the PTFE material to be more easily packed into a cavity or prosthetic during a dental procedure. 
         [0029]    The combination of volume densities between 0.15 g/cm 3  and 2.15 g/cm 3 , porous PTFE material compression, and a low crystallinity aids in more completely filling the volume of a cavity or access channel within a tooth or prosthetic and results in removing the air from within an access channel or cavity. By more completely filling the volume of a cavity or access channel and removing more air from the access channel or cavity, voids where microorganisms may grow are avoided and any gases that may be beneficial to the growth of microorganisms are removed from the cavity or access channel; thus growth of microorganisms is inhibited or significantly reduced as compared to using cotton, plumbers tape, or other packing material susceptible to forming voids within an access channel or cavity. 
         [0030]    The body of the PTFE plug  100  may also include an anti-bacterial material to aid in inhibiting microbial growth in the access channel in which the PTFE plug  100  is inserted and to also aid in inhibiting microbial growth in or on the PTFE plug  100 . In some embodiments, the PTFE plug  100  may be impregnated or coated with anti-bacterial coatings, filling, or solutions. 
         [0031]    As shown in  FIG. 1A , the PTFE plug  100  may have a particular length L between the first end  104  of the PTFE plug  100  and the second end  106  of the PTFE plug  100 . For example, the length L may be between 5 mm and 10 mm. In some embodiments, the length L may be up to 35 mm. The length L may be selected as the length suitable to fill a cavity or access channel within a tooth or prosthetic, as discussed later. 
         [0032]    The PTFE plug  100  has a circular cross section with a constant diameter along its length L. A round cross-section is suitable for filling cavities or access channels. In some embodiments, the PTFE plug  100  may have other cross-sectional shapes. For example, the PTFE plug  100  may have a quadrilateral shape such as a square or rectangle, as shown by PTFE plug  900  in  FIGS. 9A and 9B ; an oval shape, as shown by PTFE plug  1100  in  FIGS. 11A and 11B ; a triangular shape, as shown by PTFE plug  1000  in  FIGS. 10A and 10B ; or other shape suitable for filling cavities and access channels within a tooth or prosthetic. These various cross-sectional shapes can aid in more completely filing portions of an access channel, for example, when an access channel is drilled within the tooth, it may not be round. In such cases an oval shape or another shaped PTFE plug may be more suitable for use in filling the cavity than a round PTFE plug. 
         [0033]    In some embodiments, the PTFE plug  100  may be formed from a braid of several PTFE filaments in a manner similar to that of a rope. 
         [0034]    In some embodiments, the diameter of the PTFE plug  100  may vary. For example, as shown in  FIG. 1A , the PTFE plug  100  has a first diameter D 1  at the first end  104  and a second diameter D 2  at the second end  106 . Such variations in diameter may facilitate filling access channels or cavities that have varying cross-section along their depth. One such example of a PTFE plug having a varying diameter along its length is shown in  FIG. 8 , where a PTFE plug  800  has a first diameter D 1  at the first end  804  and a second diameter D 2  at the second end  806 , wherein the first diameter D 1  is smaller than the second diameter D 2  which gives a body  802  of the PTFE plug  800  a cone shape that is tapered. Other shapes, such as square shapes and oval shapes, may not be defined by a diameter, but they may have a varying cross-sectional area along their length such that they taper from one end of the PTFE plug to an opposing end of the PTFE plug. 
         [0035]    In some embodiments, the PTFE plug may be dispensed from a continuous length of PTFE material; for example, as shown in  FIG. 7 , a continuous length of PTFE filament may be provided. The continuous length of PTFE filament is not an infinite length of PTFE material, instead it is a length of material in excess of the length to fill a single cavity or access channel. For example, the PTFE filament  700  shown in  FIG. 7  may be cut into several PTFE plugs for use in filling several access channels. 
         [0036]    Referring back to  FIGS. 1A and 1B , the PTFE plug  100  or the PTFE filament  700  may have a constant diameter D of between approximately 0.040 inches and approximately 0.16 inches, such that the first diameter D 1  and the second diameter D 2  are the same. 
         [0037]    In some embodiments, the PTFE filament  700  may have a first diameter that is less than the diameter of an access channel, such as access channel  214  of  FIG. 1  and a length that is greater than the length of the access channel  214 . In some embodiments, the length of the PTFE filament  700  that is used to fill an access channel or cavity, such as access channel  214 , is many times longer than the length of the access channel. 
