Zirconia ceramics containing glassy phase

By introducing YASZ glass phase into tetragonal zirconia ceramics, Y ion segregation is suppressed, the spontaneous phase transition problem in hydrothermal environments is solved, the hydrothermal resistance and bending strength of zirconia ceramics are improved, and its application range is expanded.

CN117164355BActive Publication Date: 2025-08-19SUZHOU CHENTAI MEDICAL INSTR CO LTD
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Patent Information

Application Number
CN202310834530.5
Authority / Receiving Office
CN · China
Patent Type
Patents(China)
Current Assignee / Owner
Filing Date
2023-06-30
Publication Date
2025-08-19
Estimated Expiration
2043-06-30

AI Technical Summary

Technical Problem

The spontaneous phase transition of existing tetragonal zirconia ceramics in hydrothermal environments leads to submicron cracks and surface roughness changes, limiting their application.

Method used

The YASZ glass phase is introduced into the tetragonal phase zirconia ceramic, and a dihedral angle of 62 to 90° is formed by suppressing the segregation of Y ions to the grain boundary, and the proportion and composition of the glass phase and the crystal phase are optimized to prepare zirconia ceramics containing glass phases.

Benefits of technology

It significantly reduces the spontaneous phase change of zirconia ceramics in hydrothermal environments, improves the hydrothermal treatment capacity and four-point bending strength, and improves long-term use performance.

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Abstract

The present invention relates to a zirconia ceramic containing a glass phase, comprising 1.0-5.5 wt% of a YASZ glass phase and the balance a 3Y-TZP crystalline phase, wherein the YASZ glass phase is located between grains of the 3Y-TZP crystalline phase. The YASZ glass phase comprises 15-35 wt% Y2O3, 10-30 wt% Al2O3, 35-55 wt% SiO2, and 4-10 wt% ZrO2, and the dihedral angle formed between the YASZ glass phase and the 3Y-TZP crystalline phase is 62-85°. The present invention also relates to a bone implant prosthesis prepared from the zirconia ceramic containing the glass phase.
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Description

Technical Field

[0001] The present invention relates to zirconia ceramics containing a glass phase, and further relates to a bone implant prosthesis prepared from the zirconia ceramics containing a glass phase. Background Art

[0002] The use of artificial prostheses to replace damaged joints (including hip, knee, elbow, wrist, or ankle joints) has become the primary choice for clinical treatment of joint diseases. Currently, artificial prostheses used to replace damaged hip or knee joints include metal-on-polyethylene, metal-on-metal, ceramic-on-polyethylene, and ceramic-on-ceramic types. Among them, ceramic-on-polyethylene and ceramic-on-ceramic types are becoming increasingly common due to their significantly reduced wear. The ceramic materials used are mainly alumina ceramics, zirconia ceramics, and alumina-zirconia composite ceramics.

[0003] Zirconia ceramics have three crystalline phases: monoclinic, tetragonal, and cubic. The transformation from the tetragonal phase to the monoclinic phase is accompanied not only by energy consumption but also by a 3-5% volume expansion. This volume expansion leads to the generation of compressive stress. This synergistic effect of energy consumption and compressive stress effectively hinders crack propagation, significantly improving the fracture toughness of zirconia ceramics and earning tetragonal zirconia ceramics the reputation of "ceramic steel."

[0004] Pure zirconia exists in a monoclinic phase below 1170°C, a tetragonal phase between 1170 and 2370°C, and a cubic phase above 2370°C. Therefore, to obtain tetragonal zirconia ceramics at room temperature, stabilizers are often added to the ceramic to maintain the tetragonal phase at room temperature. Common stabilizers include Y2O3, CeO2, and MgO.

[0005] With the development of technology, it has been further discovered that tetragonal zirconia ceramics stabilized with Y2O3 spontaneously transform into a monoclinic phase in a hydrothermal environment at 100-400°C. This spontaneous phase transformation not only causes submicron cracks in the zirconia ceramics, but also alters the surface roughness of the zirconia ceramics due to the 3-5% volume change associated with the phase transformation. This phenomenon has limited the further application of tetragonal zirconia ceramics.

