Curdlan-Ceramic Composite for Implant Bone Compatibility
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Solution Overview
Problem
Ceramic materials like hydroxyapatite (HAp) and tricalcium phosphate (TCP) used in implants are fragile and lack plasticity, limiting their application in surgeries, especially in oral and facial procedures due to their mechanical weakness.
Innovation Solution
A method involving a water suspension of β-1,3-glucan (curdlan) with calcium phosphate ceramics, where the mixture is homogenized, filled into a mould, and subjected to controlled ramming to minimize air content and then heat-treated at 80-100°C to produce a composite with high mechanical endurance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic granules (HAp or TCP) are used as implant materials, then bone compatibility and bioactivity are improved, but mechanical strength and plasticity deteriorate due to fragility
Solution Approach 1:
The patent creates a composite material combining ceramic granules (HAp or TCP) with curdlan polymer. The curdlan acts as a binding agent that provides plasticity and mechanical strength while the ceramic granules maintain bone compatibility. This composite structure allows the material to exhibit both bioactivity and improved mechanical properties, resolving the contradiction between bone compatibility and mechanical strength.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the ceramic material by incorporating it into a curdlan matrix. The curdlan polymer changes the processing parameters, allowing the fragile ceramic granules to be formed into plastic shapes and sintered at controlled temperatures (80-100°C) to achieve desired mechanical properties while maintaining bone compatibility.
2Ease of operation
If ceramic materials are made more malleable using water suspension of curdlan heated to 40°C, then plasticity is improved, but mechanical endurance deteriorates due to high air content
Solution Approach 1:
The patent applies preliminary action by performing controlled ramming and compression of the curdlan-ceramic mixture before final sintering. The mixture is compressed in a mold to eliminate air pockets and achieve dense packing, then sintered at 80-100°C. This preliminary compression step removes air that would otherwise compromise mechanical endurance, while the curdlan matrix maintains plasticity during processing.
Solution Approach 2:
The patent creates a controlled environment during processing where air is minimized or excluded. The curdlan-ceramic mixture is compressed and sintered in a controlled atmosphere that prevents air entrapment. By removing air from the system during processing, the final composite achieves high mechanical endurance while maintaining the plasticity benefits of curdlan.
3Stability of the object's composition
If the mixture is thoroughly mixed until optimum homogeneity is achieved, then uniformity is improved, but processing time increases
Solution Approach 1:
The patent applies continuous mixing action to achieve uniform distribution of ceramic granules throughout the curdlan matrix. The mixture is continuously stirred and homogenized during the processing sequence, ensuring consistent composition without requiring separate mixing steps. This continuous approach achieves optimum homogeneity efficiently, balancing uniformity with processing time.
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 method results in ceramics-based composites with enhanced mechanical endurance and low air content, achieving deformation resistance and a highly homogeneous structure, suitable for implant applications.
Implementation Method 1
the matter is pushed into a mould where each portion is rammed separately until consistency containing less than 15% air is achieved and, after accurate ramming, it undergoes 5-120 minutes of heat treatment in temperatures between 80-100°C
Data Source
AI summary
The inventions solve the problem of designing a machine for producing moulded composite parts that are homogeneously structured and the problem of finding a method for producing composite for implants. The essence of the design of the machine consists in that it has a portioning assembly, whereby above a mould form unit (14) there is a guiding unit (11) located opposite a dosing unit (6) and above the aforementioned guiding unit (11) there is a pressing assembly (20) slidingly mounted on a vertical frame (19) and which is equipped with at least one piston rod (25) with a rammer (27) at its end, whereby the piston rod (25) is placed within a casing (24) into which pneumatic pipes (23) are connected. The essence of the method consists in that a preliminary moulding is being performed by thoroughly filling a preform trough and then the matter is being pushed out of the preform trough in portions and then each portion is rammed separately until consistency containing less than 15% air is achieved.