Organic/inorganic composite, manufacturing method therefor, dental material, and bone substitute material

Patent metadata

Field	Value
Publication number	US-9512280-B2
Application number	US-201214364108-A
Country	US
Kind code	B2
Filing date	Nov 20, 2012
Priority date	Dec 15, 2011
Publication date	Dec 6, 2016
Grant date	Dec 6, 2016

Abstract

Provided are: an organic/inorganic composite, and a manufacturing method therefor; and a dental material and bone substitute material manufactured using the organic/inorganic composite. The organic/inorganic composite includes: (A) 100 parts by mass of a thermoplastic resin containing as a main component at least one kind selected from a polyarylketone resin and a polysulfone resin; and (B) 60 to 300 parts by mass of an inorganic particle mixture dispersed in the thermoplastic resin, in which the inorganic particle mixture contains inorganic particles each having a particle diameter of from 200 to 700 nm at a content of 25 vol % or more, and inorganic particles each having a particle diameter of from 40 to 100 nm at a content of 10 vol % or more.

First claim

The invention claimed is:

1. An organic/inorganic composite, comprising:
(A) 100 parts by mass of a thermoplastic resin containing as a main component at least one kind selected from a polyarylketone resin and a polysulfone resin; and
(B) 60 to 300 parts by mass of an inorganic particle mixture dispersed in the thermoplastic resin,
wherein the inorganic particle mixture contains inorganic particles (B1) each having a particle diameter of from 200 to 700 nm at a content of 25 vol % or more, and inorganic particles (B2) each having a particle diameter of from 40 to 100 nm at a content of 10 vol % or more, and
wherein a volume ratio of the inorganic particles (B1) with respect to a total volume of the inorganic particles (B1) and the inorganic particles (B2) is from 0.6 to 0.8.

2. The organic/inorganic composite according to claim 1 , wherein (B) the inorganic particle mixture further contains inorganic particles each having a particle diameter of from 1 to 10 μm at a content of from 10 to 55 vol %.

3. The organic/inorganic composite according to claim 1 , wherein the inorganic particles constituting (B) the inorganic particle mixture comprise silica-based inorganic particles.

4. The organic/inorganic composite according to claim 1 , wherein the inorganic particles comprise titanium dioxide-based particles.

5. The organic/inorganic composite according to claim 1 , wherein (A) the resin comprises polyetheretherketone.

6. The organic/inorganic composite according to claim 1 , wherein the organic/inorganic composite has a bending strength of 200 MPa or more, a modulus of elasticity of 6 GPa or more, and a fracture energy of 5 N/mm or more.

7. A manufacturing method for an organic/inorganic composite, comprising melt-kneading raw materials including
(A) 100 parts by mass of a thermoplastic resin containing as a main component at least one kind selected from a polyarylketone resin and a polysulfone resin, and
(B) 60 to 300 parts by mass of an inorganic particle mixture containing inorganic particles (B1) each having a particle diameter of from 200 to 700 nm at a content of 25 mass % or more, and inorganic particles (B2) each having a particle diameter of from 40 to 100 nm at a content of 10 mass % or more,
by applying a shear flow field and an elongation field,
wherein a volume ratio of the inorganic particles (B1) with respect to a total volume of the inorganic particles (B1) and the inorganic particles (B2) is from 0.6 to 0.8.

8. A manufacturing method for an organic/inorganic composite, comprising:
supplying raw materials including
(A) 100 parts by mass of a thermoplastic resin containing as a main component at least one kind selected from a polyarylketone resin and a polysulfone resin, and
(B) 60 to 300 parts by mass of an inorganic particle mixture containing inorganic particles (B1) each having a particle diameter of from 200 to 700 nm at a content of 25 mass % or more, and inorganic particles (B2) each having a particle diameter of from 40 to 100 nm at a content of 10 mass % or more,

to a melt-kneading apparatus including an internal-return screw that transfers a melt-kneaded product of the raw materials, which is transferred to a screw forward end, back to a rear end; and
melt-kneading the raw materials under heating at from 200 to 500° C. under conditions of a rotation number of the screw of from 300 to 3,000 rpm and a shear rate of from 450 to 4,500 sec-1 by circulating the raw materials for a given period of time,
wherein a volume ratio of the inorganic particles (B1) with respect to a total volume of the inorganic particles (B1) and the inorganic particles (B2) is from 0.6 to 0.8.

