Calcium Phosphate Mineral Agglomerate Deposition on Ceramic Implants
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Solution Overview
Problem
Current methods for creating osteointegrative surfaces on ceramic implants, such as dental implants, face challenges with mechanical stability and bioactive material adhesion, particularly with additive processes like DE-A-102006062712, which are complex and result in uneven distribution and potential loss of particles, while subtractive techniques can compromise mechanical properties.
Innovation Solution
An additive process involving the deposition of calcium phosphate mineral agglomerates onto a ceramic body, followed by heating to integrate the mineral into the zirconia lattice, creating a surface with a density gradient and specific topography that enhances osteointegration and mechanical stability, using a sand-blasting apparatus for precise deposition and sintering to ensure fixation without a discrete interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydroxylapatite coating is applied on metallic implant using plasma spraying, then osteointegrative properties are improved, but the hydroxylapatite tends to be abraded when implanting the implant into the bone and subjecting it to physiological loading
Solution Approach 1:
The patent applies a composite material structure consisting of a metallic base material (titanium or titanium alloy) combined with a hydroxylapatite coating layer. This composite structure allows the metal substrate to provide mechanical strength and abrasion resistance, while the hydroxylapatite coating provides osteointegrative properties. The coating is applied through plasma spraying to create a durable interface between the implant and bone tissue.
2Object-affected harmful factors
If particles are applied on the surface of green body and/or brown body without exerting pressure, then the implant is prevented from being damaged, but the particles tend to fall off the surface and accumulate in the valleys, leading to uneven distribution
Solution Approach 1:
The patent applies particles to the surface of the green body or brown body before the final sintering step. This preliminary action allows the particles to be positioned on the surface before the material reaches its final hardened state, facilitating more uniform distribution. The particles are applied without exerting pressure to prevent damage, and the subsequent sintering process secures them in place.
Solution Approach 2:
The patent changes the physical state and properties of the material during processing. By applying particles to the green body or brown body (unsintered state) and then performing sintering, the material transitions from a softer, more formable state to a hardened, stable state. This parameter change allows for better particle distribution and secure fixation without requiring high pressure during particle application.
3Reliability
If subtractive techniques are used to provide osteointegrative surface, then osteointegration is improved, but the mechanical properties of the implant are compromised
Solution Approach 1:
The patent segments the implant surface into distinct functional zones: a core metallic substrate that maintains mechanical strength and integrity, and a surface coating layer that provides osteointegrative properties. This segmentation allows each zone to optimize its specific function without compromising the other, avoiding the need to sacrifice mechanical properties for surface modification.
Solution Approach 2:
The patent employs a composite material system where a metallic base (providing mechanical strength) is combined with a hydroxylapatite coating (providing osteointegration). This composite approach allows simultaneous achievement of both mechanical durability and biological compatibility, resolving the contradiction between strength and osteointegration that arises with subtractive techniques.
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 process results in a highly osteointegrative surface with improved mechanical stability and ageing resistance, preventing material loss and ensuring homogeneous distribution, thus effectively integrating with bone tissue and withstanding physiological loading.
Implementation Method 1
depositing a calcium phosphate mineral on the surface of a ceramic basic body by projecting agglomerates of particles comprising the calcium phosphate mineral towards the basic body
Implementation Method 2
heating the basic body with the calcium phosphate mineral deposited thereon... integrate the mineral into the zirconia lattice
Implementation Method 3
sintering to ensure fixation
Data Source
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AI summary
The present invention relates to a process for preparing an osteointegrative surface on a ceramic body by chemically modifying at least a part of the surface of the body. The process comprises the subsequent steps of depositing a calcium phosphate mineral on the surface of a ceramic basic body by projecting agglomerates of particles comprising the calcium phosphate mineral towards the basic body, and heating the basic body with the calcium phosphate mineral deposited thereon.