Device for forming dental restorations

A tool for forming dental restorations used in the oral cavity of a human being and which restorations are at least partially made of a synthetic restoration material, such as porcelain. The dental tool comprises an elongate handle section capable of being grasped by the fingers or a hand of the user thereof. A first tool section located on one end of the handle section is capable of performing a first operation in the formation of a dental restoration. A second tool section is located on the opposite end of the handle section and is cooperatable with the first tool section and used in the formation of the dental restorations from the synthetic material. These first and second tool sections are used in combination in very closely timed relatonship in order to properly form the dental restorations. A serrated surface section, which functions as a vibrating member, is also located on the handle section intermediate the first and second tool sections. This serrated surface section is designed to create a vibratory action on the dental restorations during formation thereof through reciprocative movement of the tool in order to create fluid movement in the synthetic restoration material. The present invention also provides a method of using the tool for forming the dental restorations as well as a method of making the tool for forming these dental restorations.

BACKGROUND OF THE INVENTION manipulatable 
This invention relates in general to certain new and useful improvements in 
devices and methods used in the formation of dental restorations of the 
type used in the oral cavity of a human being, and, more particularly, to 
devices of this type which are easily manipulatable to perform a plurality 
of functions, as well as methods of using and making the same. 
Dental restorations which are used in the oral cavity of a human being are 
usually constructed on a mold which becomes part of the dental 
restoration. These molds are typically formed of gypsum, a rather porous 
material which tends to absorb water. A metal frame is constructed around 
the gypsum mold and this metal frame is typically formed of a precious 
metal such as gold. Moreover, in the formation of the dental restoration, 
a restoration material is used to form the outer surface, and this 
restoration material is generally porcelain. The porcelain is applied to 
the metal framework around the gypsum mold and is thereafter baked on the 
framework. 
It is fairly important that the porcelain restoration material be properly 
applied with the desired size and shape so as to resemble the appearance 
of a tooth normally appearing in the oral cavity. In addition, the dental 
restoration should be free from any small holes and like imperfections 
which would not only mar its appearance, but affect the quality and the 
life of the dental restoration. Other metals which may be used in addition 
to gold in the metal framework are platinum and palladium. It has been 
recognized that the metal oxides, particularly in the platinum and 
palladium, bond with the porcelain in order to form the dental 
restorations. 
The porcelain restoration material, comprised mainly of feldspar, is a 
mineral substance containing aluminum oxide and silicon oxide, and may 
also contain potassium oxide, sodium oxide or calcium oxide. Feldspar is 
an effective restoration material since it is non-plastic and functions as 
an easily fusible binder. However, water is not missible with feldspar so 
that in any mixture of the feldspar and water, the water quickly settles 
out of or to the bottom of the feldspar-water composition. Nevertheless, 
in order to mold the feldspar, which is essentially the major component in 
the porcelain composition, it is necessary to have the water in the 
feldspar in order to render the same somewhat viscous to permit molding 
and shaping, as well as sizing of any composition produced therefrom. This 
is particularly true in the formation of dental restorations. 
In the formation of the dental restorations in the past, the feldspar 
material has been mixed with the water and the producers of the dental 
restorations have attempted to work fairly quickly with a feldspar-water 
composition in order to permit the molding of the final dental 
restoration. If the water is allowed to settle from the feldspar-water 
composition, the porcelain can dry or "cure" fairly rapidly thereby 
preventing further working with the porcelain. This condition materially 
contributes to the difficulty in molding the porcelain into the desired 
shape and size. Moreover, this problem often results in a high loss rate 
of the work in progress. There have been several attempts to vibrate the 
dental restoration, or at least a portion thereof, during the formation of 
the restoration, in order to cause the feldspar to absorb the water and 
thereby permit easier molding thereof. 
