Feb. 1, 193s.' QHPRANGE-UM , ‘ 2,106,809 SWAGED DENTURE AND METHOD OF MAKING THE SAME Filed Dec. 15, 1954

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Afro EY. Patented Feb. 1, 1938 2,106,809

UNITED ‘STATES PATENT OFFICE 7 2,106,809 SWAGED DENTURE AND METHOD OF MAK ING THE SAME Charles H. Prange, Lyndhurst, N. J ., and Erich H. Zahn, Port Washington, N. Y., assignors to Austenal Laboratories, Inc., New York, N. Y., a corporation of New York Application December 15, 1934, Serial No. 757,654 9 Claims. (Cl. 32-2) Our present invention relates generally to relationship to form a completely ' integrated dentures, and has particular reference to an im , unit with the weak ply on the inside. The weak proved denture base of the swaged type and to but more deformable ply imparts to the re a method of making the same. ' sultant denture base an inner surface which ac 5 While we have herein illustrated and shall here curately re?ects the con?gurations of the mouth inafter describe the present invention in con surfaces for which the denture is intended; while nection with a denture constituting what is known the stronger ply imparts to the resultant denture in the profession as a “full upper”, nevertheless the requisite rigidity and strength. it will be'understood that the invention is not One of the features of the invention leading restricted to this speci?c type of device. to a successful accomplishment of the present 10 Among the vital requirements that must be objectives resides in the manner in which the complied with in making a‘ denture of good qual two plies are bonded together into inseparable ity are the requirements‘that it embody su?i integral relationship. In accordance with our cient rigidity and staunchness to retain its gen present mode of procedure, a third ply of sheet 15 eral contour over long periods of use, and that material is swaged into conformity with the pat the inner surface (i. e., the surface that bears tern,- and consists of an extremely thin sheet of against the tissues of the mouth) conform with fusible material which is sandwiched between the as much accuracy as possible to the unique ir ?rst-mentioned piles and which ultimately serves regularities and convolutions of the mouth for as a bonding agent or spacer. The material used which it is intended. a In the case of ordinary for this bonding purpose must embody ductility; 20 swaged denture bases (as distinguished from it must have a relatively low fusibility; it must those which are cast), the simultaneous com have, an ability readily to “wet” the material pliance with these two requirements is beset with contacting its opposite surfaces; it must be un difficulty. In a swaging operation, the accurate reactive to, and una?ected by, mouth fluids; and ' conformity with the irregularities of a dental it must not be objectionable in taste or char 25' pattern results from the ductility of the material acteristics. Preferably, we employ a noble metal that is pressed against the pattern. In the case such as silver or gold, or alloys of the two. of sheet metal, the thinner the sheet the‘ greater Where silver is employed as the intermediate its ability to partake of the detailed convolutions spacer or ply, it is a further feature of our in of the pattern. A sheet of foil-like thinness vention to condition the same so as to increase 30 would be ideal, for example, from this standpoint. its “wettability” with respect to the denture base However; the thinner the sheet the weaker the material with which it is employed. We have resultant denture. found that by electroplating a silver foil with Accordingly, the manufacture of swaged den an extremely thin layer of a material of the group 35 tures has heretofore involved a sort of compro which includes copper, tin, platinum, and gold, 35 mise between the employment of a sheet of suffi the “Wetting” qualities of the silver, when fused, cient thinness to conform with the details of the are greatly ‘enhanced. pattern, yet of su?icient thickness to impart ade Brie?y, the procedural steps entering into our quate rigidity to the resultant article. present invention are (1) individually swaging In accordance with our present invention, this into conformity with the pattern the three plies 40 dilemma is obviated, and we are enabled to pro of‘ material hereinbefore mentioned, (2) nesting duce a swaged denture base which is not only of these plies together to form a denture base as suf?cient staunchness and rigidity, but which at sembly, (3) reswaging the assembly to squeeze the same time-embodies an inner surface which the intermediate bonding ply into more intimate 45 bears an unusually accurate and detailed im— 45 print of the irregularities and convolutions of contact with the surfaces contacting with it on the pattern in question. opposite sides, (4) spot-welding the plies to One of the features of our invention lies in gether to bond them preliminarily, and (5) final forming the denture base of two plies of mate ly fusing the intermediate layer so as to bond 50 rial, one of which is relatively weak but of great the elements of the assembly into a completely 50 deformability, while the other of which is less integrated unit. ‘ deformable but of greater strength. These two We achieve the foregoing, objects, and such plies are individually swaged into conformity other objects as may hereinafter appear or be with the unique irregularities of a pattern, and pointed out, in the manner illustratively exempli 55 they are thereupon bonded