Core-Shell Ceramic Support via Double Nozzle Extrusion
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Solution Overview
Problem
Current methods for manufacturing ceramic-based supports for hard tissue regeneration face limitations due to the need for high-temperature sintering, which complicates the incorporation of biofunctional materials and can result in unstable mechanical properties and uneven distribution of cells within the 3D structure, leading to issues like necrosis and reduced biocompatibility.
Innovation Solution
A method involving the use of a double nozzle extrusion container to create a core-shell structured support by extruding a calcium phosphate ceramic core and a hydrogel shell, followed by a cement reaction at room temperature, allowing for uniform distribution of biofunctional materials and cells within the 3D structure without the need for high-temperature processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature sintering is used to manufacture ceramic-based supports, then mechanical strength and structural stability are improved, but biofunctional materials and cells cannot be incorporated and mechanical properties become unstable
Solution Approach 1:
The patent changes the manufacturing temperature parameter from high-temperature sintering to room temperature cement reaction, enabling the incorporation of biofunctional materials and cells while maintaining mechanical strength through chemical bonding of ceramic particles
Solution Approach 2:
The patent replaces the thermal field-based sintering process with a chemical field-based cement reaction process, allowing biofunctional materials to be incorporated without the harmful effects of high temperature while achieving structural stability through chemical bonding
2Stability of the object's composition
If high-temperature sintering is used to manufacture ceramic-based supports, then structural stability is improved, but uniform distribution of cells and biofunctional materials is lost
Solution Approach 1:
The patent performs preliminary mixing and distribution of cells and biofunctional materials with ceramic particles in the paste before molding, ensuring uniform distribution is achieved before the cement reaction locks the structure in place
Solution Approach 2:
The patent changes the processing temperature to room temperature, preventing thermal damage to cells and biofunctional materials while maintaining uniform distribution through controlled paste preparation and molding processes
3Strength
If high-temperature sintering is used to manufacture ceramic-based supports, then mechanical strength is improved, but biocompatibility and necrosis prevention are worsened
Solution Approach 1:
The patent replaces the thermal field-based sintering process with a chemical field-based cement reaction process at room temperature, eliminating thermal damage to cells and tissues while maintaining mechanical strength through chemical bonding
Solution Approach 2:
The patent changes the processing temperature from high temperature to room temperature, preventing thermal necrosis and improving biocompatibility while maintaining mechanical strength through alternative chemical bonding mechanisms
4Stability of the object's composition
If conventional ceramic manufacturing processes are used, then structural integrity is improved, but complexity of the manufacturing process increases due to heat treatment requirements
Solution Approach 1:
The patent replaces the complex thermal field-based sintering process with a simpler chemical field-based cement reaction process that occurs at room temperature, reducing manufacturing complexity while maintaining structural integrity
Solution Approach 2:
The patent changes the processing conditions from high-temperature thermal treatment to room temperature chemical reaction, simplifying the manufacturing process by eliminating complex heat treatment steps while achieving structural integrity through cementation
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
This approach enables the production of supports with mechanical properties similar to bone, ensuring uniform distribution of cells and biofunctional materials, enhancing tissue regeneration while avoiding the limitations of high-temperature processing, such as necrosis and reduced biocompatibility.
Implementation Method 1
immersing the formed body obtained in step 3 into a setting solution and inducing a cement reaction of the ceramic (step 4)
Implementation Method 2
adding the first paste prepared in Step 1 into a container, which is connected to an internal pipe of an extrusion container including a double nozzle, and adding the second paste prepared in Step 2 into a container, which is connected to an external pipe of the extrusion container including a double nozzle and extruding and forming by layer manufacturing process
Data Source
AI summary
The present invention relates to a method for manufacturing a support for regenerating core-shell structured hard tissue and a support for regenerating core-shell structured hard tissue manufactured thereby, wherein the support may further comprise bio-functional materials, such as cells, in a core-shell structure. The method for manufacturing a support for regenerating core-shell structured hard tissue according to the present invention has an effect of manufacturing a support for regenerating core-shell structured hard tissue by a method by which a 3-dimensional structure is prepared by a layer manufacturing process through an extrusion container having a double nozzle. In addition, the support can be manufactured at room temperature, thereby having an effect of containing cells or various bio-functional materials. Furthermore, the support for regenerating core-shell structured hard tissue has a similar constitution to a bone component and thus has higher mechanical properties, and has an effect that the cells or various bio-functional materials are uniformly distributed throughout the entire 3-dimensional structure.