In the past, it was necessary for the technician to utilize several tools 
in order to form the dental restoration. One of these tools had a working 
end which was designed to pick up the porcelain from a source thereof and 
apply the same to a mold. Thereafter, another tool was utilized in order 
to pack the porcelain in a desired fashion. A third tool was necessary in 
order to shape the porcelain into the desired shape representative of a 
tooth in the oral cavity. Another tool was required in order to cut the 
porcelain and lift the same as may be desired. Several other tools were 
required in order to further shape the porcelain, compact, cut and perform 
other operations, in order to achieve the desired appearance. During the 
entire process, it was necessary to constantly create a vibratory action 
on the porcelain material, such that the porcelain material would hold the 
water, thereby enabling formation of the porcelain into the desired size 
and shape. In each case, the technician or other operator would use a tool 
or similar device to create the proper amount of vibratory action so that 
the water would temporarily be held by the porcelain during the vibratory 
action. 
From the foregoing, it can be observed that one of the primary problems in 
forming the dental restorations encountered is the substantial time delays 
resulting from finding and selecting the proper tool for using the same in 
constructing the dental restoration. For example, if one of the tools 
which might be necessary at any step in the formation of the dental 
restoration is not immediately available, water would quick precipitate 
from the porcelain composition, thereby permitting the porcelain to set-up 
in a condition where it is not capable of being further molded. This 
resulted in a complete loss of the partially completed restoration. This 
condition is fairly prominent inasmuch as the technician often encounters 
substantial delay in selecting the proper tool and, in addition, creating 
the vibratory action which is necessary to cause the feldspar to hold the 
proper amount of water. 
OBJECTS OF THE INVENTION 
It is, therefore, the primary object of the present invention to provide a 
tool for forming dental restorations used in the oral cavity of a human 
being and having a handle section with a pair of tool sections mounted 
thereon and with a serrated surface section located intermediate the pair 
of tool sections. 
It is another object of the present invention to provide a tool of the type 
stated which is highly efficient in its operation and which can be 
constructed at a relatively low unit cost. 
It is a further object of the present invention to provide a tool of the 
type stated in which one of the tool sections may be removably connected 
to the handle section of the tool. 
It is an additional object of the present invention to provide a tool 
assembly of the type stated which includes a pair of cooperating tool 
sections for forming dental restorations used in the oral cavity, and in 
addition a serrated surface which is located for vibratory movement with 
respect to the restorations during formation thereof in order to create 
fluid movement in a restoration material used in the formation of dental 
restorations. 
It is also an object of the present invention to provide a method of 
utilizing a tool in order to form dental restorations used in the oral 
cavity of a human being on a highly efficient basis, thereby reducing the 
reject rate and reducing the amount of scrap material. 
It is still another object of the present invention to provide a method of 
the type stated where a pair of tool sections are located on opposite ends 
of a handle section and which are manipulatable to perform the required 
work function, as well as a serrated surface section which is located in 
desired relationship to each of the tool sections in order to create a 
vibratory movement on the restoration in order to create fluid movement in 
the restoration material. 
It is another salient object of the present invention to provide a method 
of making tools used in the formation of dental restorations for use in 
the oral cavity and which method permits the making of such tools at a 
relatively low unit cost in a mass production operation. 
With the above and other objects in view, my invention resides in the novel 
features of form, construction, arrangement and combination of parts 
presently described and pointed out in the claims. 
SUMMARY OF THE DISCLOSURE 
The present invention relates to a tool which is capable of forming dental 
restorations for use in the oral cavity of a human being. The tool 
generally comprises an elongate handle section which is capable of being 
grasped by the fingers of the user. A first tool section is located on a 
portion of this handle section, and, in preferred embodiments thereof, is 
located on one end of the handle section. This first tool section is used 
in the formation of dental restorations from a synthetic restoration 
material, such as porcelain. A second tool section is located on another 
portion of the handle section, and, in a preferred embodiment, is located 
on an opposite end of the handle section. This second tool section is 
cooperatable with the first tool section and is also used in combination 
therewith in the formation of the dental restorations from the synthetic 
restoration material. A serrated surface section is associated with the 
elongate handle section and is also located intermediate the first and 
second tool sections. This serrated surface section is used to create a 
vibratory action on the dental restoration through reciprocative movement 
to further aid in the formation of the dental restorations. 
In a more preferred embodiment of the present invention, the first tool 
section is designed with a size and shape to pick up a synthetic 
restoration material and place the same in proper position on a mold in 
order to form a dental restoration. In addition, the second tool section 
is designed with a size and shape to carve and shape the restoration. 