together in nested ?ed in the accompanyingdrawing, wherein 65 2 2,106,809 Figure 1 is a. perspective view of an illustra the next step in the process is to subject this foil tive dental pattern; . to an electroplating action, preferably with cop Figure 2 is a perspective view of the three plies per, but, if desired, with platinum, tin, gold, or of material after they have been individua the like. An extremely thin layer of the electro swaged; > plated metal is caused to be deposited on the Figure 3 is a greatly enlarged and exaggerated opposite surfaces of the silver foil. A deposit of cross-sectional view through the assembly after approximately two per cent, and preferably less, the plies have been initially nested; by weight, is sufficient for the present purposes. Figure 4 is a view similar to Figure 3, showing Measured in inches, where the thickness of the 10 the relationship of the parts after the assembly foil is about .001 inch, the thickness of the electro 10 has been subjected to reswaging upon the die or deposited layer on each side of the foil will be no 1 pattern of Figure 1; greater than .00001 inch. ' Figure 5 is a perspective view of the assembly The foregoing electroplating process has not prior to the fusing step; and . been illustrated ‘but will be readily understood by 15 Figure 6 is a cross-sectional view through a re those skilled in the art. The con?gured foil may sultant complete denture. ' be expeditiously suspended in a suitable electro The die Ill shown in Figure 1 is made of metal plating solution to accomplish the desired pur and is an exact duplicate of the plaster model pose. , which is originally prepared by the dentist from After the foil has thus been conditioned, the 20 impressions taken within the patient’s mouth. three plies are nested together in the relation 20 It will be understood that the die It is used with ship shown in Figure 2, and are then reswaged, a companion die, also of metal, the set being pref as a unitary assembly, under the action of the die erably but not necessarily produced substantially l0 and its companion. This reswaging operation in the manner described in the Erdle Patent Num serves to press the plies ?rmly into mutual super 25 ber 1,834,123. The die It ‘and its companion (not position, and has the further important effect 25 shown) are adapted to be inserted into suitable (illustrated in ‘Figures 3 and 4) of causing the supports, so that the pair may be interposed into intermediate silver foil to be squeezed into more a hydraulic. press or the like._ When the dies intimate contact with the plies contacting its are pressed toward each other, any interposed opposite sides. - ' sheet or material is swaged into conformity. It Figures 3 and 4 are greatly exaggerated and 30 is the upper surface of the die It which is of pri greatly enlarged ‘fragmentary cross-sections mary importance, and the completed denture through the nested assembly before and after the should have an inner surface which bears an im reswaging operation. Inasmuch as the under print, as accurate and detailed as possible, at the surfaces I4, l5, and 15 of the plies H, II, and I3, irregularities of this upper surface. respectively, are each substantially identical with‘ In accordance with our invention, three plies the con?guration of the upper surface of the H, II, and I! are successively and individually die Ill, it follows that the upper surfaces of the swaged into conformity with the die ll. Each of respective plies, because of the thickness of each the piles I I and ii is preferably of sheet metal of ply, are incapable of nesting with perfect accu suitable character. For example, the metal may racy when the plies are originally placed together. be an alloy of.chromium, nickel, and steel,v or an Minute gaps, such as those illustrated at H and alloy of chromium and nickel, or of any‘ other I8, exist. During the reswaging operation, the suitable denture base material. intermediate ply I2 is deformed, by the pressure, The intermediate ply I2 is a metallic foil which into substantially the condition illustrated in may be composed of gold, silver, or, in general, Figure 4, whereby these gaps are ?lled in. This 45 any suitable fusible metal or alloy of suitable duc is, in any event, our belief as to what takes place tility. Silver has been found to be preferable. during the reswaging operation. The ply I I ultimately serves as the lingual side The assembly is then subjected to a spot-weld of the denture base, and the exposed surface of ing operation, which preliminarily bonds the the ply- I3 is the one which ultimately bears several layers together into a more permanent 50 against the tissues of the mouth. The ply II is, unit, and the result is then substantially of the therefore, referred to herein and in the appended character illustrated in Figure 5 which, it will be claims as the "inner" ply, and by this term it will understood, is also exaggerated in thickness. The - be understood that it is intended to refer to the spots I! represent the points at which spot-weld 55. surface that would be known as the "palatal” ing has taken place, and these welds are caused surface lithe case of an upper denture, or the. to take place at no specific points but merely at “ridge” 0]; "alveolar" surface in‘ the case of _a a number of judiciously selected points to insure

