Hardenable self-supporting structures and methods

A composition comprising:

• a resin system comprising at least one ethylenically unsaturated component and a crystalline component;
• greater than 60 wt-% of a filler system;
• and
• an initiator system;
• wherein the composition is in the form of a hardenable self-supporting structure having a first shape and sufficient malleability to be formed into a second shape at a temperature of about 15° C. to 38° C.

A composition comprising:

• a resin system comprising at least one ethylenically unsaturated component;
• greater than 50 wt-% of a filler system at least a portion of which is an inorganic material comprising nanoscopic particles having an average primary particle size of no greater than about 50 nm;
• an initiator system;
• and
• a surfactant system;
• wherein the composition is in the form of a hardenable self-supporting structure having a first shape and sufficient malleability to be formed into a second shape.

A composition comprising:

• a resin system comprising:
• a noncrystalline component selected from the group consisting of mono-, di-, or poly- acrylates and methacrylates, unsaturated amides, vinyl compounds, and combinations thereof;
• a crystalline component selected from the group consisting of polyesters, polyethers, polyolefins, polythioethers, polyarylalkylenes, polysilanes, polyamides, polyurethanes, and polymeric materials having crystallizable pendant moieties and the following general formula:
• 10
• wherein:
• R is hydrogen or a (C1-C4)alkyl group, X is —CH2—, —C(O)O—, —O—C(O)—, —C(O)—NH—, —HN—C(O)—, —O—, —NH—, —O—C(O)—NH—, —HN—C(O)—O—, —HN—C(O)—NH—, or —Si(CH3)2—;
• m is the number of repeating units in the polymer;
• and
• n is great enough to provide sufficient side chain length and conformation to form polymers containing crystalline domains or regions, and combinations thereof;
• greater than 60 wt-% of a filler system;
• and
• an initiator system;
• wherein the composition is in the form of a hardenable self-supporting structure having a first shape and sufficient malleability to be formed into a second shape at a temperature of about 15° C. to 38° C.;
• with the proviso that if the filler system comprises fibers, the fibers are present in an amount of less than 20 wt-%, based on the total weight of the composition.

A composition comprising:

• a resin system comprising a crystalline compound of the formula:
• 11
• wherein each Q independently comprises polyester segments, polyamide segments, polyurethane segments, polyether segments, or combinations thereof;
• a filler system;
• and
• an initiator system;
• wherein the composition is in the form of a hardenable self-supporting structure having a first shape and sufficient malleability to be formed into a second shape.

A method of preparing a composition comprising:

• combining a resin system comprising a crystalline component, greater than 60 wt-% of a filler system, and an initiator system to form a mixture;
• with the proviso that if the filler system comprises fibers, the fibers are present in an amount of less than 20 wt-%, based on the total weight of the composition;
• and
• forming the mixture into a hardenable self-supporting structure having a first shape;
• wherein the hardenable self-supporting structure having a first shape has sufficient malleability to be formed into a second shape at a temperature of about 15° C. to 38° C.

A method of preparing a composition comprising:

• combining a resin system comprising a crystalline component, greater than 70 wt-% of a filler system, and an initiator system to form a mixture;
• with the proviso that if the filler system comprises fibers, the fibers are present in an amount of less than 20 wt-%, based on the total weight of the composition;
• and
• forming the mixture into a hardenable self-supporting structure having a first shape;
• wherein the hardenable self-supporting structure having a first shape has sufficient malleability to be formed into a second shape.

A method of preparing a dental product, the method comprising:

• providing a composition comprising a resin system, a filler system, and an initiator system, wherein the composition is in the form of a hardenable, self-supporting, malleable structure having a first semi-finished shape;
• forming the self-supporting, malleable structure into a second shape at a temperature of about 15° C. to 38° C.;
• and
• hardening the self-supporting structure having the second shape to form a dental product.

A method of preparing a dental product, the method comprising:

• providing a composition comprising a resin system, a filler system, and an initiator system, wherein the composition is in the form of a hardenable, self-supporting, malleable structure having a first semi-finished shape of a preformed crown or a preformed bridge;
• forming the self-supporting, malleable structure into a second shape;
• and
• hardening the self-supporting structure having the second shape to form a dental product.

A method of preparing a dental tray, the method comprising:

• providing a composition comprising a resin system, a filler system, and an initiator system, wherein the composition is in the form of a hardenable, self-supporting, malleable structure having a first semi-finished shape of a preformed dental tray;
• forming the self-supporting, malleable structure into a second shape custom fit to the patient;
• and
• hardening the self-supporting structure having the second shape to form a dental tray.