Either one of these tool sections may be designed with a size and shape to 
lift the restoration material or to condense the restoration material. 
The serrated surface section mentioned above is generally comprised of a 
plurality of upstanding axially spaced apart ridges which are separated by 
reduced groove portions. These ridges are formed by radially outwardly 
extending rings terminating in outer annular curved edge portions. The 
ridges are sequentially formed with constantly reducing radius from one 
end of the serrated surface section to the other end thereof. 
The handle section in the tool of the present invention may preferably 
include a first threaded attachment means and the tool section includes a 
head portion with the head portion having a second threaded attachment 
means. The second threaded attachment means is cooperatable with the first 
attachment means to fixedly, but nevertheless removably, secure the head 
portion to the handle portion. The first tool section in this case is 
fixedly, and generally non-removably, attached to the head portion. 
In one embodiment of the present invention, the first attachment means may 
comprise a threaded shank on the handle section and the second attachment 
means may comprise an internally threaded recess in the head portion. In 
another embodiment of the present invention, the first threaded attachment 
means may comprise an internally threaded recess in the handle section 
with the second threaded attachment means comprising a threaded shank on 
the head portion. In addition, and in similar embodiments of the present 
invention, the second tool section may also be threadedly attached to the 
handle section. 
In some respects, it is desirable to form the handle section in a 
non-circular cross-sectional shape in order to facilitate handling 
thereof. In addition, the handle section may also be provided with a 
plurality of slightly reduced serrations in order to further facilitate 
the handling. The serrated surface which is used to cause the vibratory 
action in the most preferred embodiment of the present invention is 
located in closer proximity to one of the tool sections than to the other 
of the tool sections on the tool of the present invention. 
The two tool sections are located at opposite ends of the handle section 
which is properly sized so that the tool may be easily and quickly rotated 
through approximately a 180.degree. arc in order to utilize both the first 
and second tool sections. Moreover, the serrated surface section is 
located relative to the tool sections so that it may be quickly and easily 
located in proximity to the dental restorations to cause the 
aforementioned vibratory action thereon, without any substantial delay in 
moving from the tool section to the serrated section. 
The present invention further provides a method of using the tool for 
forming the dental restorations used in the oral cavity of a human being. 
In this case, the method comprises the engaging of the handle section of 
the tool and locating at least the first tool section on one end thereof 
relative to a mold means to perform an operation in the formation of a 
dental restoration. Thereafter, the method includes the shifting of the 
position of the tool to be located in a position where the serrated 
surface section is in proximity to the dental restoration being formed. 
The serrated surface section is then moved on the restoration, preferably 
in a reciprocative manner, to cause movement of the fluid therein. 
Thereafter, the dental tool is rotated through an approximately 
180.degree. arc to locate the second tool section in proximity to the 
dental restoration in order to permit the second tool section to operate 
on the dental restoration. 
The present invention further provides a method of making the tools for use 
in the formation of dental restorations used in the oral cavity of a human 
being. In this case, the method comprises the locating of a plurality of 
metal blank sections in a position to be formed with a handle section. The 
blanks, along with the handle sections thereon, are located in a position 
to form the serrated surface sections on each of the tools thereafter. The 
serrated sections are located in close proximity to one of the tool 
sections. In addition, the tools are provided with a first tool section on 
one end of the handle section and which first tool section is used in the 
formation of the dental restoration to be used in the oral cavity. A 
second tool section is then located on the other end of the handle section 
to be used in the formation of a dental restoration formed from a 
synthetic restoration material. 
In a preferred aspect of the present invention, one of the tool sections is 
removably attached to the handle section. Also, the other of the tool 
sections may be integrally formed with the handle section. In another 
embodiment, both of the tool sections may be removably attached, 
preferably through threaded attachment to the handle section.

DETAILED DESCRIPTION 
Referring now in more detail and by reference characters to the drawings, A 
designates a tool constructed in accordance with and embodying the present 
invention, and which is primarily useful for forming dental restorations 
to be used in the oral cavity of the human being. In this case, the tool 
of the present invention may be referred to as a "dental instrument", or a 
"dental tool" since tools of the present invention are primarily designed 
for use in creating and forming dental restorations to be used in the oral 
cavity. 
