General information on porcelain liquids

Dental porcelains are divided to two groups according to their application.
1. Metal based porcelains are baked over a metal (chrome, cobalt, nickel, or gold alloy) infrastructure. They have elements that enable seramometalic bonding.
2. Porcelain base materials are aluminum oxide, sepionite, zirconia or similar hard ceramic structures. Especially the metallic infrastructures are produced using the wax space method which was first used by Michelangelo. Where as ceramic infrastructures are produced by dipping, stacking, or copying and milling by computer which is named as Cad/cam systems.

Porcelain is applied over the infrastructure which was prepared by one of the methods stated above.

1. Application of the "bonding or base paste" which enables the ceramic-metal bonding: ceramic alloys are different than other normal dental alloys. Bonding is the intermediate material that enables the prosthetic alloy to ceramic. It is named as the metaloceramic junction.  to enable the junction metaloxides are added to the structure of bonding.
2. Opaquer: it is a structure similar to the structure of bonding which incorporates metal oxides and ceramic material. It is used to obtain the metaloceramic bonding just like the bonding agents. In order to mask the grey reflection of the metal opaquers have white oxides in their structure. They are the "main intermediate material" that enables the metal to bond the ceramic. Opaquers can be in the form of powder, cream, and spray.
3. Dentine ceramic: they are semi opaque and colored in appearance to mimic the characteristics of natural dentine. Dentine is usually pheldisphatic porcelain which is semi translucent in appearance.
4. Translucent (incisal) ceramic: it is the semi translucent layer of porcelain that forms the incisal third of the prosthesis.
5. Transparent porcelain in case of esthetic needs. It is the porcelain that forms the incisal part of the tooth which is completely transparent. It is mainly a glass like glaze structure.
6. Glaze step: it is a real glaze structure. It is used to mimic the natural appearance of tooth and minimize the water absorption.

The application of ceramic to metallic or ceramic infrastructures are the same. In cases where the infrastructure is porcelain, opaquer is directly applied without bonding. In order to bring the porcelain powders to manipulatable consistency, water, glycerin, fatty acids or wetters are used. These binding chemicals are named as "porcelain liquids".

Liquids used in dental technology are divided to three main categories:

A-Modeling liquid
B-Opaque liquid
C-Glaze liquid.

Liquids have different compositions suitable for their use.

A-Modeling liquid: it is used in mixing dentine or transparent powders.
Desired properties:
1. It enables the dentine or transparent powders to usable consistency when working. The prepared product ca be shaped over the infrastructure without flowing.
2. The ceramic mixture must form piles at the site of application without flowing. It must be able to keep its shape during the vibration which will estranging the water.
3. It must have the necessary consistency for ceramic structure. Ceramic which was prepared flow able than needed causes severe problems. High water content results in porosity and severe contraction.
4. Following stacking of the porcelain to expel the excessive liquid, water must be expelled using ultrasonic vibrating spatulas.
5. The water expelled following ultrasonic vibration is removed using paper tissue.
6. It is desirable for the ceramic to keep its moisture and not get dry during long duration works.
7. Before sintering, during pre drying the desired working time must be met.
8. Following sintering the contraction (rotre) must be at the desired rate.
9. It must not cause cracks in inter dental areas or at tubercules.
10. Following sintering, it must reflect the classic colors of the shade tab, it must not cause any color change.

Important points for the application of modeling kit:

1. The powder/ water ratio must be adequately set.
2. The ceramic must enable to remove excessive water by paper tissue after ceramic stacking and water decomposition. If the ceramic structure has been prepared excessively dry, the particles in the ceramic get sucked and cause shrinkage of the porcelain.  Liquid molecules that have been removed by enforcement make it harder for the residual liquid to evaporate and result in micro cracks.
3. One of the important points is the pre drying time. The pre drying time of the ovens must be set in accordance with the time written on the liquid packing. Predrying at high temperatures and short times, results in instant evaporation yielding to micro cracks, cracks and popping of the ceramic from the porcelain. The preheating times that the porcelain liquid producers’ advice must be strictly followed.
4. Sinterizations of dental ceramic is accomplished under vacuum to prevent porosities in the ceramic, strong structures are obtained.  It is mandatory for vacuumed ovens to have 1-2 mm Hg to enable expression of evaporated gasses and prevent the color change.