[0006] In order to solve this problem, the present invention creatively introduces a glass phase containing yttrium (Y) element into tetragonal zirconia ceramics. By inhibiting the segregation of Y ions to the grain boundaries of zirconia grains during sintering, the deficiency of Y ions in zirconia grains after sintering is significantly reduced, thereby reducing the spontaneous phase transformation of zirconia ceramics in a hydrothermal environment (tetragonal phase to monoclinic phase) and improving the long-term performance of zirconia ceramics. Summary of the Invention

[0007] In the present invention, "YASZ glass" refers to Y2O3-Al2O3-SiO2-ZrO2 glass.

[0008] In the present invention, "3Y-TZP" refers to tetragonal zirconia containing 2.0-3.5 mol%, preferably 2.5-3.2 mol%, and more preferably 3.0 mol% of Y2O3.

[0009] The invention relates to a zirconia ceramic containing a glass phase, which consists of a YASZ glass phase and a balance of a 3Y-TZP crystal phase. The YASZ glass phase is located between grains of the 3Y-TZP crystal phase, and the dihedral angle formed between the YASZ glass phase and the 3Y-TZP crystal phase is 62-90 degrees.

[0010] According to an embodiment of the present invention, the content of the YASZ glass phase in the zirconia ceramic may be 1.0-5.5 wt%, 1.5-5.0 wt%, 1.5-4.5 wt%, 2.0-4.0 wt%, 2.0-3.5 wt%, 3.0-3.5 wt%, 3.0-3.2 wt%, 2.0-2.5 wt% or 2.2-2.5 wt%.

[0011] According to an embodiment of the present invention, the dihedral angle formed between the YASZ glass phase and the 3Y-TZP crystal phase is 62 to 90°, preferably 62 to 85°, more preferably 65 to 80°, further preferably 65 to 75°, further preferably 65 to 70°, and most preferably 65-68°.

[0012] According to an embodiment of the present invention, the YASZ glass phase is composed of 15-35wt% Y2O3, 10-30wt% Al2O3, 35-55wt% SiO2 and 4-10wt% ZrO2, preferably composed of 28-35wt% Y2O3, 10-20wt% Al2O3, 40-55wt% SiO2 and 4-10wt% ZrO2, further preferably composed of 30-35wt% Y2O3, 10-20wt% Al2O3, 45-50wt% SiO2 and 4-10wt% ZrO2, and most preferably composed of 30-32wt% Y2O3, 10-20wt% Al2O3, 45-50wt% SiO2 and 4-10wt% ZrO2.

[0013] According to the zirconia ceramic containing a glass phase of the present invention, the grain size of the 3Y-TZP crystal phase is ≤1.0 micron, preferably ≤0.6 micron, and most preferably ≤0.4 micron.

[0014] The present invention also relates to bone implant prostheses made of zirconium oxide ceramics containing a glass phase, including hip joint prostheses, knee joint prostheses, elbow joint prostheses, wrist joint prostheses, ankle joint prostheses, and the like.

[0015] The zirconia ceramics containing a glassy phase of the present invention can also be used for other industrial applications.

[0016] In nature, hafnium (Hf) and zirconium elements exist in the form of a solid solution and are difficult to separate. Therefore, in this application, "zirconium oxide (ZrO2)" contains ≤5wt% hafnium oxide.

[0017] In this application, "hydrothermal treatment" refers to exposure to water vapor at a temperature of 134±2°C and a pressure of 0.2 MPa in an autoclave. For details, please refer to Section 4.8 of ISO 13356.

[0018] In the present application, “vol%” refers to volume percentage, “wt%” refers to mass percentage, and “mol%” refers to molar percentage.

[0019] In this application, X-ray diffraction analysis (abbreviated as "XRD"; CuKα, 30 kV, 15 mA) was used to determine the crystalline phase content. Therefore, the crystalline phase content obtained refers to the crystalline phase content in the surface layer penetrated by the X-rays during XRD analysis. The sample size was 10 mm × 10 mm × 2 mm. The test results are the average content of five samples.

[0020] In this application, room temperature refers to -20°C to 40°C.