The tool A of the present invention comprises a handle section 20 having a 
non-circular side wall 22, preferably of an octagonal shape. However, the 
shape of the side wall can adopt any geometric form including a circular 
side wall, although non-circular side walls, and preferably eight-sided 
(octagon) shaped side walls, are desired in order to facilitate gripping 
of the handle section 20. In addition, the handle section 20 may be 
serrated as shown in FIGS. 1-3 of the drawings in order to further 
facilitate gripping thereof by the fingers of the user of the tool. 
However, in this case, gripping serrations are located only on seven of 
the side walls with the eighth remaining relatively smooth and flat. 
The handle section 20 is generally elongate in construction as illustrated 
and is provided at its right-hand end, reference being made to FIG. 1, 
with a relatively flat transverse end wall 24. In addition, the elongate 
handle section 20 is provided with an internally threaded recess 26 in 
order to threadedly, and thereby fixedly, but nevertheless removably, 
receive the threaded shank 28 of a head section 30. This head section 30 
has essentially the same diametral size and shape as the handle section 20 
and is threadedly, but nevertheless removably, secured thereto through the 
externally threaded shank 28 fitting within the internally threaded recess 
26 formed within the handle section 20. 
The head section 30 rigidly carries a first tool section 32 which is used 
in the formation of a dental restoration to be used in the oral cavity of 
a human being. This tool section 32 comprises a blade-like element 34 
provided with a shank 36, the latter of which extends into, and is rigidly 
and retentively retained within, the head 30. In this case, the flange 36 
can either be inserted into the head 30 and retained therein by means of 
any suitable adhesive or the like. Otherwise, the flange 36 can actually 
be molded into and integrally formed into the head 30 during the formation 
thereof. 
The handle section 20 is preferably formed of a metal material of the type 
normally used in the construction of tools of this type and, in this case, 
is preferably a high tensile steel material. However, other forms of 
metals may be used in the construction of the handle section forming part 
of the tool. The head section 30 is preferably formed of a moldable 
plastic material, such as polyethylene, polystyrene, polybutadiene, 
various copolymers thereof and the like. In this way, the head section 30 
may be formed in a relatively inexpensive manner. Nevertheless, the 
threaded shank 28 may be removably, but nevertheless threadedly, secured 
in a retentive manner in the internally threaded recess 26 formed in the 
handle section 20. As indicated above, the tool section 32 may have a 
portion thereof formed within the head 30 during the formation of the 
latter. In addition, the flange 36 of the tool section 32 may be inserted 
within a slot which is formed in the head section 30 and retentively 
retained therein. If desired, the flange 36 may be provided with a pair of 
apertures 37 for the plastic to flow through during formation of the head 
30 to thereby physically attach the flanges 36 to the head 30. 
FIG. 5 of the present invention more fully illustrates a modified form of 
tool section 38 which may be used in the tool of the present invention. In 
this case, the tool section 38 comprises an enlarged head 40 comprised of 
a cylindrically shaped side wall 42 and a forward transverse end wall 44, 
along with a diametrally-reduced tubular boss 46 formed at the rearward 
end thereof. The tubular boss 46 has an externally threaded section 48 for 
threaded attachment to the internally threaded recess 26 formed within the 
handle section 20. In addition, a work member, such as a tool section 50, 
is provided with an outwardly extending blade 52 and a rearwardly 
extending shank or flange 54, the latter of which extends into the head 40 
through an aperture in the front wall 44. Thereafter, the entire central 
cavity of the head 40 is filled with a moldable plastic through the 
externally threaded tubular boss 46 so that the rearwardly extending 
flange 54 is permanently embedded in the solid molded plastic filler 56, 
in the manner as further illustrated in FIG. 5. In this case, any form of 
structural steel may be used to form the outer head shell 40 and any form 
of injectable moldable plastic may be used to form the inner core 56. 
Again, the tool section 50 may be formed of a structural metal of the type 
described. 