         [0038]    The various shapes of PTFE plugs, and filaments  100 ,  700 ,  800   900 ,  1000 ,  1100 , can reduce the time a dentist or oral surgeon spends during a procedure. For example, when a dentist or oral surgeon has a PTFE plug  100  that has a shape, length L, and diameter or cross-sectional area that is particularly suited to a particular cavity or access channel within a prosthetic, then the dentist or oral surgeon spends less time preparing and packing fill material during the procedure, which may reduce the total time of procedure. For example, in some embodiments, the diameter of the PTFE plug may be less than the diameter of the cavity or access channel. When the a dentist or dental surgeon compresses the PTFE plug within the cavity or access channel, the diameter of the PTFE plug increases and the outer surface of the PTFE plug expands and contacts the inner surface of the cavity or access channel. 
         [0039]    In some embodiments, the diameter of the PTFE plug may be greater than the diameter of the cavity or access channel. When the a dentist or dental surgeon compresses the PTFE plug within the cavity or access channel, the diameter of the PTFE plug shrinks to conform to the inner surface of the cavity or access channel. 
         [0040]      FIG. 2  shows an embodiment of a dental implant system  200 . The dental implant system  200  includes a dental implant  202 , a prosthetic  212 , and a fastener  206  that attaches the prosthetic  212  to the implant  202 . The fastener  206  attaches the prosthetic  212  to the implant  202  when the threads  210  of the fastener  206  engage with the sidewalls of the threaded hole  204  of the implant  202  and the head  208  of the fastener  206  clamps the flange  224  of the prosthetic  212  to the implant  202 . 
         [0041]    The prosthetic  212  includes an access channel  214  for receiving the fastener  206 . After the fastener is inserted into the access channel  214  and has secured the prosthetic  212  to the implant  202 , the head  208  of the fastener  206  substantially fills a bottom portion of the access channel  214 . The middle portion of the access channel  214  is filled with the PTFE plug  100  and compressed to fill the voids within the access channel to provide support for an overlaying polymer filling material  218 . 
         [0042]    The top portion of the access channel  214  is then sealed with the overlaying polymer filling material  218 . The polymer filling material  218  includes an outer surface  220  that, combined with an outer surface  216  of the prosthetic, forms a working or biting surface  221  of the prosthetic  212 . 
         [0043]    As shown in  FIG. 2 , the PTFE plug  100  fills the access channel  214  and, after the polymer filling material  218  is formed, the access channel  214  is sealed off and devoid of voids and air that would otherwise provide for growth of microorganisms within the access channel  214 . 
         [0044]      FIG. 3  depicts an exploded view of the dental implant system  200  shown in  FIG. 2 . To install the dental implant system  200  into a patient, a cavity  172  is formed in a jawbone  170  of a patient. The cavity  172  may be formed by the removal of a tooth or by other means such as surgically forming the cavity  172  within the jawbone  170 . In some embodiments, the implant  202  may form the cavity  172  within the jawbone  170 . 
         [0045]    The implant  202  is then inserted into and secured within the cavity  172 . After the implant  202  is secured within the cavity  172 , the prosthetic  212  is secured to the implant  202  by inserting the fastener  206  into the access channel  214  and then into a threaded hole  204  of the implant  202 . As the fastener is screwed into the implant  202 , the head  208  of the fastener  206  clamps the prosthetic  212  to the implant  202 . 
         [0046]    With the prosthetic  212  secured to the implant  202 , the access channel  214  is then filled with the PTFE plug  100  and compressed to fill the voids within the access channel to provide support for the overlaying polymer filling material  218 . 
         [0047]    The PTFE plug may have a predetermined size and shape based on the shape of the access channel  214  within the prosthetic  212 . In some embodiments, the PTFE plug  100  may have a size and shape, and in particular a length and diameter (or cross-sectional area), that is selected based on the shape and volume of the access channel  212  that is filled by the PTFE plug  100 . For example, a dentist or dental surgeon may be provided with a prosthetic  212  having an access channel  214  of a known size along with a fastener  206  also being a known size. By knowing the size of the fastener  206  or a part of the fastener, such as the head  208 , and in particular the volume or amount the fastener  206  will occupy within the known size of the access channel  214 , a PTFE plug  100  of a predetermined size and shape may be provided to the dentist or dental surgeon for use in filling the access channel  214 . 