[0021] In this application, the bending strength refers to the four-point bending strength, and the test specimen size is 3mm×4mm×45mm. The test result refers to the average strength of 12 specimens.

[0022] In this application, the dihedral angle between the glass phase and the crystalline phase is observed using a high-resolution transmission electron microscope. DETAILED DESCRIPTION

[0023] The present invention is further specifically described by the following examples, but the present invention is not limited to these examples.

[0024] In the examples, the 3Y-TZP powder used is a tetragonal zirconia powder containing 3 mol% Y2O3, purchased from Hebei Hengbo New Materials Technology Co., Ltd.

[0025] Example 1 Preparation of zirconia ceramics 1

[0026] 500 g of 3Y-TZP powder was dry-pressed at 100 MPa, then heated from room temperature to 1500 °C at a rate of 20 °C / h, kept at this temperature for 3 hours, and then cooled to room temperature in the furnace.

[0027] The obtained sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0028] According to the test, the four-point bending strength is 1020 MPa. The phase composition before hydrothermal treatment is 0.5 vol% monoclinic phase and the rest is tetragonal phase. After 10 hours of hydrothermal treatment, the monoclinic phase content is 25.4 vol% and the rest is tetragonal phase.

[0029] Example 2 Preparation of zirconia ceramics 2

[0030] Chemically pure Y2O3 powder, Al2O3 powder, SiO2 powder, and ZrO2 powder were mixed together in a weight ratio of 30:14:50:6, and anhydrous ethanol was added to the mixture in a ball mill. The mixture was poured out and dried, placed in a platinum crucible, and melted in a glass melting furnace at 1550°C for 2 hours. The crucible was then directly removed and poured into deionized water to obtain glass cullet. The glass cullet was then ball-milled into glass powder.

[0031] 3Y-TZP powder and glass powder were mixed in a weight ratio of 98.8:1.2, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, dry-pressed at 100 MPa, and then heated from room temperature to 1500°C at a rate of 20°C / hour, kept warm for 3 hours, and cooled to room temperature with the furnace.

[0032] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0033] After testing, the four-point flexural strength is 963MPa; the dihedral angle between the zirconia grains and the glass phase is 68°; the crystal phase composition before hydrothermal treatment is monoclinic zirconia content of 0.5vol%, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 7.2vol%, and the rest is tetragonal zirconia.

[0034] Example 3 Preparation of zirconia ceramics 3

[0035] The 3Y-TZP powder and the glass powder prepared in Example 2 were mixed in a weight ratio of 98.2:1.8, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, and dry-pressed at 100 MPa. Then, the temperature was raised from room temperature to 1500°C at a rate of 20°C / hour, kept at this temperature for 3 hours, and cooled to room temperature with the furnace.

[0036] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0037] After testing, the four-point flexural strength is 950MPa; the dihedral angle between the zirconia grains and the glass phase is 68°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 6.5vol%, and the rest is tetragonal zirconia.

[0038] Example 4 Preparation of Zirconia Ceramic 4

[0039] The 3Y-TZP powder and the glass powder prepared in Example 2 were mixed in a weight ratio of 98.0:2.0, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, and dry-pressed at 100 MPa. Then, the temperature was raised from room temperature to 1500°C at a rate of 20°C / hour, kept at this temperature for 3 hours, and cooled to room temperature with the furnace.

[0040] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0041] After testing, the four-point flexural strength is 941MPa; the dihedral angle between the zirconia grains and the glass phase is 68°; the crystal phase composition before hydrothermal treatment is monoclinic zirconia content of 0.5vol%, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 3.0vol%, and the rest is tetragonal zirconia.

[0042] Example 5 Preparation of Zirconia Ceramic 5

[0043] The 3Y-TZP powder and the glass powder prepared in Example 2 were mixed in a weight ratio of 97.8:2.2, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, and dry-pressed at 100 MPa. Then, the temperature was raised from room temperature to 1500°C at a rate of 20°C / hour, kept at this temperature for 3 hours, and cooled to room temperature with the furnace.

[0044] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0045] After testing, the four-point bending strength is 940MPa; the dihedral angle between the zirconia grains and the glass phase is 68°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 2.5vol%, and the rest is tetragonal zirconia.