lower denture. ' ‘ . the maintenance of the relative positions of the In accordance with the present invention, the plies. 60 ply II has a thickness of the order of .010-.012 The assembly is then subjected to a heat treat 60 inch; while the ply I8 is of foil-like thinness, of ment, preferably in an oven, and while this the order of approximatehr .003 vinch. The foil procedure has not been illustrated it will be un 1|! Illias a thickness no greater than about .001 derstood by those skilled'in the art. The heat nc . is sumcient to cause a fusing of the intermediate When the plies are individually swaged against ply, and, because of the lower fusibility of this the die l0, it will be found that the ply II, because‘ ply, the other plies remain unaffected. The fus- ' of its relative thinness, and hence because of its ing temperature causes the intermediate ply to corresponding increased ‘ductility, partakes'lwith flow, and virtually to braze the. main plies l2 remarkable accuracy of the unique irregularities and i3 together in an intimate manner. The 70 of the surface of the die II. A corresponding fusing procedure is carried on in a hydrogen at imprint, but of lesser accuracy in details, is pro mosphere. - vided on the ply ll. Needless to say, the ply l2 After cooling, the denture base, which is now conforms with little dimculty to every minute ir a completely integrated unit, is subjected to the

regularity. ~ , further procedures which lead to the production Where the intermediate ply I2 is of silver foil, roflua complete denture. For example, upon ref 3 erence to Figure 6, it will be observed that a being less deformable but of greater strength, mesh support 2i) is soldered or welded onto the whereby the denture-base is of adequate rigidity marginal portions which are to bear the arti?cial and has an inner surface bearing an accurate and teeth. A wire or metal abutment 2| is then detailed imprint of the pattern; and a fused welded onto the base along the inner margin of spacer between 'the plies bonding them together G1 the mesh support 20; and attaclmient material into a completely integrated unit, said spacer 22, bearing the arti?cial teeth 23, is then applied, comprising metallic foil coextensive in area with this material being ?rmly held in position by its said plies and consisting of a metal of the group interengagement with the mesh support 20, and which includes silver, gold, and alloys thereof. abutting along its inner margin against the 2. A denture base assembly consisting of three shoulder 2|. nested plies of sheet material individually swaged Polishing and burnishing then completes the into conformity with the same uniquely irregular denture. . pattern, the inner ply being relatively weak but With reference to the electroplating procedure of great deformability, the outer ply being less 15 hereinbefore mentioned, we are not able at the deformable but of greater strength, and the in present time to state with absolute certainty the termediate ply being metal foil of relatively low reasons for its bene?cial effects. It is our theory, fusibility and chosen from the group which in however, that the copper or similar electroplated cludes silver, gold and alloys thereof. I layer, because of its higher degree of "wettabil 3. A denture base assembly consisting of three 20 ity”, enhances the free ?owing of the silver when nested plies of sheet material individually swaged the latter is fused. We refer, by the term “wet into conformity with the same uniquely irregu tability” to the ability of a liquid to flow over lar pattern, the inner ply being relatively weak and wet a solid with which it is in contact. This but of great deformability, the outer ply being ability depends in large measure upon the ad less deformable but of greater strength, and the 25 hesion tension between the liquid and the solid, intermediate ply being a foil of silver electro and probably depends also upon the surface ten plated with an extremely thin layer of a metal sion of the liquid. which conditions the silver to enhance its degree An untreated silver foil is found to be de of wettability with respect to the other plies. ?cient in its ability to “wet” the surfaces with 4. A denture base assembly consisting of three 30 which it is in contact. By conditioning it, how nested plies of sheet material individually swaged 3O ever, by the electroplating procedure hereinbe into conformity with the same uniquely irregu fore mentioned, its wettability is enhanced to a lar pattern, the inner ply being relatively weak degree which makes the present process entirely but of great deformability, the outer ply being feasible. During the fusing, the minute electro less deformable but of greater strength, and-the 35 plated deposit undoubtedly alloys with the silver, intermediate ply being a foil of silver electro 35 but the added ingredient is present in such a plated with an extremely thin layer of a metal small proportion that its presence, after the of .the group which includes copper, platinum, fusing, is practically inappreciable. Its bene-' gold, and tin. ?cial effect arises from the fact that, while it is 5. The method of making a metallic denture 40 present as an alloying ingredient in only a minute base with an inner surface bearing anaccurate 40 proportion, it is concentrated in its ventirety be and detailed imprint of a uniquely irregular pat fore the fusing on the‘ exposed surfaces of the tern, which consists in individually swaging into

