Method of Making Porous Metal Articles
First Claim
1. A method of making a porous biocompatible metal article, the method comprising:
- a. combining a metal powder with a first homogenizing aid to form metal granules;
b. blending the metal granules and an extractable particulate to form a composite;
c. forming the composite into a green article;
d. removing the extractable particulate from the green article to form a metal matrix and pore structure; and
e. sintering the metal matrix and pore structure.
1 Assignment
0 Petitions
Accused Products
Abstract
In one embodiment, the present invention may be a method of making a porous biocompatible metal article by combining a metal powder with a homogenizing aid to form metal granules, including blending the metal granules and an extractable particulate to form a composite, forming the composite into a green article, removing the extractable particulate from the green article to form a metal matrix and pore structure, and sintering the metal matrix and pore structure. Furthermore the present invention may include a second homogenizing aid combined with the extractable particulate. The present invention also includes shaping the metal matrix and pore structure with or without the use of a binder.
13 Citations
38 Claims
-
1. A method of making a porous biocompatible metal article, the method comprising:
-
a. combining a metal powder with a first homogenizing aid to form metal granules; b. blending the metal granules and an extractable particulate to form a composite; c. forming the composite into a green article; d. removing the extractable particulate from the green article to form a metal matrix and pore structure; and e. sintering the metal matrix and pore structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
-
-
19. A method of making a porous metal article, the method comprising:
-
a. combining a metal powder with a first homogenizing aid to form metal granules; b. blending the metal granules and an extractable particulate to form a composite; c. forming the composite into a green article; d. sintering the green article. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
-
-
38. A method of making a porous metal article, the method comprising:
-
a. emulsifying a first homogenizing aid in water to form an emulsion; b. spraying the emulsion onto a fluidized bed of a metal powder to form metal granules, wherein the first homogenizing aid is a water insoluble organic material, and the metal powder is selected from the group consisting of commercially pure titanium powder and titanium alloy powder between approximately 1 micron and 150 microns; c. drying the metal granules at between approximately 30 and 80 degrees Celsius; d. sieving the granules to −
70 mesh;e. combining an extractable particulate with a second homogenizing aid, wherein the extractable particulate is spherical potassium chloride having an average diameter of 50-600 microns, and wherein the second homogenizing aid is polyethylene glycol having a molecular weight of approximately 200; f. blending the metal granules and the extractable particulate to form a composite; g. shaping the composite to form a green article by applying a pressure of less than 15,000 pounds-per-square inch to the composite; h. removing the extractable particulate and the second homogenizing aid through dissolution in water to form a metal matrix and pore structure, wherein the first homogenizing aid provides a shape to the metal matrix and pore structure by binding the metal powder; i. removing the first homogenizing aid by heating the metal matrix and pore structure; and j. sintering the metal matrix and pore structure.
-
Specification