[0046] Example 6 Preparation of Zirconia Ceramic 6

[0047] The 3Y-TZP powder and the glass powder prepared in Example 2 were mixed in a weight ratio of 97.5:2.5, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, and dry-pressed at 100 MPa. Then, the temperature was raised from room temperature to 1500°C at a rate of 20°C / hour, kept at this temperature for 3 hours, and cooled to room temperature with the furnace.

[0048] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0049] After testing, the four-point flexural strength is 935MPa; the dihedral angle between the zirconia grains and the glass phase is 68°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 2.4vol%, and the rest is tetragonal zirconia.

[0050] Example 7 Preparation of Zirconia Ceramic 7

[0051] The 3Y-TZP powder and the glass powder prepared in Example 2 were mixed in a weight ratio of 97.0:3.0, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, and dry-pressed at 100 MPa. Then, the temperature was raised from room temperature to 1500°C at a rate of 20°C / hour, kept at this temperature for 3 hours, and cooled to room temperature with the furnace.

[0052] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0053] After testing, the four-point flexural strength is 882MPa; the dihedral angle between the zirconia grains and the glass phase is 68°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 2.4vol%, and the rest is tetragonal zirconia.

[0054] Example 8 Preparation of Zirconia Ceramic 8

[0055] 3Y-TZP powder and glass powder 1 prepared in Example 2 were mixed in a weight ratio of 96.5:3.5, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, dry-pressed at 100 MPa, and then heated from room temperature to 1500°C at a rate of 20°C / hour, kept warm for 3 hours, and cooled to room temperature with the furnace.

[0056] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0057] After testing, the four-point bending strength is 821MPa; the dihedral angle between the zirconia grains and the glass phase is 68°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 2.4vol%, and the rest is tetragonal zirconia.

[0058] Example 9 Preparation of Zirconia Ceramic 9

[0059] The 3Y-TZP powder and the glass powder prepared in Example 2 were mixed in a weight ratio of 95.0:5.0, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, and dry-pressed at 100 MPa. Then, the temperature was raised from room temperature to 1500°C at a rate of 20°C / hour, kept at this temperature for 3 hours, and cooled to room temperature with the furnace.

[0060] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0061] After testing, the four-point bending strength is 734MPa; the dihedral angle between the zirconia grains and the glass phase is 68°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 2.5vol%, and the rest is tetragonal zirconia.

[0062] Example 10 Preparation of Zirconia Ceramic 10

[0063] Chemically pure Y2O3 powder, Al2O3 powder, SiO2 powder, and ZrO2 powder were mixed together in a weight ratio of 32:15:45:8, and anhydrous ethanol was added to the mixture and mixed evenly in a ball mill. The mixture was poured out and dried, placed in a platinum crucible, and melted in a glass melting furnace at 1550°C for 2 hours. The crucible was then directly removed and poured into deionized water to obtain glass cullet. The glass cullet was ball-milled into glass powder 1.

[0064] 3Y-TZP powder and glass powder were mixed in a weight ratio of 97.8:2.2, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, dry-pressed at 100 MPa, and then heated from room temperature to 1500°C at a rate of 20°C / hour, kept warm for 3 hours, and cooled to room temperature with the furnace.

[0065] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0066] After testing, the four-point flexural strength is 940MPa; the dihedral angle between the zirconia grains and the glass phase is 65°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 2.5vol%, and the rest is tetragonal zirconia.

[0067] Example 11 Preparation of Zirconia Ceramic 11

[0068] Chemically pure Y2O3 powder, Al2O3 powder, SiO2 powder, and ZrO2 powder were mixed together in a weight ratio of 35:22:35:8, and anhydrous ethanol was added to the mixture and mixed evenly in a ball mill. The mixture was poured out and dried, placed in a platinum crucible, and melted in a glass melting furnace at 1550°C for 2 hours. The crucible was then directly removed and poured into deionized water to obtain glass cullet. The glass cullet was then ball-milled into glass powder.

[0069] 3Y-TZP powder and glass powder were mixed in a weight ratio of 97.5:2.5, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, dry-pressed at 100 MPa, and then heated from room temperature to 1500°C at a rate of 20°C / hour, kept warm for 3 hours, and cooled to room temperature with the furnace.

