Method and apparatus for forming porous metal implants
First Claim
Patent Images
1. A method for preparing a porous metal implant comprising:
- a. preparing a mixture comprising;
i. a biocompatible metal powder;
ii. a spacing agent selected from the group consisting of hydrogen peroxide, urea, ammonium carbonate, ammonium bicarbonate, ammonium carbamate, calcium hydrogen phosphate, naphthalene, and mixtures thereof; and
iii. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder;
b. forming the mixture into a shape; and
c. removing the spacing agent by melting or sublimation thereof to form a plurality of pores within the metal implant.
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Abstract
A method for providing a porous metal implant. A mixture of a biocompatible metal, a spacing agent, and a binder is provided. The mixture is formed into a shaped the spacing agent is removed to form a plurality of pores in the implant. A shaped porous metal implant is also provided.
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Citations
35 Claims
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1. A method for preparing a porous metal implant comprising:
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a. preparing a mixture comprising; i. a biocompatible metal powder; ii. a spacing agent selected from the group consisting of hydrogen peroxide, urea, ammonium carbonate, ammonium bicarbonate, ammonium carbamate, calcium hydrogen phosphate, naphthalene, and mixtures thereof; and iii. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder; b. forming the mixture into a shape; and c. removing the spacing agent by melting or sublimation thereof to form a plurality of pores within the metal implant. - View Dependent Claims (2, 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 34, 35)
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6. A method for preparing a porous metal implant comprising:
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a. preparing a mixture comprising; i. a biocompatible metal powder; ii. a spacing agent; and iii. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder; b. forming the mixture into a shape; and c. removing the spacing agent to form a plurality of pores within the metal implant, wherein the non-polar liquid binder comprises d-limonene.
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21. A moldable mixture for providing a porous metal implant comprising:
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a. a biocompatible metal powder; b. a spacing agent; and c. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder, wherein the difference in the sublimation temperature of the spacing agent and the sublimation temperature of the non-polar liquid binder is less than about 200°
C. - View Dependent Claims (22, 23, 25, 26, 27, 28, 30)
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24. A moldable mixture for providing a porous metal implant comprising:
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a. a biocompatible metal powder; b. a spacing agent; and c. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder, wherein the non-polar liquid binder is d-limonene.
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29. A method of securing a moldable mixture for providing a porous metal implant comprising:
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a. providing a mixture comprising a biocompatible metal powder, a spacing agent, and a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder; b. placing a securing element comprising a metal foil about at least a portion of the mixture; c. molding the mixture into a formed shape while the mixture is in the securing element; d. subliming the spacing agent and non-polar liquid binder from the formed shape; e. removing the securing element; and f. sintering the formed shape.
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31. A method for preparing a porous metal implant comprising:
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a. preparing a mixture comprising; i. a biocompatible metal powder; ii. a spacing agent; and iii. a non-polar liquid binder comprising d-limonene, wherein the spacing agent is substantially insoluble in the non-polar liquid binder; b. forming the mixture into a shape; and c. thermal cycling the mixture within a single heating unit to remove the spacing agent and the non-polar liquid binder and sinter the metal powder to form a plurality of pores within the metal implant. - View Dependent Claims (32)
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33. A method for preparing a porous metal implant comprising:
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a. preparing a mixture comprising; i. a biocompatible metal powder; ii. a spacing agent; and iii. a non-polar liquid binder, wherein the spacing agent is substantially insoluble in the non-polar liquid binder; b. forming the mixture into a shape; and c. thermal cycling the mixture within a single heating unit to remove the spacing agent and the non-polar liquid binder and sinter the metal powder to form a plurality of pores within the metal implant, wherein the thermal cycling includes at least one sintering and at least one quenching.
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Specification