B-Opaquer liquid.*it is the group of liquid produced for powder opaque applications. Opaque liquids are denser in composition than modeling liquids. Desired properties of opaque liquids:

1. Must have the necessary viscosity during application. Opaquers have chemicals in their composition which enable binding. During application, it wets particles of powder grains to converge.  The increase in powder particles per unit brings easiness in application, homogenous structure and increase in blocking out. The size of the ceramic particles affects flow ability.
2. It is desired for the flow ability to be adequate. In case of excessively flow able opaquer application, opaquer flows through the prosthetic structure and causes build ups at the cervical area. Opaquer must be applied at a certain thickness at must keep its place at where it is placed. Opaquer must have enough properties to cover the shining of metal.
3. The opaquer liquid, like the dentin liquid, must be suitable with the pre drying times. The densities and the drying times of dentin and opaquer liquids are different. Even though the opaquer liquid is thicker than dentin liquid its pre drying time is shorter, because the opaquer layer is applied thinner. This way the opaquer dries in a shorter time. Since dentin is applied thicker it dries later. It is necessary for the dentin liquid to dry for a little longer time for the liquid to evaporate. Producers develop new formulations to shorten the pre drying time of dentin in order to shorten the working time.
4. During working phase, no micro cracks, blasts or roughness should appear. Necessary ceramic bonds must be building between ceramic layers.

Important points for opaquer liquid work:

1. First the powder/water ratio must be set right.
2. Thick porcelain layers must be avoided. Especially at pontics occlusions and sinterizations
bubbles can form due to evaporation difficulties.
3. Vacuum when applied in the proper is helpful in removing gasses trapped in the ceramic and preventing color change.

C-Glaze liquid;* is the liquid produced for working with glaze powder. The desired properties for glaze powder are:
1- Must be at applicable viscosity.
2- After procedure especially at molars, it must not flow through the fissures causing the modeling to disappear

Important points at opaquer and glaze work:

1- The powder/liquid ratio must be properly set like in other liquids. When the ratio is not properly set, enough powder layer does not form on the surface. Since there is no glaze likes ceramic available the desired shine can not be met.
2- Glaze liquids have no positive or negative effect on shine. After the evaporation of the liquid, a thin glaze structure is left over the surface. Following drying sinterizations is performed. Desired brightness is achieved according to the structure of the powder.

METHOD USED

For the application of porcelain over metallic infrastructure, the bonding powder is mixed with an appropriate opaquer liquid. It is applied over the sanded metal. It is sintered at 980 C heats. Base paste can be applied for a second time at will. Our company produces a porcelain bond named KERAMBOND under the trade name KERAM&KERAMİK.

The second phase is the opaquer step. Cream opaquer is produced as 2 ml ready to use injectors. (Our own product KERAMOPAK)

*Other method of application:*mixing powder opaquer with, opaquer liquid *(our own product STANDART OPAQUER AND EXTRA CREAMY OPAQUER LİQUİD)* desires consistency is achieved, it is applied using special brushes. It is sintered at 940-970 Cº. the procedure can be repeated for a second time if desired.

STANDART OPAQUER LİQUİD carried the properties mansioned above for opaquer liquids

Properties of EXTRA CREAMY OPAQUER LİQUİD:

*Creamy opaquers are preferred because of ease of use. Ready to use opaquers are used less common due to their high prices.

Even though powder opaquers are more economic, it is harder at application to use. The product we have prepared brings brush ability to the powder opaquer therefore making it easier to use. The binders in its composition, regulate the viscosity of opaquer we have formulated and enable it to be brushed easily and form an even surface.

The opaquer that is prepared at the appropriate consistency, will allow the porcelain layers applied over itself to be sintered without flowing. It will ease stacking of desired amount of porcelain at necessary places on the crown, (Modeling). With the help of retentive characteristic obtained by the opaquer, flows at the cervical regions following vibration are prevented.

With the help of its thick consistency, an equal thickness and homogenous distribution is achieved using less amount of powder. Liquid, enables powders to get closer, the voids between powders are lessened. Maximum economy (at least 30 %) and quality is achieved at ceramic use. Since the thin layer of opaquer efficiently masks and binds, it leaves more space for the application of porcelain.

