Powder metallurgy processes – Powder metallurgy processes with heating or sintering – Consolidation of powder prior to sintering
Patent
1998-09-18
2000-02-08
Mai, Ngoclan
Powder metallurgy processes
Powder metallurgy processes with heating or sintering
Consolidation of powder prior to sintering
419 2, 419 36, 264 44, 264669, B22F 312
Patent
active
060225092
ABSTRACT:
An implant component adapted for bone attachment or replacement is molded from a feed stock which contains a soluble major binder, a backbone binder and structural powder material. After the feed stock is injection molded to form a compact or preform, the major binder is removed from the green article, leaving a structure of interconnected porosity or texture, while the backbone binder remains until the component is sintered. Preferably, the amount of the soluble binder is set to increase the porosity, or reduce the stiffness, of the finished component, thus introducing a biocompatible or growth-enhancing level of porosity or stiffness during the molding process. In further or alternative embodiments, the component may be injection molded onto or about a solvent-leachable spacer preform and/or adjacent to another injected or molded portion of the component which serves as a structural body, frame or shell. In these cases, all or a part of the molded portion may be formed with a conventional precision powder molding feed stock to achieve a high packing density/low shrinkage frame or support for the spacer preform or additional porous molding. The invention also includes constructions wherein the component body is injection molded against or about a support core or plate to form a hybrid article. The resulting implant component is unitized by the sintering process into a single article having the desired dimensions, strength and porosity.
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Caldarise Salvatore
Matthews Frank D.
Johnson & Johnson Professional Inc.
Mai Ngoclan
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