Manufacture of porous net-shaped materials comprising alpha or beta tricalcium phosphate or mixtures thereof
First Claim
1. A method of producing a porous tricalcium phosphate net-shaped material having an intended final shape, comprising:
- preparing a powder reactant mixture comprising calcium oxide powder and phosphorus pentoxide powder, wherein a mole percent ratio of said calcium oxide powder to said phosphorus pentoxide powder allows the powdered reactant mixture to form tricalcium phosphate upon subsequent combustion;
forming said powder reactant mixture into said intended final shape by placing said powder reactant mixture into a combustible or noncombustible die having said intended final shape and compressing said powder reactant mixture to form a formed reactant mixture;
if said die is noncombustible, removing said formed reactant mixture from said die; and
heating said formed reactant mixture to at least an ignition temperature of said formed reactant mixture to produce said porous tricalcium phosphate net-shaped material by a combustion synthesis reaction, wherein said porous tricalcium phosphate net-shaped material is selected from the group consisting of an alpha tricalcium phosphate, a beta tricalcium phosphate and mixtures thereof.
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Abstract
Methods for producing porous tricalcium phosphate net-shaped material are provide. The methods involve preparing a reactant mixture comprising calcium oxide and phosphorus pentoxide in a mole percent ratio that allows the mixture to form tricalcium phosphate upon combustion thereof, forming this mixture into a desired final shape in a die with compression, and carrying out a combustion synthesis therewith. Net-shaped TCP materials of the combustion synthesis, comprising alpha tricalcium phosphate or mixtures of alpha and beta tricalcium phosphate, are optionally further treated to effect transition of the alpha phase to the beta phase. The net-shaped TCP materials can have a uniform or non-uniform porosity.
19 Citations
27 Claims
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1. A method of producing a porous tricalcium phosphate net-shaped material having an intended final shape, comprising:
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preparing a powder reactant mixture comprising calcium oxide powder and phosphorus pentoxide powder, wherein a mole percent ratio of said calcium oxide powder to said phosphorus pentoxide powder allows the powdered reactant mixture to form tricalcium phosphate upon subsequent combustion; forming said powder reactant mixture into said intended final shape by placing said powder reactant mixture into a combustible or noncombustible die having said intended final shape and compressing said powder reactant mixture to form a formed reactant mixture; if said die is noncombustible, removing said formed reactant mixture from said die; and heating said formed reactant mixture to at least an ignition temperature of said formed reactant mixture to produce said porous tricalcium phosphate net-shaped material by a combustion synthesis reaction, wherein said porous tricalcium phosphate net-shaped material is selected from the group consisting of an alpha tricalcium phosphate, a beta tricalcium phosphate and mixtures thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A method of producing a porous tricalcium phosphate net-shaped material having at least two layers of different porosities, comprising:
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preparing a first powder reactant mixture comprising calcium oxide powder and phosphorus pentoxide powder, wherein a mole percent ratio of said calcium oxide powder to said phosphorus pentoxide powder allows the first powder reactant mixture to form tricalcium phosphate upon combustion; placing the first powder reactant mixture into a combustible or noncombustible die having an intended shape for the porous tricalcium phosphate net-shaped material and compressing the first powder reactant mixture to form a compressed first reactant mixture; if the die is noncombustible, removing the compressed first reactant mixture from the die; heating the compressed first reactant mixture to at least an ignition temperature of the compressed first reactant mixture to produce a first layer of material by a combustion synthesis reaction, the first layer of material having a first porosity, wherein the first layer of material is selected from the group consisting of an alpha tricalcium phosphate, a beta tricalcium phosphate and mixtures thereof, wherein the compressed first reactant mixture has a composition that results in the first layer of material having a first pore size; preparing a second powder reactant mixture comprising calcium oxide powder and phosphorus pentoxide powder, wherein a mole percent ratio of the calcium oxide powder of the second powder reactant mixture to the phosphorus pentoxide powder of the second powder reactant mixture allows the second powder reactant mixture to form tricalcium phosphate upon combustion; placing the second powder reactant mixture into a combustible or noncombustible die having the intended shape and compressing the second powder reactant mixture to form a compressed second reactant mixture; if the die is noncombustible, removing the compressed second reactant mixture from the die; placing the compressed second reactant mixture on the first layer of material to form a dual layer material; and heating the dual layer material to at least an ignition temperature of the second reactant mixture to produce the porous tricalcium phosphate net-shaped material, wherein the porous tricalcium phosphate net-shaped material comprises the first layer of material and a second layer of material, wherein the second layer of material is formed by a combustion synthesis reaction, wherein the second layer of material is fused to the first layer of material, wherein the second layer of material of said porous tricalcium phosphate net-shaped material has a second porosity, wherein the second layer of material is selected from the group consisting of an alpha tricalcium phosphate, a beta tricalcium phosphate and mixtures thereof, wherein a composition of the compressed second reactant mixture results in the second layer of material having a second pore size. - View Dependent Claims (23)
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24. A method of producing a porous tricalcium phosphate net-shaped material having at least two layers of different porosities, comprising:
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preparing a first powder reactant mixture comprising calcium oxide powder and phosphorus pentoxide powder, wherein a mole percent ratio of the calcium oxide powder to the phosphorus pentoxide powder allows the first powder reactant mixture to form a tricalcium phosphate material having a first porosity when combusted; placing the first powder reactant mixture into a combustible or noncombustible die having an intended shape for the porous tricalcium phosphate net-shaped material and compressing the first powder reactant mixture; preparing a second powder reactant mixture comprising calcium oxide powder and phosphorus pentoxide powder, wherein the mole percent ratio of the calcium oxide powder of the second powder reactant mixture to the phosphorus pentoxide powder of the second powder reactant mixture allows the second powder reactant mixture to form a tricalcium phosphate material having a second porosity when combusted; placing the second powder reactant mixture into the die on top of the first powder reactant mixture and compressing the second powder reactant mixture and the first powder reactant mixture to form a compressed mixture; if the die is noncombustible, removing said compressed mixture from the die; and rapidly heating said compressed mixture in a furnace at a temperature sufficient to produce the porous tricalcium phosphate net-shaped material by a combustion synthesis reaction, wherein the porous tricalcium phosphate net-shaped material is selected from the group consisting of an alpha tricalcium phosphate, a beta tricalcium phosphate and mixtures thereof. - View Dependent Claims (25)
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26. A method for preparing a tricalcium phosphate net-shaped material, comprising:
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preparing a powder reactant mixture comprising calcium oxide powder and phosphorus pentoxide powder, wherein a mole percent ratio of said calcium oxide powder to said phosphorus pentoxide powder allows the powder reactant mixture to form tricalcium phosphate when combusted; forming said powder reactant mixture into an intended final shape by placing said powder reactant mixture into a combustible die having said intended final shape and compressing said powder reactant mixture to form a compressed mixture; and rapidly heating said compressed mixture in a furnace at a temperature sufficient to produce said tricalcium phosphate net-shaped material by a combustion synthesis reaction, wherein said tricalcium phosphate net-shaped material is selected from the group consisting of an alpha tricalcium phosphate, a beta tricalcium phosphate, and mixtures thereof. - View Dependent Claims (27)
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Specification