JPWO2007148788A1 - 多孔質セラミックス材料およびその製造方法 - Google Patents
多孔質セラミックス材料およびその製造方法 Download PDFInfo
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- JPWO2007148788A1 JPWO2007148788A1 JP2008522541A JP2008522541A JPWO2007148788A1 JP WO2007148788 A1 JPWO2007148788 A1 JP WO2007148788A1 JP 2008522541 A JP2008522541 A JP 2008522541A JP 2008522541 A JP2008522541 A JP 2008522541A JP WO2007148788 A1 JPWO2007148788 A1 JP WO2007148788A1
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- Prior art keywords
- porous ceramic
- slurry
- ceramic material
- pores
- cut surface
- Prior art date
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- Granted
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- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical group [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 claims description 22
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Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
- A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
- A61L27/56—Porous materials, e.g. foams or sponges
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
- A61L27/02—Inorganic materials
- A61L27/10—Ceramics or glasses
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
- A61P43/00—Drugs for specific purposes, not provided for in groups A61P1/00-A61P41/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/007—Producing shaped prefabricated articles from the material by freezing the material
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/03—Shaped 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 magnesium oxide, calcium oxide or oxide mixtures derived from dolomite
- C04B35/04—Shaped 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 magnesium oxide, calcium oxide or oxide mixtures derived from dolomite based on magnesium oxide
- C04B35/043—Refractories from grain sized mixtures
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped 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 aluminium oxide
- C04B35/111—Fine ceramics
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/447—Shaped 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
-
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Abstract
Description