silver. 7 /. . conformity with said pattern three plies of sheet In certainicases, the intermediate bonding lay material, one of said plies being of relatively thin 45 er needn'ot be conditioned in this manner, as will metallic denture base material and hence rela 45 be readily understood. In the case of gold, for tively weak but of great deformability, another , example, no electroplating procedure is neces of said plies being of relatively thick metallic sary to enable a foil of gold or gold and silver denture base material and hence of less deforma alloy or the like to flow freely and to effect its bility but relatively strong, the third ply be 50 bonding action with a maximum degree of ef ing metal foil of relatively low fusibility chosen ficiency. from the group which includes silver and gold, It‘xwill also be understood that, under certain nesting said plies with the foil in the middle and circumstances, the spot-welding procedure may the deformable ply on the inside, and fusing said be dispensed with. foiltto bond the plies into a completely integrated 55 The applicability of the invention to dentures uni . . 55 , other than “uppers".will be obvious from the 6. The method of making a metallic denture foregoing description. base with an inner surface bearing an accurate In general, it will be understood that changes and detailed imprint of a uniquely irregular pat in the details, herein described and illustrated tern, which consists in individually swaging into 60 for the purpose of explaining the nature of our conformity with said pattern three plies of sheet 60 invention, may be made by those skilled in the material, one ‘of said plies being of relatively thin art without departing from, the spiritand scope of metallic denture base material and hencerela the invention as expressed in the appended tively weak but of greatdeformability, another claims. It is, therefore, intended that these de of said plies being of relatively thick metallic 65 tails be interpreted as illustrative, and not in a denture base material and hence of less deforma 65 limiting sense. bility but relatively strong, the third ply being Having thus described our invention, and illus metal foil of relatively low fusibility chosen from trated its use, what we claim as new and desire the group which includes silver and gold, nesting to secure by Letters Patent is said plies with the foil in the middle and the de l. A metallic denture base comprising two nest 70 ed plies of metallic denture base material coex formable ply on the inside, reswaging the nested tensive in area with each other and individually assembly to squeeze the foil into more intimate swaged into conformity with the same uniquely contact with the plies on each side of it, spot-' irregular pattern, the inner ply being relatively welding the assembly to bond the plies prelimi weak but of great deformability, the outer ply narily, and subjecting. the assembly to a heat 75 4 9,108,809 su?lcient to fuse said foil, whereby the plies are swaging a sheet of silver foil into conformity with - bonded into a completely integrated unit, said pattern, then electroplating said foil with 7. The method of making a metallic denture an extremely thin layer of a metal which condi base with an inner surface bearing an accurate tions said foil to enhance its wettability with re and detailed imprint of a uniquely irregular pat spect to the other plies, nesting said plies with 5 tern, which consists in individually swaging into the conditioned silver foil in the middle and the conformity with said pattern three plies of sheet - deformable ply on the inside, and fusing said material, one of said plies being of relatively thin silver foil to bond the plies into a completely in metallic denture base material and hence‘ rela tegrated unit. tively weak but of great deformability, another 9. The method of making a denture base with of said plies being- of relatively thick metallic an inner surface bearing an accurate and de denture base material and hence of less deform tailed imprint of a uniquely irregular pattern, ' ability but relatively strong, the third ply being which consists in individually swaging into con- ‘ metal foil of relatively low fusibility chosen from formity with said pattern two plies of denture 15 the class which includes silver and gold, nesting base material, one of said plies being relatively said plies with the foil in the middle and the de weak but of great defonnability, the other ply formable ply on the inside, reswaging the nested being less deformable but of greater strength, assembly to squeeze the foil into more intimate swaging a sheet of silver foil into conformity contact with the plies on each side of it, and sub with said pattern, then electroplating said foil jecting the assembly to a heat su?lcient to fuse with an extremely thin layer of a metal of the 2o. said foil, thereby bonding the plies into a com group which includes couper, platinum, gold, pletely integrated 'unit. and tin, nesting said plies with the plated silver 8. The method of making a denture base with foil in the middle and the deformable ply on the ' an inner surface bearing an accurate and de inside, and fusing said silver foil, whereby an tailed imprint of a uniquely irregular pattern, alloy is formed having a high degree of wettability 25 which consists in individually swaging into con with respect to the other plies, and whereby the formity with said pattern two plies of denture latter are bonded together into a completely in base material, one of said plies being relatively tegrated unit. weak but of great deformability, the other ply CHARLES H. PRANGE. 30 being less deformable but of greater strength, ERICH H. ZAHN. 30