Method and apparatus for forming porous metal implants
AssigneeBiomet Manufacturing, LLC
InventorsNed M. Hamman, James Fleming, Elizabeth A. Schlueter, Isaac Janson, Jason D. Meridew, Mukesh Kumar
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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.
Claims35
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.
A method for preparing a porous metal implant comprising:
- 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.
A moldable mixture for providing a porous metal implant comprising:
- 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.
A moldable mixture for providing a porous metal implant comprising:
- 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.
A method of securing a moldable mixture for providing a porous metal implant comprising:
- 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.
A method for preparing a porous metal implant comprising:
- 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.
A method for preparing a porous metal implant comprising:
- 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.
Dependencies are inferred from the claim text.