         [0048]    In some embodiments, the dentist or oral surgeon selects a PTFE plug  100  of a particular size and shape during the procedure. In some embodiments, the dentist or oral surgeon selects a PTFE filament of a particular diameter or cross-sectional area and shape and cuts the PTFE filament to a length appropriate for filling a portion of the access channel  214  while leaving an appropriate portion of the access channel  214  open for the polymer filling material  218 . 
         [0049]    In some embodiments, the PTFE plug  100  may be multiple PTFE plugs  100 , each sized and shaped to fill a portion of the access channel  214 . 
         [0050]    After the PTFE plug  100  is placed and compacted within the access channel  214 , the polymer filling material  218  is used to fill the remaining portion of the access channel  214  and to seal the access channel  214  from an environment external to the access channel  214 . 
         [0051]    In some embodiments, for example when using a PTFE filament  700 , a PTFE plug is formed by inserting the PTFE filament  700  into the access channel  214  and compacting the PTFE filament  700  into the access channel  214 . 
         [0052]    In such embodiments, the PTFE filament  700  has a diameter less than the diameter of the access channel  214  and a length that is greater, sometimes many times greater, for example, 3-5 times greater than the length of the access channel  214 . To form the PTFE plug within the access channel  214 , a dentist inserts an end of the PTFE filament  700  into the access channel  214  and then proceeds to push additional length of PTFE filament  700  into the access channel  214 . This may cause the PTFE filament  700  to fold over itself and deform inside the access channel  214  until the PTFE filament  700  has deformed to fill the access channel  214 . 
         [0053]      FIG. 4  shows an embodiment of a dental implant system  300 . The dental implant system  300  includes a dental implant  302 , a prosthetic  312 , an abutment  322 , and a fastener  306  that attaches the abutment  322  to the implant  302 . The fastener  306  attaches the abutment  322  to the implant  302  when the threads  310  of the fastener  306  engage with the sidewalls of the threaded hole  304  of the implant  302  and the head  308  of the fastener  306  clamps the flange  324  of the abutment  322  to the implant  302 . 
         [0054]    The abutment  322  includes an access channel  314  for receiving the fastener  306 . The access channel is formed by a hollow cylindrical extension  326  that extends from a base of the abutment  322 . After the fastener  306  is inserted into the access channel  314  and has secured the abutment  322  to the implant  302 , the head  308  of the fastener  306  substantially fills a bottom portion of the access channel  314 . The top portion of the access channel  314  is filled with the PTFE plug  100 . 
         [0055]    After the PTFE plug  100  is placed and compacted into the access channel  314 , the access channel  314  is then capped and sealed off by the prosthetic  312  that is placed over the abutment  322 . The prosthetic  312  includes a channel  328  that is sized and shaped to mate with an exterior surface of the extension  326 . 
         [0056]    As shown in  FIG. 3 , after placement of the prosthetic  312 , the PTFE plug  100  fills the access channel  314 , resulting in the access channel  314  being devoid of voids and air that would otherwise provide for growth of microorganisms within the access channel  314 . 
         [0057]    To install the dental implant system  300  into a patient, a cavity is formed in the jaw bone of a patient. The implant  302  is then inserted into and secured within the cavity. After the implant  302  is secured within the cavity, the abutment  322  is secured to the implant  302  by inserting the fastener  306  into the access hole channel  314  and then into the threaded hole  304  of the implant  302 . As the fastener is screwed into the implant  302 , the head  308  of the fastener  306  clamps the abutment  322  to the implant  302 . 
         [0058]    With the abutment  322  secured to the implant  302 , the access channel  314  is then filled with the PTFE plug  100 , the prosthetic  312  is secured to the abutment  322 , and the access channel  314  is sealed. The PTFE plug  100  may have a predetermined size and shape based on the shape of the access channel  314  within the abutment  322 . In some embodiments, the PTFE plug  100  may have a size and shape, and in particular a length and diameter, that is selected based on the shape and volume of the access channel  312  that is filled by the PTFE plug  100 . For example, a dentist or dental surgeon may be provided with an abutment  322  having an access channel  314  of a known size along with the fastener  306  also being a known size By knowing the size of the fastener  306  or a part of the fastener, such as the head  308 , and in particular the volume or amount the fastener  306  will occupy within the known size of the access channel  314 , a PTFE plug  100  of a predetermined size and shape may be provided to the dentist or dental surgeon for use in filling the access channel  314 . 
