Monolithic Biocompatible Metallic Implant Layer
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Solution Overview
Problem
Current implantable materials for bone substitution lack the ability to distribute stresses uniformly, leading to stress shielding, bone resorption, and inadequate vascularization, which can result in implant failure and prolonged remodeling times.
Innovation Solution
An implantable material with an open cell metal structure and a monolithic layer of biocompatible metallic material, such as tantalum, is developed, which provides interconnected porosity and uniform stress distribution, mimicking the properties of cancellous bone, and is fabricated using a method that avoids chemical-vapor-deposition to enhance strength and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chemical-vapor-deposition is used to form a layer of biocompatible metallic material, then the layer can be formed on the substrate, but the layer lacks sufficient strength and uniformity
Solution Approach 1:
The patent changes the manufacturing parameters by using a physical vapor deposition process instead of chemical-vapor-deposition, and by controlling deposition conditions (temperature, pressure, deposition rate) to achieve a monolithic layer with both high strength and uniform thickness. The layer is deposited at temperatures between 200-600°C and pressures between 0.01-1 atm to optimize both strength and uniformity.
Solution Approach 2:
The patent creates a composite structure combining a substrate with a monolithic layer of biocompatible metallic material (such as tantalum, titanium, or their alloys). This composite structure leverages the strength of the metallic layer while maintaining the properties of the substrate, achieving both high strength and uniformity through proper material selection and deposition control.
2Productivity
If chemical-vapor-deposition is used to build a layer of biocompatible metallic material, then the layer can be formed on the substrate, but the manufacturing process is slow
Solution Approach 1:
The patent replaces the chemical-vapor-deposition process with a physical vapor deposition process, substituting chemical reactions with physical deposition mechanisms. This substitution enables faster deposition rates while maintaining layer quality, as the physical process allows for more rapid material transfer without the constraints of chemical reaction rates.
3Adaptability or versatility
If a porous scaffold material is used to provide structural support, then tissue ingrowth is permitted, but stress distribution is inadequate leading to bone resorption
Solution Approach 1:
The patent applies local quality by creating a porous scaffold structure with specific pore size, shape, and distribution characteristics that are optimized for both tissue ingrowth and stress distribution. The local porosity is controlled to allow vascularization and tissue penetration while maintaining sufficient mechanical integrity to distribute stresses uniformly, preventing stress shielding and bone resorption.
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 implantable material effectively distributes stresses throughout the bone structure, preventing bone resorption and promoting vascularization, leading to faster bone ingrowth and mineralization, and reducing the risk of implant failure by mimicking the mechanical properties of cancellous bone.
Implementation Method 1
reducing most of the monolithic layer precursor (e.g., about 90 percent to 100 percent) on the substrate to form the monolithic layer of the biocompatible material
Data Source
AI summary
Various embodiments disclosed relate to an implant. The implant includes a substrate. The implant further includes a monolithic layer comprising a biocompatible metallic material, having at least one of an amorphous and a crystalline microstructure contacting the substrate.