[0070] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0071] After testing, the four-point bending strength is 782MPa; the dihedral angle between the zirconia grains and the glass phase is 45°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 2.5vol%, and the rest is tetragonal zirconia.

[0072] Example 12 Preparation of Zirconia Ceramic 12

[0073] Chemically pure Y2O3 powder, Al2O3 powder, SiO2 powder, and ZrO2 powder were mixed together in a weight ratio of 15:27:50:8, and anhydrous ethanol was added to the mixture and mixed evenly in a ball mill. The mixture was poured out and dried, placed in a platinum crucible, and melted in a glass melting furnace at 1550°C for 2 hours. The crucible was then directly removed and poured into deionized water to obtain glass cullet. The glass cullet was then ball-milled into glass powder.

[0074] 3Y-TZP powder and glass powder were mixed in a weight ratio of 97.5:2.5, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, dry-pressed at 100 MPa, and then heated from room temperature to 1500°C at a rate of 20°C / hour, kept warm for 3 hours, and cooled to room temperature with the furnace.

[0075] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0076] After testing, the four-point flexural strength is 940MPa; the dihedral angle between the zirconia grains and the glass phase is 70°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 8.9vol%, and the rest is tetragonal zirconia.

[0077] Example 13 Preparation of Zirconia Ceramic 13

[0078] Chemically pure Y2O3 powder, Al2O3 powder, SiO2 powder, and ZrO2 powder were mixed together in a weight ratio of 30:10:54:6, and anhydrous ethanol was added to the mixture in a ball mill. The mixture was poured out and dried, placed in a platinum crucible, and melted in a glass melting furnace at 1550°C for 2 hours. The crucible was then directly removed and poured into deionized water to obtain glass cullet. The glass cullet was then ball-milled into glass powder.

[0079] 3Y-TZP powder and glass powder were mixed in a weight ratio of 97.5:2.5, anhydrous ethanol was added and mixed evenly on a ball mill, poured out and dried, dry-pressed at 100 MPa, and then heated from room temperature to 1500°C at a rate of 20°C / hour, kept warm for 3 hours, and cooled to room temperature with the furnace.

[0080] The sintered body was processed into 12 four-point bending strength test bars and 10 XRD specimens, of which 5 XRD specimens were hydrothermally treated for 10 hours.

[0081] After testing, the four-point flexural strength is 936MPa; the dihedral angle between the zirconia grains and the glass phase is 85°; the crystal phase composition before hydrothermal treatment is 0.5vol% monoclinic zirconia, and the rest is tetragonal zirconia. After 10 hours of hydrothermal treatment, the monoclinic zirconia content is 12.5vol%, and the rest is tetragonal zirconia.

[0082] The results of the above examples are summarized in the following table.

[0083]

[0084] From Examples 2 to 13 above, it can be seen that the addition of glass containing the Y element to the tetragonal zirconia ceramics forms a glassy phase between the zirconia grains. The high Y content in the glass inhibits the segregation of Y ions within the zirconia grains to the grain boundaries during sintering, thereby preventing the depletion of Y ions within the zirconia grains. This depletion of Y ions within the zirconia grains is the primary cause of the spontaneous transformation of the tetragonal phase into the monoclinic phase during hydrothermal treatment. Therefore, the addition of the glassy phase containing Y ions improves the ceramic's resistance to hydrothermal treatment.

[0085] As shown in Example 12, if the Y element content in the glass phase is too low, the inhibitory effect on Y ion segregation decreases, and the overall hydrothermal aging resistance is still insufficient.

[0086] If the glass phase content is too low, as shown in Examples 2 and 3, some zirconium oxide grains lack the glass phase, and Y ion segregation still occurs within these grains, resulting in a high monoclinic phase content after hydrothermal treatment. If the glass phase content is too high, as shown in Example 9, a connected glass network forms, resulting in a decrease in four-point flexural strength.

