Ceramic bone substitute material and method for the production thereof

Patent metadata

Field	Value
Publication number	US-10328181-B2
Application number	US-201414787618-A
Country	US
Kind code	B2
Filing date	Apr 28, 2014
Priority date	Apr 30, 2013
Publication date	Jun 25, 2019
Grant date	Jun 25, 2019

Abstract

A method for producing a ceramic osseoconductive bone substitute material, the bone substitute material, intervertebral disk implants containing the substitute bone material, and to methods of using the bone substitute material.

First claim

The invention claimed is:

1. A method for producing a bone substitute material, including at least one porous ceramic osseoconductive part, comprising the steps of:
a) providing a foam having a pore density of 30 to 80 ppi;
b) preparing a ceramic infiltrate suspension that contains a ceramic material selected from the group consisting of an Al 2 O 3 -based ceramic material and a ZTA ceramic material;
c) infiltrating the foam with the ceramic infiltrate suspension;
d) debinding the ceramic material and burning out the foam; and
e) sintering; wherein the sintering comprises the steps of prefiring at a temperature in the range of 1400 to 1500° C., and hot isostatic pressing in an inert gas atmosphere at less than or equal to 1400 bar and a temperature of less than or equal to 1500° C.

2. The method according to claim 1 , wherein the foam is open-pore foam.

3. The method according to claim 1 , wherein the foam has a pore density of from 40 to 50 ppi.

4. The method according to claim 1 , wherein step b), preparing the ceramic infiltrate suspension, comprises the following steps:
b.1) blending a solvent and the ceramic material to form a mixture;
b.2) homogenizing and degassing the mixture in an asymmetric mixer and/or an intensive mixer to form the infiltrate suspension, said infiltrate suspension having a rheology; and
b.3) setting the rheology of the infiltrate suspension.

5. The method according to claim 4 , wherein the solvent is water.

6. The method according to claim 4 , wherein in step b.2) the homogenizing and the degassing the mixture in an asymmetric mixer and/or an intensive mixer is performed under vacuum.

7. The method according to claim 6 , wherein in step b.2) the homogenizing and the degassing the mixture in performed in the asymmetric mixer.

8. The method according to claim 4 , wherein in step b.2) the homogenizing and the degassing the mixture in performed in the asymmetric mixer.

9. The method according to claim 1 , wherein a solids loading of the infiltrate suspension is between 5 and 50% by volume, based on the volume of the suspension.

10. The method according to claim 1 , wherein a surface porosity is entirely or partially filled with a ceramic compound, whereby a joining region for joining to another component is obtained.

11. The method according to claim 10 , wherein the ceramic compound comprises Al 2 O 3 .

12. The method according to claim 1 , wherein method step d), debinding and burning out, is carried out at temperatures of less than 600° C. and a debinding rate of <0.1% by weight/(cm 3 h).

13. The method according to claim 1 , wherein the ceramic material comprises the Al 2 O 3 -based ceramic material.

Assignees

• Ceram Gmbh
• Univ Friedrich Alexander Er
• Fridrich Alexander Univ Erlangen Nuernberg

Inventors

• Wecker Heinrich
• Kelnberger Alfons
• Greil Peter
• Fey Tobias
• Schmidt Johanna
• Zierath Bodo

Classifications

• A61F2002/30011

  differing in porosity · CPC title

• A61L2430/02

  for reconstruction of bones; weight-bearing implants · CPC title

• A61L27/105

  containing Al2O3 · CPC title

• A61L27/10

  Ceramics or glasses · CPC title

• A61L27/56 Primary

  Porous materials, {e.g. foams or sponges} · CPC title