At its left-hand end, reference being made to FIGS. 1 and 2, the handle 
section 20 merges into a diametrally reduced neck portion 58 which 
integrally merges into a serrated surface section 60 which is initially 
diametrally enlarged with respect to the diametrally reduced neck section 
58. The serrated section 60 is more fully illustrated in FIG. 6 of the 
drawings and is comprised of a series of axially, spaced apart, radially 
extending ring sections 62, each formed by a pair of radially, outwardly 
extending walls 64 connected by a rounded outer annular edge 66. Valleys 
67 connecting each of the ring sections 62 are also rounded. Moreover, 
each of the edges 66 are diametrally reduced in succession relation to one 
another over the overall length of the external serrated section 60. 
While the construction as illustrated in FIG. 6 is described herein as a 
preferred construction, any form of serrated surface construction may be 
utilized in creating a vibratory action on the dental restorations being 
formed. In this respect, it is important that the serrated surface section 
60 be designed so that it is capable of forming a vibratory action on the 
dental restoration to be used in the oral cavity in order to move any 
fluid in the dental restoration material, typically the porcelain 
material, which is used in the formation of the dental restoration. 
The blade 34 actually adopts the form of a posterior carver in the shape 
and size as illustrated in FIGS. 1 and 2 of the drawings. One of the 
unique aspects of the present invention is that the tool section 32 is 
formed so that the blade 34 is relatively thin in cross-sectional shape. 
Moreover, the blade 34 is formed so that it is relatively pliable and 
flexible, capable of being elastically deformable, but nevertheless which 
is capable of performing the required function in the formation of the 
dental restoration. In this case, it is preferable that the blade 34 be 
formed of a high tensile strength steel, although other structural metals 
could be used. 
The serrated section 60 integrally merges into a second tool section 68 
which adopts the form of a cutter and lifter. In this case, the second 
tool section 68 includes an extension 70 which extends from the serrated 
section 60 and integrally merges into a curved spoon-like device 72 having 
a relatively sharp outer edge 74. This particular tool section 68 is 
designed to cut and lift the dental restoration material during the 
formation of the dental restoration for use in the oral cavity. 
FIG. 7 illustrates a modified form of dental tool constructed in accordance 
with and embodying the present invention. In this case, the tool 
illustrated in FIG. 7 is similar in many respects to the dental tool 
illustrated in FIGS. 1-6. However, in this embodiment, the dental tool of 
FIG. 7 comprises a first tool section 32 which has a work member in the 
form of a carver 76 extending from a head section 78, the latter of which 
is removably secured to the handle section 20. At the left-hand portion of 
the handle section 20 is located a serrated section 60, similar to the 
serrated section in FIG. 2. Integrally merging into the serrated section 
60 is a second tool section in the form of a cutter and lifter 68 which is 
also similar to the cutter and lift section in FIG. 2. 
FIGS. 8 and 9 illustrate yet another modified form of tool in accordance 
with the present invention used in the formation of dental restorations. 
The tool illustrated in FIGS. 8 and 9 of the drawings includes a handle 
section 20, with a first tool section 80 on one end thereof. In this case, 
the first tool section 80 includes a head 82 which is threadedly or 
otherwise fixedly attached to the handle section 20 and extending 
outwardly from the head section 82 is a work member 84, in the form of a 
posterior and interior carver, connected to the head section 82 by means 
of an extended shank 86. At its left-hand end, the handle section 20 
merges into the serrated surface section 60 through the diametrally 
reduced neck 58 and this serrated surface section 60 integrally merges 
into a second tool section 88. The tool section 88 adopts a form of a 
lingueal shaper and carver. 
FIGS. 10 and 11 illustrate an additional embodiment of the present 
invention in which both first and second tool sections are removably, but 
nevertheless fixedly, secured to a handle section. The embodiment of FIG. 
10 comprises a handle section 90 similar to the previously described 
handle section 20. However, the handle section 90 is provided at its 
forward end with a head 92, the latter carrying a work member 94 which 
also adopts the form of an interproximal condenser. The head 92 is 
provided with an internally threaded recess 95 which is sized to 
accommodate an externally threaded shank 96 extending forwardly from the 
handle section 90. In this way, the head 92 is threadedly, but 
nevertheless removably, affixed to the handle section 90. At its rearward 
end, a second tool section 98 is also threadedly secured to the handle 90. 
