Bone Substitute Material via Spray Deposition and Isostatic Pressing
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Solution Overview
Problem
Current bone substitute materials lack the biomechanical properties of natural bone, such as elasticity, viscoelasticity, and lamellar structural properties, leading to catastrophic failure under compression, and pose risks like limited availability, immune reactions, and viral transmission with natural bone grafts.
Innovation Solution
A calcium phosphate-based bone substitute material is developed using chemical solution spray deposition and isostatic press processes with reinforced biocompatible polymer fibers, mimicking natural bone structure and porosity, and incorporating calcium carbonate layers for enhanced mechanical strength and osteoinductive activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If natural bone grafts are used to promote new bone growth, then osteoconductive properties and biocompatibility are improved, but availability is limited and risks of immune reactions and viral transmission increase
Solution Approach 1:
The patent creates synthetic bone substitute materials that copy the hierarchical structure and chemical composition of natural bone. The device produces calcium phosphate ceramics with controlled porosity and lamellar structures that mimic natural bone architecture, providing osteoconductive properties without the risks associated with natural bone grafts
Solution Approach 2:
The invention controls key parameters including Ca/P ratio (1.5-2.0), porosity (30-70%), pore size (10-500 micrometers), and lamellar thickness (1-10 micrometers) to optimize both availability and biocompatibility. These parameter adjustments enable synthetic materials to achieve natural bone-like properties while eliminating supply limitations
2Reliability
If synthetic bone substitute materials are used to ensure availability and reduce immune reactions, then biocompatibility is improved, but biomechanical properties such as elasticity and viscoelasticity are insufficient leading to catastrophic failure under compression
Solution Approach 1:
The patent employs composite material strategies by combining calcium phosphate ceramics with reinforcing elements and creating multi-phase structures. The hierarchical composite architecture includes nanoscale crystallites, micrometer-scale lamellae, and macroscopic porous structures, which collectively enhance compressive strength while maintaining elasticity and viscoelasticity
Solution Approach 2:
The invention implements local quality variations through controlled porosity gradients, varying lamellar thicknesses, and region-specific mineralization levels. This allows different regions of the bone substitute to have optimized properties for their specific functions, with stronger regions for load-bearing and more porous regions for cell infiltration and nutrient transport
3Strength
If dense ceramic materials are used to provide rigidity and strength, then mechanical strength is improved, but elasticity and viscoelasticity are lost resulting in sudden catastrophic failure under compression
Solution Approach 1:
The patent utilizes porous material structures with controlled pore sizes (10-500 micrometers) and porosity levels (30-70%). The porous architecture provides mechanical energy absorption through pore collapse and cell wall bending, which imparts elasticity and prevents catastrophic failure while maintaining adequate compressive strength for load-bearing applications
4Strength
If natural bone structure with hierarchical organization is replicated to achieve biomechanical properties, then elasticity and viscoelasticity are improved, but manufacturing precision and control over porosity and pore size become more difficult
Solution Approach 1:
The patent segments the bone substitute manufacturing process into distinct stages: initial pore formation, lamellar structure development, and mineralization. This segmentation allows independent control of porosity (30-70%), pore size (10-500 micrometers), and lamellar thickness (1-10 micrometers) through separate process parameters, achieving hierarchical structure with controlled precision
Solution Approach 2:
The invention employs systematic parameter changes during processing, including temperature gradients (20-400°C), pressure variations, and chemical composition adjustments to control the formation and evolution of porous structures. These parameter transitions enable precise control over porosity and pore size while replicating natural bone's hierarchical organization
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 solution provides a bone substitute material with excellent osteoconductive and osteoinductive characteristics, achieving compressive strength and viscoelasticity comparable to natural bone, suitable for load-bearing applications like spinal surgeries, while minimizing immune responses and ensuring biocompatibility.
Implementation Method 1
a chemical solution spray deposition device that accommodates porous and composite laminar structures
Implementation Method 2
chemical solution spray deposition (CSSD) method
Implementation Method 3
isostatic press processes with reinforced biocompatible polymer fibers
Implementation Method 4
calcium phosphate-based bone substitute material... incorporating calcium carbonate layers
Implementation Method 5
Natural bone mineral is fundamentally a mixture of amorphous and crystalline calcium phosphate of HAP (hydroxyapatite)
Data Source
AI summary
A method for fabricating a substitute component for bone, including the processes of: provision of a chemical spray including at least three of calcium chloride, hydrogen phosphate, hydrogen carbonate and water to form a combined solution; reaction and precipitation of the combined solution onto a substrate; allowing the precipitated particles to form a porous structure on the substrate; applying substantially isostatic pressure to the porous structure to form a compressed structure; and (optional) providing one or more through-holes in the compressed structure to promote osteoinduction.