CA2143733A1 - Alpha-tricalcium phosphate ceramic and production method thereof - Google Patents

Alpha-tricalcium phosphate ceramic and production method thereof

Info

Publication number
CA2143733A1
CA2143733A1 CA002143733A CA2143733A CA2143733A1 CA 2143733 A1 CA2143733 A1 CA 2143733A1 CA 002143733 A CA002143733 A CA 002143733A CA 2143733 A CA2143733 A CA 2143733A CA 2143733 A1 CA2143733 A1 CA 2143733A1
Authority
CA
Canada
Prior art keywords
tricalcium phosphate
alpha
powder
sintering
ceramic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002143733A
Other languages
French (fr)
Inventor
Yoshikazu Umezu
Osamu Hayashi
Kazutake Yoshizawa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Advance KK
Original Assignee
Advance KK
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Advance KK filed Critical Advance KK
Publication of CA2143733A1 publication Critical patent/CA2143733A1/en
Abandoned legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/447Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on phosphates, e.g. hydroxyapatite

Abstract

A high purity .alpha.-tricalcium phosphate ceramic having a superior biocompatibility for use mainly as a bone filler, is produced by shaping a powder material formed by a wet method, followed by sintering it and then cooling at a predetermined rate.

Description

- 1 - 214373~3-C314-US/CA

ALPHA-TRICALCIUM PHOSPHATE CERAMIC AND
PRODUCTION METHOD THEREOF

BACKGROUND OF THE INVENTION
1. Field of the Invention The present invention relates to an a-tricalcium phosphate ceramic having a superior biocompatibility for use mainly as a bone filler and a method for producing the same.
2. Description of the Related Art In the past, hydroxyapatite and ~-tricalcium phosphate have been known as ceramics for use as bone fillers. These ceramics are known to be bioactive materials and can bond directly with a natural bone. In general, when these materials are implanted in bone, a thin layer of bioapatite forms in the body at the interface between the bone and the materials. A new bone is said to be formed starting from this point. That is, after bioapatite is formed at the surface of the materials, it is believed that the materials are not dissolved or absorbed much at all. In fact, these materials have slow rates of absorption into the body and are never completely replaced by a new bone.
On the other hand, a-tricalcium phosphate is said not to exhibit formation of a bioapatite layer at the interface of the bone with the material, has a faster rate of absorption in the body compared with hydroxyapatite and ~-tricalcium phosphate, and has an extremely high ability to form a new bone. The ideal bone filler should have a high bone-forming ability and should completely disappear and be completely replaced by bone. For a long time, it has been thought that if production of a shaped article made of a-tricalcium phosphate were possible, it could be an extremely favorable bone filler. However, a-tricalcium phosphate has been difficult to fabricate as a ceramic up to now 21~3733 due to the difficulty of formation by a wet method, the unavoidable formation of cracks at the time of sintering, and other reasons.
SUMMARY OF THE INVENTION
Accordingly, the objects of the present invention are to eliminate the above-mentioned disadvantages of the prior art and to provide a high purity ~-tricalcium phosphate ceramic and a method for producing an a-tricalcium phosphate ceramic, which is expected to use as a material for an ideal bone filler.
In accordance with the present invention, there is provided a method for producing an a-tricalcium phosphate ceramic comprising the steps of:
shaping a powder material under pressure, or simultaneously with the shaping under pressure;
sintering the shaped powder; and, then cooling the sintered product.
In accordance with the present invention, there is also provided a method for producing an a-tricalcium phosphate ceramic shaping a powder material obtained by a wet method using the monoaxial press method or CIP method (i.e., cold isostatic pressing method);
sintering the shaped powder material at a temperature of 1100 to 1500C for 1 to 200 hours; and, then cooling the sintered product at a cooling rate of 100 to 2000C/hrs.
In accordance with the present invention, there is further provided a method for producing an a-tricalcium phosphate ceramic comprising the steps of:
sintering a powder material obtained by a wet method using a hot press method or HIP method (i.e., hot isostatic pressing method) at a temperature of 200 to 1500C for 1 to 200 hours.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the description set forth below with reference to the _ 3 - 2143733 accompanying drawings, wherein:
Fig. 1 is a graph showing the relationship between the sintering temperature and the relative density of the a-tricalcium phosphate ceramic obtained in Example 3;
Fig. 2 is a view of a photograph of a non-decalcified sample (implanted 3 months) of an a-tricalcium phosphate ceramic when implanted in the femur of an osteophoresis model rat obtained in Example 4; and Fig. 3 is a view of a photograph of a non-decalcified sample (implanted 3 months) of a hydroxyapatite ceramic when implanted in the femur of an osteophoresis model rat obtained in Example 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The method for producing an a-tricalcium phosphate ceramic according to the present invention will now be explained in further detail below.
The a-tricalcium phosphate in the present invention means the high temperature stable phase of tricalcium phosphate and is expressed in chemical composition as Ca3 ( P04 ) 2 . Tricalcium phosphate has ~-phase (low temperature phase), y-phase (high pressure phase), and a-phase (high temperature phase), which are the same in composition. The stable region of the a-phase is 1125 to 1500C.
The method of production of a dense ceramic of a-tricalcium phosphate is as follows. As an example of the wet method, an aqueous solution of phosphoric acid is gradually added dropwise to, for example, a 0.5M
