Porous Calcium Silicate Bone Implant With Carbonation-Toughened Structure

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Solution Overview

Problem

Existing bioactive bone implant materials, such as 45S5 bioglass, lack the mechanical properties required for load-bearing applications due to brittleness and low strength, while calcium silicate ceramics have insufficient biological properties for effective bone regeneration.

Innovation Solution

A composite material comprising calcium silicate ceramics processed through High Temperature Sintering (HTS) followed by Low Temperature Solidification (LTS) carbonation, which enhances mechanical properties and osteoinductivity by increasing density and controlling ion release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If 45S5 bioglass is used for bone implant, then osteoinductivity and biocompatibility are improved, but mechanical strength and fracture toughness deteriorate due to high brittleness

Engineering Contradiction:

ImproveosteoinductivityVSAvoidfracture toughness

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent creates a composite material system combining calcium silicate ceramic matrix with bioglass particles. This composite structure allows the material to simultaneously achieve the osteoinductivity of bioglass and the mechanical strength of calcium silicate ceramic, resolving the contradiction between biological activity and mechanical properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the composition parameters of the calcium silicate ceramic by controlling the particle size distribution (bimodal or multimodal distribution) and the amount of bioglass particles incorporated. By adjusting these parameters, the material achieves optimal balance between mechanical strength and osteoinductivity.

Inventive Principle:

Principle #35Parameter changes

2Strength

If calcium silicate ceramic is used for bone implant, then mechanical strength is improved, but ion solubility increases causing cytotoxicity

Engineering Contradiction:

Improvecompressive strengthVSAvoidion solubility

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent creates local quality differentiation within the ceramic matrix by incorporating bioglass particles of specific size ranges. The bioglass particles are distributed throughout the calcium silicate matrix, creating local regions with different dissolution characteristics. This local modification reduces overall ion solubility while maintaining mechanical strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bioglass particles act as intermediaries that modify the dissolution behavior of the calcium silicate matrix. The bioglass particles create a barrier that controls the release rate of ions from the calcium silicate, thereby reducing cytotoxicity while preserving mechanical properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If high temperature sintering is applied to calcium silicate, then density and mechanical properties are improved, but ion release concentration increases

Engineering Contradiction:

Improvebending strengthVSAvoidion release concentration

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent segments the calcium silicate material into a composite structure with bioglass particles dispersed throughout. This segmentation creates multiple phases with different thermal and dissolution properties. The bioglass particles act as nucleation sites that control ion release while the calcium silicate matrix provides structural strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the thermal processing parameters by applying controlled high temperature sintering followed by specific cooling rates. This thermal history creates a microstructure with optimal balance between density, mechanical strength, and controlled ion release. The bimodal particle size distribution is also optimized during this process.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite material achieves mechanical properties comparable to cortical bone, including high compressive strength, bending strength, and fracture toughness, while promoting bone growth and healing.

Implementation Method 1

High Temperature Sintering (HTS) processed calcium silicate scaffolds

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

Low Temperature Solidification (LTS, carbonation) increases the density of High Temperature Sintering (HTS) processed calcium silicate scaffolds

Methodology Applied

Scientific EffectCarbonation:

Data Source

PatentUS12629457B2Structural implant for bone repair

Publication Date: 2026.05.19 RUTGERS THE STATE UNIV

AI summary

Disclosed are composite materials comprising a porous, carbonated, calcium silicate ceramic having a microstructure comprising interconnected open pores; where the calcium silicate surface defining the pores is partially or completely coated with an amorphous silica layer, and the silica coating comprises an overlayer of calcium carbonate crystals; where the silica coating and calcium carbonate overlayer form a network that interconnects throughout the ceramic microstructure, but do not completely occlude the pores. Also disclosed are methods of forming such composite materials.