(1)材料内部に実質的に一方向に配向した空孔を有する多孔質セラミックス材料であり、空孔の配列方向を高さ方向とする直径3mm×高さ5mmの円柱状の当該材料からなる試験片をその片端から1mmまでをポリエチレングリコールに浸したときに30秒以内に該試験片全体にポリエチレングリコールが浸透する、多孔質セラミックス材料。
(2)(a)実質的に一方向に配向した空孔を有し、(b)気孔率が40〜90%であり、(c)空孔の配向方向に対して垂直方向の第1の切断面、および、第1の切断面と平行であり第1の切断面から空孔の配向方向に5mm離れた第2の切断面の両方において、空孔1つあたりの断面積の平均値が0.05×10-3〜50×10-3mm2である、多孔質セラミックス材料。
(3)材料内部に実質的に一方向に配向する空孔を有し、配向方向に垂直な該空孔の断面積が少なくとも配向方向の5mmの長さにわたって0.05×10-3〜100×10-3mm2である、多孔質セラミックス材料。
(4)気孔率が40〜90%である(3)に記載の多孔質セラミックス材料。
(5)主成分がリン酸カルシウムである、(1)〜(4)のいずれかに記載の多孔質セラミックス材料。
(6)リン酸カルシウムがハイドロキシアパタイトおよび/またはリン酸三カルシウムで
ある、(5)に記載の多孔質セラミックス材料。
(7)(1)〜(6)のいずれかに記載の多孔質セラミックス材料からなる、多孔質セラミックスインプラント材料。
(8)工程(A):セラミックス原料を水に分散させてスラリーを調製する工程、
工程(B):スラリーを所定の容器に充填し、スラリー容器の一方の端部を冷却してスラリーを該端部側から一方向に凍結させる工程、
工程(C):凍結させたスラリーを乾燥させて成形体を得る工程、及び
工程(D):乾燥させた成形体を焼成する工程、
を含み、工程(B)において、上記一方の端部以外のスラリー容器の周囲をスラリーの凝固点より高い温度にまで冷却する、多孔質セラミックス材料の製造方法。
12 空孔
21 スラリー
31 容器
41 試料台
51 セラミックス原料の粒子
61 氷
62 空孔
本発明の材料の気孔率は好ましくは40〜90%であり、より好ましくは50〜90%であり、さらに好ましくは60〜90%である。気孔率が40%以上であれば、多くの血液や骨髄液等が材料内に含浸するために、充分な骨組織の形成が見込まれる。一方、気孔率90%以下であれば、多孔質セラミックス材料は高強度である。
嵩密度=(サンプルの重さ)/(サンプルの体積)
気孔率=(1−嵩密度/3.16)×100
上記範囲内であれば、血液や骨髄液が通過するのに十分な大きさであり、かつ、毛細管現象により血液や骨髄液が通過し易くなる。ただし、本発明の課題を達するためには、材料内の全ての空孔が上記断面積をもつことは要さない。また、血液や骨髄液中に含まれる細胞等が多孔質セラミックス材料に侵入するためには、配向方向に垂直な断面における空孔の短径が少なくとも10μm、好ましくは20μm、より好ましくは30μm以上あることが好ましい。
図2は、本発明の多孔質セラミックスス材料の製造方法の一例を示す。
図2示すように、本発明の材料の製造方法は、セラミックス原料を水中に分散させるスラリー調製工程と(工程A)、得られたスラリーを一方向から凍結させ霜柱状の氷を成長させる凍結工程と(工程B)、凍結したスラリーを真空凍結乾燥し氷を昇華させ、マクロ孔を有する成形体を作る乾燥工程と(工程C)、氷を昇華させた成形体を加熱処理により焼成し、成形体を構成する骨格中にミクロ孔を形成する焼成工程(工程D)を有する。
図2(A)はスラリーの調製を模式的に表す。工程Aに用いるスラリー21は、セラミックス原料を水に分散させて調製することができる。ここで、「セラミックス原料」とはセラミックス材料を製造するための粒子のことであり、好ましくはリン酸カルシウム系セラミックス材料を製造するための粒子のことである。また、スラリー21には好ましくは後述する添加剤が溶解または分散している。
前述の原料スラリーを収容したスラリー容器31は、試料台41の上にあり、試料台41は冷却板75の上にあり、冷却板75は液体窒素などといった冷却媒体73と接触する熱伝達ロッド74と接続している。冷却媒体73は冷却媒体容器72に入っている。一方、スラリー容器31の上方には冷却装置76があり、この冷却装置76には冷却媒体77が収容されている。
ブロック体の形状に成形する方法としては、特に制限されること無く、既知の方法を用いればよい。具体的には、機械加工による成形法、乾式成形法および湿式成形法等が挙げられる。一般にセラミックス材料は硬くて脆い素材であるため、セラミックス層の厚さが不均一である従前の多孔質セラミックス材料は、機械加工性が極めて低かった。本発明のセラミックス材料は、上記のように、空孔が一方向に配向しており、且つその気孔径もほぼ均一なため、貫通気孔と貫通気孔との間のセラミックス層の厚さもほぼ均一である。したがって、従前の多孔質セラミックス材料に比べ、優れた機械加工性を示す。
図7は実施例1の材料の断面のSEM観察像である。図7は空孔の配向方向と平行な断面の複数の観察像を連結したものである。図7によれば、約10mm以上の長さにわたる空孔の存在が見受けられる。