suspension of calcium hydroxide. This is stirred and a uniform reaction is caused to obtain amorphous tricalcium phosphate. This amorphous tricalcium phosphate is filtered, then dried at, for example, 60C, then pulverized by a kneader. The resultant powder is provisionally sintered at a temperature of 600 to 1200C
is homogeneously mixed with a thickening agent, then is shaped using a press at a pressure of 50 to 200 MPs.
Note that during the sintering, amorphous tricalcium 4 21~3733 phosphate is formed in the temperature range of 600 to 750C, ~-tricalcium phosphate in the temperature range of 775 to 1100C, and ~-tricalcium phosphate in the temperature range of 1125 to 1200C. The shaped article is sintered at a temperature of 1150 to 1500C, preferably 1350 to 1450C, for 1 to 200 hours, more preferably 50 to 100 hours, and then cooled at a cooling rate of 500 to 1000 C/hr. The press used may be a monoaxial press, hot press, rubber press, etc.
The method of production of the porous ceramic of a-tricalcium phosphate is as follows. A thickening agent is homogeneously mixed with a powder of tricalcium phosphate formed by the above-mentioned method, then the mixture is made into a slurry by addition of water or ethanol. The slurry is then uniformly impregnated into a plastic sponge and subjected to the same sintering as with the above dense body.
By sintering at a high temperature over a long period as mentioned above, it is possible to fabricate a single phase ~-tricalcium phosphate ceramic having a high purity and a mole ratio of Ca/P of about 1.50. Further, by changing the conditions of formation, conditions of sintering, etc., it is possible to fabricate shaped articles containing hydroxyapatite, ~-tricalcium phosphate, tetracalcium phosphate, and other calcium phosphates as well.
EXAMPLES
The present invention will now be further illustrated by, but is by no means limited to the following Examples.
Example 1 Alpha-tricalcium phosphate powder and ~-tricalcium phosphate powder formed by the wet method were fabricated into disk shaped articles of diameters of about 28 mm and thicknesses of about 5 mm by using a monoaxial press.
These were sintered at a temperature range of 1000 to 1500C and were identified in phase by the powder X-ray diffraction method. As a result, it was found that high purity a-tricalcium phosphate ceramic what was obtained from a-tricalcium phosphate powder when sintered at conditions of 1400 to 1450C and high purity a-tricalcium phosphate ceramic was obtained from ~-tricalcium phosphate powder when sintered at conditions of 1150 to 1400C. Further, depending on the conditions, it was possible to fabricate a tricalcium phosphate ceramic with an a-phase at the surface and a ~-phase inside. The relationship between the sintering temperature and phase is shown in Table 1.
Table 1 Sintering a-TCP ~-TCP
temperature Ceramic After Ceramic After surface pulver- surface pulver-(C) ization ization 1150 a+~ a+~ a a 1200 a+~ a+~ a a 1250 a+~ a+~ a a 1300 a a+~ a a 1350 a a+~ a a 1400 a a a a 1450 a a In the Table, the a-TCP and ~-TCP mean the a-tricalcium phosphate powder and ~-tricalcium phosphate powder of the starting materials. "Ceramic surface"
shows the information of the powder X-ray diffraction from the surface of the sintered body, while "After pulverization" shows the information from the powder after pulverization of the sintered body.
Next, the relative densities of a-type tricalcium phosphate ceramics obtained when sintering shaped articles of a-tricalcium phosphate powder at a fixed 1400C, but changing the sintering time were found. It was learned that the relative density increased along with the sintering time and that an approximately 95 percent dense body was obtained with a sintering time of 21~3733 100 hours.
Example 2 Alpha-tricalcium phosphate powder formed by the wet method was heat treated under pressure using a hot press under conditions of 80 MPs and 1350C, whereupon a high purity ~-tricalcium phosphate ceramic was obtained.
Example 3 Alpha-tricalcium phosphate powder, ~-tricalcium phosphate powder, and amorphous tricalcium phosphate powder formed by the wet method were made into slurries by adding 50 percent of water. These were then impregnated into polyurethane sponges, then dried and sintered at a sintering temperature of 1400C and a sintering time of 50 hours, whereupon high purity ~-type tricalcium phosphate ceramics were obtained. These had sufficient practical strength as a bone filler (see Fig. 1).
Example 4 Dense bodies of ~-tricalcium phosphate and hydroxyapatite cut into rectangular columns of 0.7 mm x 0.7 mm x 5 mm were implanted into the femur of osteophoresis model rats subjected to ovariectomies to observe the reaction with bone tissue. As a result, in the case of ~-tricalcium phosphate, new bone was formed directly around the specimen. There was no interposition of fibrous connecting tissue observed. The new bone and the material bonded directly. Further, the new bone substantially completely covered the surface of the specimen and the rectangular column material became rounded, so there were signs of absorption over time and the possibility was suggested of complete disappearance with long term implantation (see Fig. 2).
On the other hand, in the case of the hydroxyapatite, fibrous connecting tissue was formed around the specimen. There was little formation of new bone. Further, the shape of the article remained the same as at the time of implantation, so there was no sign of dissolution and it was believed that there would be no absorption even with long-term implantation (see Fig. 3).
As explained above, according to the method of production of the present invention, it is possible to produce a ceramic usable as a bone filler, superior in biocompatibility, high in the ability to form bone, and having the ability of being replaced by bone.