Since the evaporation rate is slow, it does not dry easily; it can stay at room conditions and open air for long periods without losing its properties.

* EXTRA CREAMY OPAQUER LİQUİD can be used with cream opaquer, base paste or bonding.

The pre drying time recommended is 4-5 minutes. It must never be shorter than 4 minutes. If necessary, the desired consistency can be achieved by standard opaquer liquid.

Dentine and transparent powders are mixed with modeling liquids till reaching the appropriate consistency. The porcelain mixture is transferred on the crown using specially designed brushes. The porcelain structure is formed into a tooth. Since the praxis demands artistic skills, it is time consuming. Water which is expelled during application steps by vibration is removed using paper tissues. Dentine and transparent layers are applied successively. Following application of the necessary amount the wet porcelain is carefully modeled to the desired form. After modeling, it is sintered for the first baking. Due to the evaporation of water present in the structure, a loss of volume (retre) occurs. Necessary additions for modeling are made and second sintering is performed.

The problems of the method:

 1. Time loss due to slow work..
2. High loss of volume following the evaporation of liquid, resulting from porcelain powders non adequate binding.
3. Second baking procedure and obtaining a more porous ceramic structure. Porous ceramic structure results in low strength, esthetic problems and loss of labor.
4. Detailed forming at the high consistency state is the cause of flows and slipping during modeling.
5. Removal of excess water continuously by paper tissue, results in loss of color particles and color paling and time loss.
6. Artistic work can not be performed at modeling stage due to fear of breaking and rupture.
7. Ruptures occur during transferring to oven when elongations at the margins are performed due to prosthesis shortening.
8. It causes drying of the mixed powder at the working field and loss of working viscosity.
9. Extra liquid use due to drying, results in higher material and labor costs.

Moderation liquids produced by our company:
*UNIVERSAL    250 ml-1000 ml*
*SPEED            250 ml-1000 ml*
*KERANOR 3    200 ml-1000 ml*
*KERANOR 6    200 ml-1000 ml*
*STİL 3            200 ml-1000 ml*
*STİL 6            200 ml-1000 ml*

A thin layer of glaze is applied to the sintered and adjusted porcelain at the glaze step. In other words, the glaze liquid is mixed with the glaze powder and applied at desired consistency using a brush. The esthetic coloring or make up of the prosthesis is performed at this stage.

The glaze shines the porcelain and reduces its water absorption capacity. Besides the shining of the prosthesis, mimics the indispensable affect of natural tooth.

The glaze powder we have prepared is *BRIGTH GLAZE,* and its liquid is *K&K GLAZE Liquid*

The innovations that our new modeling liquid (TURKAFORM)*brings:
*It can be named as new generation porcelain modeling liquid. With pure liquid the porcelain powder is not prepared in a liquid viscosity but in a rather doughy more viscous manner.
*Application and modeling is really easy its just like the consistency and ease of play dough of children. Due to the properties we have developed, the “new working method” is defined.
*The conveniences that doughy ceramic application offers: *
*it facilitates the workability of ceramic tremendously. Modeling is facilitated. The porcelain that is doughy at hands can easily be shaped. An advantage is a cured at working time and professional capacity. It provides tremendous convenience and time economy at artistic works that require great expertise. It enables the prosthesis to be formed in better anatomic and esthetic forms. Due to binders in its structure, the modeling phase is easier and safer.
The colors that give the porcelain its natural look and color are formed originally without any loss.
The most important advantage is minimizations of the porcelain shrinkage from 30-40 % to 10-15 %. The rate of minimization at shrinkage, results in ceramic structure having less voids, in other words, homogenization. Less voids means stronger porcelain. **
All advantages occur by only one sintering of the ceramic application.

Operating manual: First stage is the mixing stage of the powder. Approximately, 4 parts of powder is mixed with one part of liquid. In order to assure a healthy and easy mix, the mixing process is performed on a sanded glass. First of all little amount of powder is mixed with the liquid. The doughy plastic structure obtained is taken to hand and little amounts of liquid are added till the desired consistency is reached. After the process a doughy structure is reached that has never been defined before. The dough formed is quite elastic, it can easily be shaped. During application it can be shaped with hand or a spatula if desired. It does not stick to the spatula used. It keeps the given shape, contours and the tubercular forms successfully.

