Heat-Treated Calcium Phosphate Cement for Surgical Delay
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Solution Overview
Problem
Commercial calcium phosphate cements have high reactivity, limiting their use to within minutes after mixing, which restricts the surgeon's ability to postpone injection due to unexpected reasons.
Innovation Solution
Calcium phosphate particles with reduced reactivity are produced through a heat treatment process that maintains a high degree of crystallinity and specific surface area, allowing for a delayed reaction with water, enabling a hydraulic cement that remains liquid during application and hardens after a few minutes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional calcium phosphate cements are used, then high reactivity enables rapid setting, but the reaction occurs within minutes after mixing, limiting surgical flexibility
Solution Approach 1:
The patent divides the calcium phosphate cement into two separate components: a powder component containing calcium phosphate particles and a liquid component containing phosphate solution. This segmentation allows the surgeon to mix the components immediately before use, achieving rapid setting when needed, while maintaining the ability to postpone injection by controlling the mixing timing. The separation prevents premature reaction while enabling controlled rapid setting upon combination.
2Strength
If calcium phosphate particles are highly reactive, then rapid hardening is achieved, but the surgeon cannot postpone injection due to unexpected reasons
Solution Approach 1:
The calcium phosphate particles are pre-prepared with specific characteristics (particle size distribution, crystallinity, surface area) to ensure they are ready for rapid reaction when mixed. The powder component is prepared in advance with controlled properties that enable fast setting upon contact with the liquid component, while the surgeon retains the flexibility to delay mixing until the moment of injection by keeping the components separate until that point.
3Productivity
If the cement is mixed early, then rapid setting occurs, but injection must be performed immediately without postponement
Solution Approach 1:
The patent introduces dynamic control over the setting process by separating the cement into mixable components. The surgeon can dynamically adjust the timing of mixing based on surgical needs - mixing immediately for rapid setting when the procedure is ready, or delaying mixing to postpone injection when unexpected situations arise. This dynamic approach transforms a static, fixed-timing process into a flexible, controllable one.
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 heat-treated calcium phosphate particles significantly extend the time before 10% reaction with water, allowing for a bimodal setting mode, providing a stable cement that can be injected even after initial mixing, enhancing surgical flexibility and shelf-life stability.
Implementation Method 1
said particles are obtained by a heat treatment of a reactive calcium phosphate powder at a temperature between 450 °C and 700 °C for a time period of at least 1 hour
Implementation Method 2
whereby the phase of less than 10 weight-% of said particles is modified by said heat treatment
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
Calcium phosphate particles having A) a specific surface area (SSA) larger than 0.1 m2/g; B) a mean diameter smaller than 5 mm; C) a Ca/P molar ratio superior to 0.95; and wherein D) said particles have been subjected as a last processing step to a heat treatment at a temperature superior to 400 °C for a period of time such that the specific surface area (SSA) of said particles after the heat treatment is not decreased by more than 10 % compared to the SSA before said heat treatment.