Claims (6)

1. A method for producing an .alpha.-tricalcium phosphate ceramic comprising the steps of:
shaping a powder material under pressure, or simultaneously with the shaping under pressure;
sintering the shaped powder; and, then, cooling the sintered product.
2. A method for producing an .alpha.-tricalcium phosphate ceramic comprising the steps of:
shaping a powder material obtained by a wet method using the monoaxial press method or CIP
method;
sintering the shaped powder material at a temperature of 1100 to 1500°C for 1 to 200 hours; and, then cooling the sintered product at a cooling rate of 100 to 2000°C/hr.
3. A method for producing an .alpha.-tricalcium phosphate ceramic, wherein the powder material obtained by the wet method is impregnated in a porous plastic material, followed by sintering.
4. A method for producing an .alpha.-tricalcium phosphate ceramic comprising the steps of:
sintering a powder material obtained by a wet method using a hot press method or HIP method at a temperature of 200 to 1500°C for 1 to 200 hours.
5. A method for producing an .alpha.-tricalcium phosphate ceramic as claimed in any one of claims 2 to 5, wherein the powder material formed by a wet method is at least one powder selected from the group consisting of .beta.-tricalcium phosphate powder, .alpha.-tricalcium phosphate powder, and amorphous calcium phosphate powder, and mixtures of these powders with hydroxyapatite.
6. An .alpha.-tricalcium phosphate ceramic having an .alpha.-type single phase.
CA002143733A 1994-03-02 1995-03-01 Alpha-tricalcium phosphate ceramic and production method thereof Abandoned CA2143733A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP6-54790 1994-03-02
JP5479094 1994-03-02

Publications (1)

Publication Number Publication Date
CA2143733A1 true CA2143733A1 (en) 1995-09-03

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Family Applications (1)

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Country Status (6)

Country Link
US (1) US5679294A (en)
EP (1) EP0705802A4 (en)
KR (1) KR960701809A (en)
CN (1) CN1126464A (en)
CA (1) CA2143733A1 (en)
WO (1) WO1995023775A1 (en)

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US5571493A (en) * 1994-11-04 1996-11-05 Norian Corporation Reactive tricalcium phosphate compositions and uses
US5820632A (en) * 1988-04-20 1998-10-13 Norian Corporation Prepared calcium phosphate composition and method
US5900254A (en) * 1988-04-20 1999-05-04 Norian Corporation Carbonated hydroxyapatite compositions and uses