         [0059]      FIG. 5  shows an embodiment of a dental implant supported bar system  400 . The system  400  includes a dental implant  402 , an implant supported bar  440  and a fastener  406  that attaches the implant supported bar  440  to the implant  402 . The fastener  406  attaches the implant supported bar  440  to the implant  402  when the threads  410  of the fastener  406  engage with the sidewalls of the threaded hole  404  of the implant  402  and the head  408  of the fastener  406  clamps the flange  426  of the implant supported bar  440  to the implant  202 . 
         [0060]    The implant supported bar  440  includes an access channel  414  for receiving the fastener  406 . After the fastener is inserted into the access channel  414  and has secured the supported bar  440  to the implant  402 , the head  408  of the fastener  406  substantially fills a bottom portion of the access channel  414 . The middle portion of the access channel  414  is filled with the PTFE plug  100  and the top portion of the access channel  414  is sealed with an overlaying polymer filling material  418 . The polymer filling material  418  includes an outer surface  420  that is co-planer with the outer surface  416  of the implant supported bar  440 . 
         [0061]    As shown in  FIG. 5 , the PTFE plug  100  fills the access channel  414  and, after the polymer filling material  418  is formed, the access channel  414  is sealed off from the external environment and devoid of voids and air that would otherwise provide for growth of microorganisms within the access channel  414 . 
         [0062]    To install the system  400  into a patient, a cavity is formed in the jaw bone of a patient. The cavity may be formed by the removal of a tooth or by other means such as surgically forming the cavity within the jaw bone. The implant  402  is then inserted into and secured within the cavity. After the implant  402  is secured within the cavity, the implant supported bar  440  is secured to the implant  402  by inserting the fastener  406  into the access hole channel  414  and then into the threaded hole  404  of the implant  402 . As the fastener is screwed into the implant  402 , the head  408  of the fastener  406  clamps the implant supported bar  440  to the implant  402 . 
         [0063]    With the implant supported bar  440  secured to the implant  402 , the access channel  414  is then filled with the PTFE plug  100  and polymer filling material  418 . The PTFE plug may have a predetermined size and shape based on the shape of the access channel  414  within the implant supported bar  440 . In some embodiments, the PTFE plug  100  may have a size and shape, and in particular a length and diameter, that is selected based on the shape and volume of the access channel  414  that is filled by the PTFE plug  100 . For example, a dentist or dental surgeon may be provided with an implant supported bar having an access channel  414  of a known size along with a fastener  406  also of a known size. By knowing the size of the fastener  406  or a part of the fastener, such as the head  408 , and in particular the volume or amount the fastener  406  will occupy within the known size of the access channel  414 , a PTFE plug of a predetermined size and shape may be provided to the dentist or dental surgeon for use in filling the access channel  414 . 
         [0064]    After the PTFE plug  100  is placed and compacted within the access channel  414 , the polymer filling material  418  is used to fill the remaining portion of the access channel  414  and to seal the access channel  414  from an environment external to the access channel  414 . 
         [0065]      FIG. 6  shows an embodiment of a tooth  550  having a filled and sealed access channel  514 . In a root canal procedure, an access channel  514  is formed in the tooth  550 , so that a dentist or dental surgeon can gain access to the interior of the roots  552  of the tooth  550 . After the dentist or dental surgeon has completed their work on the tooth, a portion of the access channel  514  is filled with the PTFE plug  100  and the top portion of the access channel  514  are sealed with an overlaying polymer filling material  518 . The polymer filling material  518  includes an outer surface  520  that, combined with the outer surface  516  of the tooth  550 , forms a working or biting surface of the tooth  550 . 
         [0066]    As shown in  FIG. 5 , the PTFE plug  100  fills the access channel  514  and, after the polymer filling material  518  is formed, the access channel  514  is devoid of voids and air that would otherwise provide for growth of microorganisms within the access channel  514 . 
         [0067]    The various embodiments described above can be combined to provide further embodiments. 
         [0068]    These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.