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US 6,183,515 B2Granted
Artificial bone implants
AssigneeBoard of Regents, The University of Texas System
InventorsJoel W. Barlow, Goonhee Lee, Richard H. Crawford, Joseph J. Beaman, Harris L. Marcus, Richard J. Lagow
Life of this patent
Estimating the term…
Abstract
A process for making bone implants from calcium phosphate powders is disclosed. This process involves selectively fusing layers of calcium powders that have been coated or mixed with polymer binders. The calcium powder mixture may be formed into layers and the polymer fused with a laser. Complex three-dimensional geometrical shapes can be automatically replicated or modified using this approach.
Claims22
An implant produced by
- a. forming a mixture of a calcium phosphate composition and a binder;
- b. selectively fusing the binder to form an implant green part;
- and
- c1. infiltrating the implant green part;
- or
- c2. sintering the implant green part to form an implant,
- wherein
- the calcium phosphate composition does not decompose to produce water during step b, and
- the implant
- replicates a naturally complex bone geometry,
- has a complex three-dimensional shape with a well-defined cavity, the cavity replicating internal complex bone geometry,
- has a controlled, interconnected porosity, and
- has a mole ratio of calcium to phosphorus of 0.5 to 1.
10 more elements
An implant produced by selectively fusing a calcium phosphate composition with a binder to form an implant green part;
- and sintering the implant green part to form an implant,
- wherein
- the calcium phosphate composition does not decompose to produce water during fusing, and
- the implant
- replicates a naturally complex bone geometry,
- has a complex three-dimensional shape with a well-defined cavity, the cavity replicating internal complex bone geometry,
- has a controlled, interconnected porosity, and
- has a mole ratio of calcium to phosphorus of 0.5 to 1.
5 more elements
An implant produced by selectively fusing a calcium phosphate composition with a binder to form an implant green part;
- infiltrating the green part, and sintering the green part to form an implant,
- wherein
- the calcium phosphate composition does not decompose to produce water during fusing, and
- the implant
- replicates a naturally complex bone geometry,
- has a complex three-dimensional shape with a well-defined cavity, the cavity replicating internal complex bone geometry,
- has a controlled, interconnected porosity, and
- has a mole ratio of calcium to phosphorus of 0.5 to 1.
5 more elements
An implant produced by
- a. forming a mixture of particles of a calcium phosphate composition and a binder;
- b. forming a layer of the mixture;
- c. selectively fusing the binder;
- d. repeating steps b. and c. a desired number of times to form a plurality of layers, wherein each layer is fused to adjacent layers to form the implant green part;
- and
- e1. infiltrating the implant green part;
- or
- e2. sintering the implant green part to form an implant,
- wherein
- the calcium phosphate composition does not decompose to produce water during step c, and
- the implant
- replicates a naturally complex bone geometry,
- has a complex three-dimensional shape with a well-defined cavity, the cavity replicating internal complex bone geometry,
- has a controlled, interconnected porosity, and
- has a mole ratio of calcium to phosphorus of 0.5 to I.
12 more elements
An implant produced by
- a. forming a mixture of a calcium phosphate composition and a binder;
- b. selectively fusing the binder to form an implant green part;
- and
- c1. infiltrating the implant green part;
- or
- c2. sintering the implant green part to form an implant,
- wherein
- the calcium phosphate composition does not decompose to produce water during step b, and
- the implant
- has a designed complex three-dimensional shape with a well-defined cavity, the cavity having an opening to a surface, the opening having a smaller cross sectional area than the cavity,
- has a controlled, interconnected porosity, and
- has a mole ratio of calcium to phosphorus of 0.5 to 1.
9 more elements
An implant produced by selectively fusing a calcium phosphate composition with a binder to form an implant green part;
- and sintering the implant green part to form an implant,
- wherein
- the calcium phosphate composition does not decompose to produce water during fusing, and
- the implant
- has a designed complex three-dimensional shape with a well-defined cavity, the cavity having an opening to a surface, the opening having a smaller cross sectional area than the cavity,
- has a controlled, interconnected porosity, and
- has a mole ratio of calcium to phosphorus of 0.5 to 1.
4 more elements
An implant produced by selectively fusing a calcium phosphate composition with a binder to form an implant green part;
- infiltrating the green part, and sintering the green part to form an implant,
- wherein
- the calcium phosphate composition does not decompose to produce water during fusing, and
- the implant
- has a designed complex three-dimensional shape with a well-defined cavity, the cavity having an opening to a surface, the opening having a smaller cross sectional area than the cavity,
- has a controlled, interconnected porosity, and
- has a mole ratio of calcium to phosphorus of 0.5 to 1.
4 more elements
An implant produced by
- a. forming a mixture of particles of a calcium phosphate composition and a binder;
- b. forming a layer of the mixture;
- c. selectively fusing the binder;
- d. repeating steps b. and c. a desired number of times to form a plurality of layers, wherein each layer is fused to adjacent layers to form the implant green part;
- and
- e1. infiltrating the implant green part;
- or
- e2. sintering the implant green part to form an implant,
- wherein
- the calcium phosphate composition does not decompose to produce water during step c, and
- the implant
- has a designed complex three-dimensional shape with a well-defined cavity, the cavity having an opening to a surface, the opening having a smaller cross sectional area than the cavity,
- has a controlled, interconnected porosity, and
- has a mole ratio of calcium to phosphorus of 0.5 to 1.
11 more elements
Dependencies are inferred from the claim text.