[0087] Furthermore, as shown in Example 11, when the dihedral angle between the glass phase and the crystalline phase is too low, a connected glass network is easily formed, resulting in a decrease in the four-point bending strength of the entire material. As shown in Example 13, when the dihedral angle between the glass phase and the crystalline phase is too large, the glass phase is unevenly distributed between the grains, resulting in some areas lacking the glass phase. In these areas, the zirconia grains are still deficient in Y ions, resulting in insufficient overall hydrothermal aging resistance.

[0088] Therefore, considering the hydrothermal aging resistance and four-point bending strength, Examples 4 to 6 are preferred.

[0089] Example 14 Preparation of Zirconia-Based Ceramic Femoral Head for Hip Replacement

[0090] In Examples 1-13 above, a rubber mold in the shape of a femoral head for hip replacement was used during dry pressing. This resulted in a spherical zirconia ceramic sintered body containing a glassy phase after sintering. This spherical sintered body was then ground to produce a hip joint ceramic femoral head prosthesis.

[0091] Example 15 Preparation of Zirconia-Based Ceramic Prosthesis for Knee Replacement

[0092] In Examples 1-13 above, a rubber mold in the shape of a tibial plateau tray for a knee joint prosthesis was used during dry pressing. This resulted in a zirconia ceramic sintered body containing a glassy phase and shaped like the tibial plateau tray. This was then ground to produce a zirconia ceramic prosthesis for knee replacement.

Claims

1. A zirconia ceramic containing a glass phase, comprising 1.0-5.5 wt% of YASZ glass powder and the balance of 3Y-TZP powder, wherein the YASZ glass phase formed by the YASZ glass powder is located between the grains of the 3Y-TZP crystal phase formed by the 3Y-TZP powder, wherein: The YASZ glass powder consists of 15-35wt% Y2O3, 10-30wt% Al2O3, 35-55wt% SiO2 and 4-10wt% ZrO2, and the dihedral angle formed between the YASZ glass phase and the 3Y-TZP crystal phase is 62-85°.

2. The zirconia ceramic containing a glass phase according to claim 1, wherein the content of the YASZ glass powder is 2.0-3.5wt%, the YASZ glass powder is composed of 28-35wt% Y2O3, 10-20wt% Al2O3, 40-55wt% SiO2 and 4-10wt% ZrO2, and the dihedral angle formed between the YASZ glass phase and the 3Y-TZP crystal phase is 65-80°.

3. The zirconia ceramic containing a glass phase according to claim 2, wherein the content of the YASZ glass powder is 2.0-3.0wt%, the YASZ glass powder is composed of 30-35wt% Y2O3, 10-20wt% Al2O3, 45-50wt% SiO2 and 4-10wt% ZrO2, and the dihedral angle formed between the YASZ glass phase and the 3Y-TZP crystal phase is 65-75°.

4. The zirconia ceramic containing a glass phase according to claim 3, wherein the content of the YASZ glass powder is 2.0-2.5wt%, the YASZ glass powder is composed of 30-32wt% Y2O3, 10-20wt% Al2O3, 45-50wt% SiO2 and 4-10wt% ZrO2, and the dihedral angle formed between the YASZ glass phase and the 3Y-TZP crystal phase is 65-70°.

5. The zirconia ceramic containing a glass phase according to claim 4, wherein the content of the YASZ glass powder is 2.2-2.5wt%, the YASZ glass powder is composed of 30-32wt% Y2O3, 10-20wt% Al2O3, 45-50wt% SiO2 and 4-10wt% ZrO2, and the dihedral angle formed between the YASZ glass phase and the 3Y-TZP crystal phase is 65-70°. 6 . The zirconia ceramic containing a glassy phase according to claim 1 , wherein the grain size of the 3Y-TZP crystal phase is ≤1.0 μm.

7. The zirconia ceramic containing a glassy phase according to claim 6, wherein the grain size of the 3Y-TZP crystal phase is ≤ 0.6 μm.

8. The zirconia ceramic containing a glassy phase according to claim 7, wherein the grain size of the 3Y-TZP crystal phase is ≤ 0.4 μm.

9. A bone implant prosthesis prepared using the zirconia ceramic containing a glass phase according to any one of claims 1 to 8, comprising an artificial femoral head and liner for hip replacement and a knee joint prosthesis for knee replacement.

Citation Information

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