In this case, the second tool section 98 comprises an elongate portion 100 
comprised of a working member 102 in the form of a lingueal condenser, and 
connected to the head section 98 through a serrated section 104, 
substantially equivalent to the serrated section 60. This serrated section 
104 is provided with an externally threaded shank 105, which is designed 
to be threadedly, but nevertheless removably, connected to an internally 
threaded recess 106 formed within the handle section 90 in the manner as 
illustrated in FIG. 10 of the drawings. 
FIGS. 12-17 illustrate various forms of tool sections which may be used in 
the present invention. In this case, each of the tool sections illustrated 
in FIGS. 12-17 comprise a head substantially equivalent to the head 30 for 
removable attachment to the body section 20. However, the working members 
extending from the head differ slightly in each of these respects. FIG. 12 
represents one form of work member 114 in the form of a labial condenser. 
FIG. 13 illustrates another form of work member 116 in the form of a 
labial condenser 116. FIG. 14 illustrates an additional labial condenser 
118 having a flat forward edge 120. FIG. 15 illustrates a labial condenser 
122 with parallel side edges 124. FIG. 16 illustrates a cutter 126 having 
a tapered cutting edge 128. FIG. 17 illustrates a spade 130 having 
approximately twice the size of any of the aforementioned work members. In 
each case, any of the first tool members described in connection with 
FIGS. 12-17 may be used in connection with any of the previously described 
tools of the present invention. 
One of the unique aspects of the present invention is that the tool 
described herein is capable of being utilized in such manner that the 
first and second tool sections are capable of being quickly rotated and 
manipulated in order to perform the work on the dental restoration. In 
addition, the serrated surface section is located with respect to one of 
the tool sections so that it can be almost instantaneously moved into a 
position where it is capable of creating the necessary vibratory action in 
order to move fluid into the restoration material, such as the porcelain. 
In this way, the porcelain cannot irrevocably harden which would otherwise 
result in the destruction of the dental restoration thus formed. In 
essence, with the tool of the present invention, it is possible to "pack" 
the restoration material and vibrate this material almost simultaneously 
therewith in order to permit movement of the water into the restoration 
material in order to enable molding and shaping of the same. 
It has been established in accordance with the present invention that the 
gypsum which forms the mold is quite porous and tends to absorb the water 
included in the feldspar forming the porcelain restoration material. 
Consequently, it is incumbent upon any technicians producing dental 
restorations to move fairly quickly in a manner so that the gypsum does 
not absorb the water, thereby rendering the feldspar fairly useless. 
However, the tools of the present invention are so uniquely designed so 
that both packing operations and shaping operations can be performed 
fairly quickly. In addition, the vibratory action necessary to create a 
movement of water into the feldspar on the thus formed dental restoration 
is sufficient in order to enable the operator to form the desired end 
product. The restorations thus formed have a dense appearance due to the 
ability to pack and condense the restoration material while in a fairly 
pliable state. In addition, the restorations have a good color appearance 
and good vitality. Moreover, from a standpoint of physical 
characteristics, the restorations have very low porosity thereby 
inhibiting bacteria formation and air entrapment which increases the life 
of the restorations. 
Some of the work members used in the present invention are uniquely 
designed to also facilitate in the formation of the dental restorations. 
Particularly the carver 78 is designed so that an upper edge 132 is 
slightly divergent inwardly toward an axis passing through the handle 
section 20. A lower edge 134 is curved and merges into the upper edge 132 
at a point 136. The work member 126 is also uniquely designed so that the 
upper edge 128 merges into a bottom edge 138 at a point 140, with the 
bottom edge 140 being essentially parallel to an axis passing through the 
handle 20. 
Thus, there has been illustrated and described a unique and novel 
instrument used in creating dental restorations for use in the oral cavity 
along with a method of using the same and a method of making the same. It 
should be understood that many changes, modifications, variations and 
other uses and applications will become apparent to those skilled in the 
art after considering this specification and the accompanying drawings. 
Therefore, any and all such changes, modifications, variations and other 
uses and applications are deemed to embodied by this invention which is 
limited only by the following claims.