図10は比較例2の材料の断面のSEM観察像である。図10は空孔の配向方向と平行な断面の複数の観察像を連結したものである。図10によれば、空孔の長さは約4mm程度にすぎない。
本出願は日本で出願された特願2006−174372を基礎としており、その内容は本明細書に全て包含される。
(1)材料内部に実質的に一方向に配向した空孔を有する多孔質セラミックス材料であり、空孔の配向方向を高さ方向とする直径3mm×高さ5mmの円柱状の当該材料からなる試験片をその片端から1mmまでをポリエチレングリコールに浸したときに30秒以内に該試験片全体にポリエチレングリコールが浸透する、多孔質セラミックス材料。
(2)(a)実質的に一方向に配向した空孔を有し、(b)気孔率が40〜90%であり、(c)空孔の配向方向に対して垂直方向の第1の切断面、および、第1の切断面と平行であり第1の切断面から空孔の配向方向に5mm離れた第2の切断面の両方において、空孔1つあたりの断面積の平均値が0.05×10-3〜50×10-3mm2である、多孔質セラミックス材料。
(3)材料内部に実質的に一方向に配向する空孔を有し、配向方向に垂直な該空孔の断面積が少なくとも配向方向の5mmの長さにわたって0.05×10-3〜100×10-3mm2である、多孔質セラミックス材料。
(4)気孔率が40〜90%である(3)に記載の多孔質セラミックス材料。
(5)主成分がリン酸カルシウムである、(1)〜(4)のいずれかに記載の多孔質セラミックス材料。
(6)リン酸カルシウムがハイドロキシアパタイトおよび/またはリン酸三カルシウムで
ある、(5)に記載の多孔質セラミックス材料。
(7)(1)〜(6)のいずれかに記載の多孔質セラミックス材料からなる、多孔質セラミックスインプラント材料。
(8)工程(A):セラミックス原料を水に分散させてスラリーを調製する工程、
工程(B):スラリーを所定の容器に充填し、スラリー容器の一方の端部を冷却してスラリーを該端部側から一方向に凍結させる工程、
工程(C):凍結させたスラリーを乾燥させて成形体を得る工程、及び
工程(D):乾燥させた成形体を焼成する工程、
を含み、工程(B)において、上記一方の端部以外のスラリー容器の周囲をスラリーの凝固点より高い温度にまで冷却する、多孔質セラミックス材料の製造方法。
図10は比較例2の材料の断面のSEM観察像である。図10は空孔の配向方向と平行な断面の複数の観察像を連結したものである。図10によれば、空孔の長さは約4mm程度にすぎない。
本出願は日本で出願された特願2006−174372を基礎としており、その内容は本明細書に全て包含される。
Claims (8)
- 材料内部に実質的に一方向に配向した空孔を有する多孔質セラミックス材料であり、空孔の配列方向を高さ方向とする直径3mm×高さ5mmの円柱状の当該材料からなる試験片をその片端から1mmまでをポリエチレングリコールに浸したときに30秒以内に該試験片全体にポリエチレングリコールが浸透する、多孔質セラミックス材料。
- (a)実質的に一方向に配向した空孔を有し、
(b)気孔率が40〜90%であり、
(c)空孔の配向方向に対して垂直方向の第1の切断面、および、第1の切断面と平行であり第1の切断面から空孔の配向方向に5mm離れた第2の切断面の両方において、空孔1つあたりの断面積の平均値が0.05×10-3〜50×10-3mm2である、多孔質セラミックス材料。 - 材料内部に実質的に一方向に配向する空孔を有し、配向方向に垂直な該空孔の断面積が少なくとも配向方向の5mmの長さにわたって0.05×10-3〜100×10-3mm2である、多孔質セラミックス材料。
- 気孔率が40〜90%である請求項3に記載の多孔質セラミックス材料。
- 主成分がリン酸カルシウムである、請求項1〜4のいずれか1項に記載の多孔質セラミックス材料。
- リン酸カルシウムがハイドロキシアパタイトおよび/またはリン酸三カルシウムである、請求項5に記載の多孔質セラミックス材料。
- 請求項1〜6のいずれか1項に記載の多孔質セラミックス材料からなる、多孔質セラミックスインプラント材料。
- 工程(A):セラミックス原料を水に分散させてスラリーを調製する工程、
工程(B):スラリーを所定の容器に充填し、スラリー容器の一方の端部を冷却してスラリーを該端部側から一方向に凍結させる工程、
工程(C):凍結させたスラリーを乾燥させて成形体を得る工程、及び
工程(D):乾燥させた成形体を焼成する工程、
を含み、
工程(B)において、上記一方の端部以外のスラリー容器の周囲をスラリーの凝固点より高い温度にまで冷却する、多孔質セラミックス材料の製造方法。
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JP6266972B2 (ja) * | 2013-12-13 | 2018-01-24 | 三井金属鉱業株式会社 | 焼成治具用多孔質セラミックス、焼成治具用多孔質セラミックスの製造方法および冷却装置 |
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