The dough is kept at room temperature for some time and let to harden. When the porcelain bulk is hardened enough forming can be further carries out easily by carving if necessary. These kinds of carving applications are special to our product and it has never been defined before else where.
If more porcelain stacking is desired, the shaped and carved porcelain is wetted with the liquid using a brush. Wetting facilitates addition of the second layer of porcelain to the previous layer.

When necessary the stacking of the wet porcelain is continued by additions or carvings.
In conventional applications brushes were used to carry the wet ceramic structure over the metal or ceramic infrastructure.

One of the most important differences of us is the brush application, performing of the stacking using spatula or hand like play dough, and obtaining a perfect ceramic structure as a result.

The anatomic structures necessitating from esthetic and anatomic considerations are easily carved on the ceramic structure using a spatula.

The additions and the main ceramic structure are dried and sintered enabling the additive structures to bind.

Several methods can be used due to habituations of the technician:
With a heat source (a hair dryer) can be used.
If the technicians’ habit is so, the open door area of a ceramic oven can be used.
Drying can also be performed by sprinkling dry ceramic powder over the wet ceramic powder and letting it to absorb the excess liquid.
It is dried for a few seconds, transparent is stacked over the hardened structure, and after forming again using a spatula and the result is achieved by a single baking.

The advantages that the liquid we have developed offers are as follows:
1. The amount of the liquid can be changed, enabling the porcelain powder to be changed from flow to very viscous dough. Using a spatula or hand it can be transferred over the crown making up a new method of porcelain field.
2. It enables the transferring of big masses over the crown at once. Conventional methods of porcelain stacking necessitates several applications coursing great loss of time.
3. Due to its doughy consistency, anatomic forming is facilitated using a spatula.
4. Thanks to binders in its structure, it provides a more stable structure following drying procedure. It enables forming by carving and cutting named as modeling.
This kind of application is possible with our product for the first time, which makes it unique all around the world and enable obtaining a patent.
5. Since the drying phase offers opportunities to obtain fully wet, semi-wet and fully dry phases, it provides the technician the opportunity to make corrections and new modeling alternatives.
6. Since the dough formed is more viscous compared to conventional liquids, and less liquid is used, the volume loss (shrinkage, retre) during baking is minimized. Minimization of retre, shrinkage, which is one of the most important problems of dental technicians and strengthening of the porcelain structure, is accepted as a great advantage.

7. The need of several sinterizations resulting from several stacking of porcelain is not necessary. This results both ease to the technician and time saving.
8. Sinterizations is performed in ovens with 2000 Watt power at 850-1000 degrees centigrade. It results in 30 minutes shortening for the sinterizations period in each prosthesis. With a saving of 1000 Watts per application it both minimizes the costs of technician and adds benefit to the countries economy.
9. Since it is consumed in little amounts compared to conventional methods it is more economic.
10. It also saves paper tissue used to remove the inter crystalline water during ceramic application.
11. It eliminates color changes occurring from inevitable color loss during removal of water. Therefore, the colors are produced in close set to their original scale colors.
12. If desired, following stacking of the dentine, conventional shaping with the brush can be performed.
13. Repair of the missing or malformed ceramic structures can be easily performed.
14. More artistic and natural modeling is possible.
15. The doughy ceramic mass that has been prepared can be packed and used in 24 hours without loosing its consistency. It saves time and labor needed for new work and mixture preparation every time. It increases the number of crowns a technician can produce per time.
16. Especially at the cervical regions, it eliminates the risk of breaks during removal from the model and carrying to the oven.  Also it eliminates the shrinkage following sinterizations.

It constitutes a doughy structure from general porcelain and dental porcelain and all porcelain types. It can easily be used instead of binders used in industry during pressing technique.

It enables in ceramic industry to perform intermediate "injection" printing.  For artists, factories working at decorative and artwork, it is easily shaped due to its doughy structure. It does not necessitate pouring into a mould. It provides ease at home style artwork ceramic production.

Since this kind of application is possible for the first time in our product, it was possible for us to receive a patent.