Claims
- 1. A solid part, comprising a metallic monolith having a dense core surrounded by a porous periphery.
- 2. The part of claim 1, wherein the porous periphery is characterized by a multitude of interconnected pores.
- 3. The part of claim 2, wherein the porosity varies from more than 25% porosity near the surface to less than 5% porosity 100 μm or more from the surface.
- 4. A solid part, comprising a shaped metallic structure having a dense core surrounded by a porous periphery characterized by a multitude of interconnected pores.
- 5. The part of claim 4, wherein the porosity varies from more than 25% porosity near the surface to less than 5% porosity 100 μm or more from the surface.
- 6. The part of claim 4, wherein the shaped metallic structure is monolithic.
- 7. A solid part, comprising a metallic monolith having a dense core surrounded by a porous periphery characterized by a multitude of interconnected pores.
- 8. A prosthesis, comprising:
a monolithic metallic substrate having a dense core surrounded by a porous periphery; and a coating of bioactive material on the substrate.
- 9. The prosthesis of claim 8, wherein the porous periphery is characterized by a multitude of interconnected pores.
- 10. The prosthesis of claim 8, wherein the bioactive material is hydroxyapatite.
- 11. A prosthesis, comprising:
a monolithic metallic substrate having a dense core surrounded by a porous periphery characterized by a multitude of interconnected pores; and a coating of hydroxyapatite on the substrate.
- 12. A dental implant, comprising:
a monolithic metallic screw having a dense core surrounded by a porous periphery characterized by a multitude of interconnected pores; and a coating of bioactive material on the screw.
- 13. The dental implant of claim 12, wherein the metallic screw is a titanium screw.
- 14. The dental implant of claim 12, wherein the bioactive material is hydroxyapatite.
- 15. A dental implant, comprising:
a monolithic titanium screw having a dense core surrounded by a porous periphery characterized by a multitude of interconnected pores, the porous periphery having a porosity that varies from more than 25% porosity near the surface to less than 5% porosity 100 μm or more from the surface; and a coating of hydroxyapatite on the screw.
- 16. A method, comprising:
compacting a metal powder; and exposing the compacted powder to microwaves under conditions sufficient to transform the compressed powder into a monolith having a dense core surrounded by a porous periphery.
- 17. The method of claim 16, wherein exposing the compacted powder to microwaves under conditions sufficient to transform the compressed powder into a monolith having a dense core surrounded by a porous periphery comprises exposing the compacted powder to microwaves at 1.0 kilowatt-2.5 kilowatts for not more than 20 minutes.
- 18. A method, comprising:
transforming metal powder into a monolith having a dense core surrounded by a porous periphery; and coating the monolith with a bioactive material.
- 19. A method, comprising:
pressing titanium powder into a desired shape; exposing the compressed powder to microwaves under conditions sufficient to transform the compressed powder into a monolith having a dense metal core surrounded by a porous metal periphery; and coating the periphery with hydroxyapatite.
- 20. A method, comprising:
compacting titanium powder without external heating; microwave sintering the compacted powder to form a substrate; and depositing hydroxyapatite on the substrate.
- 21. A method, comprising:
compacting titanium powder without external heating; microwave sintering the compacted powder to form a substrate having a dense core surrounded by a porous periphery; and depositing hydroxyapatite on the periphery of the substrate.
- 22. A method, comprising:
compacting titanium powder into a desire shape without external heating, the shape having a core and a periphery surrounding the core; and sintering the compacted powder including heating the core to a temperature greater than the temperature in the periphery.
- 23. The method of claim 22, wherein sintering comprises exposing the compacted powder to microwaves.
- 24. A method, comprising:
compacting a metal powder into a desired shape; sintering the compacted powder with microwaves to form a sintered substrate; and electrodepositing a bioactive material on the substrate.
- 25. A method, comprising:
compacting titanium particles having a particle size less than 325 mesh into a desired shape; thermally insulating the compacted powder; exposing the insulated compacted powder to microwaves at 1.0 kilowatt-2.5 kilowatts for not more than 20 minutes to form a sintered substrate; electrocrystallizing hydroxyapatite on the substrate; and calcining the coated substrate.
- 26. A method, comprising:
compacting titanium particles having a particle size less than 325 mesh into a desired shape; thermally insulating the compacted powder; exposing the insulated compacted powder to microwaves at 1.0 kilowatt-2.5 kilowatts for not more than 20 minutes to form a sintered substrate; washing the substrate in an ultrasonic bath; drying the substrate; etching the substrate in nitric acid; immersing the substrate as an anode in an electrolyte that includes Ca(NO3)2, and NH4H2PO4; immersing a cathode in the electrolyte; generating 0.5 to 1.5 amperes of electrical current between the anode and cathode for 5-20 minutes to form a coated substrate; drying the coated substrate; and calcining the coated substrate at 100° C. to 400° C.
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims subject matter disclosed in provisional patent application serial No. 60/262,730 filed Jan. 19, 2001 titled Microwave Sintering, Bioactive Coating By Electrodeposition And Osseointegration, which is incorporated herein by reference in its entirety.
STATEMENT OF RIGHTS TO INVENTIONS MADE UNDER FEDERALLY FUNDED RESEARCH AND DEVELOPMENT
[0002] Part of the work performed during the development of this invention was funded by the National Science Foundation under contract no. DMII-0085100. The United States government may have certain rights in the invention.
Provisional Applications (1)
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Number |
Date |
Country |
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60262730 |
Jan 2001 |
US |