9. The manufacturing method for an organic/inorganic composite according to claim 7 , wherein (B) the inorganic particle mixture comprises inorganic particles surface-treated with a surface treatment agent containing a (meth)acrylic group.

10. The manufacturing method for an organic/inorganic composite according to claim 9 , wherein the inorganic particles surface-treated with a surface treatment agent containing a (meth)acrylic group comprise inorganic particles surface-treated with a surface treatment agent represented by the following formula (1):
CH2=C(R1)-COO—(CH2) n -Si-R2 m R3(3- m )  Formula (1)

in the formula (1), R1 represents a hydrogen atom or a methyl group, R2 represents an alkoxy group having 1 to 6 carbon atoms, an isocyanate group, or a chlorine atom, R3 represents a hydrocarbon group having 1 to 6 carbon atoms, m represents 1, 2, or 3, and n represents an integer of from 3 to 20.

11. A dental material, comprising a organic/inorganic composite, wherein the organic/inorganic composite comprise:
(A) 100 parts by mass of a thermoplastic resin containing as a main component at least one kind selected from a polyarylketone resin and a polysulfone resin; and
(B) 60 to 300 parts by mass of an inorganic particle mixture dispersed in the thermoplastic resin,
wherein the inorganic particle mixture contains inorganic particles (B1) each having a particle diameter of from 200 to 700 nm at a content of 25 vol % or more, and inorganic particles (B2) each having a particle diameter of from 40 to 100 nm at a content of 10 vol % or more, and
wherein a volume ratio of the inorganic particles (B1) with respect to a total volume of the inorganic particles (B1) and the inorganic particles (B2) is from 0.6 to 0.8.

12. A bone substitute material, comprising a organic/inorganic composite,
wherein the organic/inorganic composite comprise:
(A) 100 parts by mass of a thermoplastic resin containing as a main component at least one kind selected from a polyarylketone resin and a polysulfone resin; and
(B) 60 to 300 parts by mass of an inorganic particle mixture dispersed in the thermoplastic resin,
wherein the inorganic particle mixture contains inorganic particles (B1) each having a particle diameter of from 200 to 700 nm at a content of 25 vol % or more, and inorganic particles (B2) each having a particle diameter of from 40 to 100 nm at a content of 10 vol % or more, and
wherein a volume ratio of the inorganic particles (B1) with respect to a total volume of the inorganic particles (B1) and the inorganic particles (B2) is from 0.6 to 0.8.

13. The manufacturing method for an organic/inorganic composite according to claim 8 , wherein (B) the inorganic particle mixture comprises inorganic particles surface-treated with a surface treatment agent containing a (meth)acrylic group.

14. The manufacturing method for an organic/inorganic composite according to claim 13 , wherein the inorganic particles surface-treated with a surface treatment agent containing a (meth)acrylic group comprise inorganic particles surface-treated with a surface treatment agent represented by the following formula (1):
CH2=C(R1)-COO—(CH2) n -Si-R2 m R3(3- m )  Formula (1)

in the formula (1), R1 represents a hydrogen atom or a methyl group, R2 represents an alkoxy group having 1 to 6 carbon atoms, an isocyanate group, or a chlorine atom, R3 represents a hydrocarbon group having 1 to 6 carbon atoms, m represents 1, 2, or 3, and n represents an integer of from 3 to 20.

15. The organic/inorganic composite according to claim 1 , wherein the volume ratio of the inorganic particles (B1) with respect to the total volume of the inorganic particles (B1) and the inorganic particles (B2) is from 0.7 to 0.8.

16. The manufacturing method for an organic/inorganic composite according to claim 7 , wherein the volume ratio of the inorganic particles (B1) with respect to the total volume of the inorganic particles (B1) and the inorgan

Assignees

• Tokuyama Dental Corp
• Nat Inst Of Advanced Ind And Tech
• Nat Iinstitute Of Advanced Ind Science And Tech

Inventors

• Yamagawa Jun-Ichiro
• Shimizu Hiroshi
• Li Yongjin

Classifications

• A61K6/17

  Particle size · CPC title

• A61K6/891

  Compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• C08G65/4012

  Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones · CPC title

• C08G2650/40

  containing ketone groups, e.g. polyarylethylketones, PEEK or PEK · CPC title

• C08K2003/2241

  Titanium dioxide · CPC title