Green Ceramic Machining Without Embedding Mass
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Solution Overview
Problem
Current methods for manufacturing ceramic bodies, particularly for complex implants like femoral knee components, face challenges in achieving strong, intricate geometries without the use of embedding masses like wax, which can contaminate and complicate the machining process.
Innovation Solution
A method involving the creation of a green ceramic body that is machined without embedding in an embedding mass, and optionally bisqued and infiltrated, allowing for the production of strong, finished ceramic bodies with precise geometries using techniques like CNC machining and vacuum chucks, avoiding the need for attachable substances like wax.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ceramic bodies are machined using embedding mass (wax), then the ceramic can be held securely during machining, but the embedding mass contaminates the machining process and requires additional removal steps
Solution Approach 1:
The patent removes the embedding mass (wax) from the machining process entirely. Green ceramic bodies are machined directly without being embedded in wax, eliminating the contamination problem while maintaining machining capability through direct gripping or clamping methods.
Solution Approach 2:
The patent introduces a removable support structure or clamping mechanism that acts as an intermediary to hold the green ceramic body during machining without requiring embedding mass. This allows secure positioning without contamination.
2Strength
If complex ceramic implant geometries are created by machining fired ceramic blocks, then the final strength is adequate, but the process is expensive and cannot achieve intricate geometries
Solution Approach 1:
The patent performs preliminary shaping of the ceramic body while it is in the green state, before firing. This allows complex geometries to be created more easily and economically in the green state, then the body is fired to achieve the required strength for implant applications.
Solution Approach 2:
The patent changes the physical state parameter of the ceramic from fired (hard, strong) to green (softer, more machinable), performs machining operations, then returns it to the fired state to achieve both intricate geometry and required strength.
3Object-generated harmful factors
If ceramic bodies are machined in the green state without embedding mass, then contamination is eliminated and costs are reduced, but the green body may be difficult to hold securely during machining
Solution Approach 1:
The patent introduces clamping devices, fixtures, or support structures as intermediaries to securely hold the green ceramic body during machining operations. These devices grip the green body without requiring embedding mass, maintaining both contamination-free processing and machining stability.
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 method enables the production of strong, finished ceramic bodies that conform to intricate geometries, reducing costs and eliminating contaminants, and allows for the creation of complex implants like posterior stabilized femoral knee components with enhanced strength and precision.
Implementation Method 1
bisquing the initial green body can form a bisqued green body of ceramic
Data Source
AI summary
Ceramic bodies can be made by providing an initial green body of ceramic; and machining the initial green body to provide a machined green ceramic body. Embedding the initial green body in an embedding mass can be avoided. The initial green body can be bisqued, infiltrated an adjuvant such as machining wax, removing the infiltrated body, and machining it. Highly detailed ceramic products can be generated. The machined green ceramic body may be fired and/or further processed to provide a more finished ceramic body. Examples include a femoral component for a posterior stabilized knee implant, a component body for an artificial rotation device containing knee implant prosthesis a dental implant or bridge, an ice skating blade, and so forth. Zirconia ceramics are advantageously employed, for an example, Mg-TTZ.