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IL116477A (en) 1995-12-21 2000-02-29 Hadasit Med Res Service Bone graft substitute and process for producing same
US5935172A (en) * 1996-06-28 1999-08-10 Johnson & Johnson Professional, Inc. Prosthesis with variable fit and strain distribution
JP4358374B2 (en) * 1999-08-10 2009-11-04 日本特殊陶業株式会社 Method for producing biological implant material
US6375935B1 (en) 2000-04-28 2002-04-23 Brent R. Constantz Calcium phosphate cements prepared from silicate solutions
US7820191B2 (en) 2000-04-28 2010-10-26 Skeletal Kinetics, Llc Calcium phosphate cements prepared from silicate solutions
US6840961B2 (en) * 2001-12-21 2005-01-11 Etex Corporation Machinable preformed calcium phosphate bone substitute material implants
ES2193864B1 (en) * 2002-01-16 2004-10-16 Neos Ceramica E Investigacion, S.L. CERAMIC PASTA WITH NON-CONVENTIONAL FORMULATION WITH CONTENTS IN PHOSPHORUS OVER 2% BY WEIGHT. PROCEDURE FOR THEIR ELABORATION AND ADVANTAGES.
US20040250730A1 (en) * 2003-06-12 2004-12-16 David Delaney Calcium phosphate cements prepared from silicate-phosphate solutions
US7306786B2 (en) * 2003-07-28 2007-12-11 Skeletal Kinetics, Llc Calcium phosphate cements comprising a water-soluble contrast agent
US7261718B2 (en) 2003-09-11 2007-08-28 Skeletal Kinetics Llc Use of vibration with polymeric bone cements
US7261717B2 (en) 2003-09-11 2007-08-28 Skeletal Kinetics Llc Methods and devices for delivering orthopedic cements to a target bone site
US7252833B2 (en) * 2003-11-18 2007-08-07 Skeletal Kinetics, Llc Calcium phosphate cements comprising an osteoclastogenic agent
US8118812B2 (en) 2004-03-09 2012-02-21 Skeletal Kinetics, Llc Use of vibration in composite fixation
US9707024B2 (en) 2004-03-09 2017-07-18 Skeletal Kinetics, Llc Use of vibration in composite fixation
US20050257714A1 (en) * 2004-05-20 2005-11-24 Constantz Brent R Orthopedic cements comprising a barium apatite contrast agent
US7252841B2 (en) * 2004-05-20 2007-08-07 Skeletal Kinetics, Llc Rapid setting calcium phosphate cements
US7175858B2 (en) * 2004-07-26 2007-02-13 Skeletal Kinetics Llc Calcium phosphate cements and methods for using the same
BRPI0807003A2 (en) * 2007-02-06 2014-04-15 Indiana Nanotech Division Of Therametric Technologies Inc HYBRID ORGANIC / INORGANIC CHEMICAL SYSTEMS, INCLUDING FUNCTIONAL HYBRID CALCIUM PHOSPHATE SYSTEMS, AND A SOLID METHOD TO PRODUCE THE SAME
CA2683678A1 (en) * 2007-04-13 2008-10-23 Dr. H. C. Robert Mathys Stiftung Method for producing pyrogene-free calcium phosphate
JP4392460B1 (en) * 2008-11-13 2010-01-06 株式会社カタリメディック Calcium phosphate porous material with low residual amount of aromatic hydrocarbon
US8409538B2 (en) 2008-12-04 2013-04-02 Skeletal Kinetics Llc Tricalcium phosphate coarse particle compositions and methods for making the same
US8673364B2 (en) * 2009-09-28 2014-03-18 Skeletal Kinetics, Llc Rapid setting high strength calcium phosphate cements comprising cyclodextrins
US8652373B2 (en) * 2010-07-09 2014-02-18 Indian Institute Of Technology Kanpur Hydroxyapatite poly(etheretherketone) nanocomposites and method of manufacturing same
MY169686A (en) 2011-01-27 2019-05-13 Sirim Berhad A method of converting limestone into tri-calcium phosphate and tetra-calcium phosphate powder simultaneously
CN105920673B (en) * 2016-05-18 2019-03-05 上海交通大学 Complex phase porous stent structure preparation method based on temperature regulation complex phase apatite ingredient

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US5820632A (en) * 1988-04-20 1998-10-13 Norian Corporation Prepared calcium phosphate composition and method
US5900254A (en) * 1988-04-20 1999-05-04 Norian Corporation Carbonated hydroxyapatite compositions and uses
US5952010A (en) * 1988-04-20 1999-09-14 Norian Corporation Paste compositions capable of setting into carbonated apatite
US5962028A (en) * 1988-04-20 1999-10-05 Norian Corporation Carbonated hydroxyapatite compositions and uses
US6334891B1 (en) 1992-10-16 2002-01-01 Norian Corporation Paste compositions capable of setting into carbonated apatite
US5571493A (en) * 1994-11-04 1996-11-05 Norian Corporation Reactive tricalcium phosphate compositions and uses
US5709742A (en) * 1994-11-04 1998-01-20 Norian Corporation Reactive tricalcium phosphate compositions
US5885540A (en) * 1994-11-04 1999-03-23 Norian Corporation Reactive tricalcium phosphate compositions

Also Published As

Publication number Publication date
KR960701809A (en) 1996-03-28
EP0705802A4 (en) 1996-08-28
WO1995023775A1 (en) 1995-09-08
EP0705802A1 (en) 1996-04-10
US5679294A (en) 1997-10-21
CN1126464A (en) 1996-07-10

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