CN102448506A - 陶瓷切割模板 - Google Patents

陶瓷切割模板 Download PDF

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CN102448506A
CN102448506A CN2010800240221A CN201080024022A CN102448506A CN 102448506 A CN102448506 A CN 102448506A CN 2010800240221 A CN2010800240221 A CN 2010800240221A CN 201080024022 A CN201080024022 A CN 201080024022A CN 102448506 A CN102448506 A CN 102448506A
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R.普雷伊斯
H.韦克
M.埃施勒
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Abstract

本发明涉及一种切割模板或者切割块，优选是用于医疗技术中的切割模板或者切割块。

Description

陶瓷切割模板
本发明的主题是一种切割模板(Schnittschablone)或者切割块(Sägeblock)，优选是用于医疗技术中的切割模板或者切割块。
在每个膝盖模板植入(Knie-TEP-Implantation)过程中，将所谓的切割模板或者切割块固定到股骨上。使用这种切割模板，通常进行三个切割来使得股骨表面与股骨部件的几何形状相配合。对每个切割来说，在切割模板中存在着引导(在1模板中的3或者4切割引导)。在这个引导中，切割是用摆锯锯条来进行的。现今，锯条和切割模板主要是由生物相容性金属合金制成的。
取决于制造商，切割块中的导轨的宽度是1.2-1.5mm。由于锯条的振动和锯条与导轨之间存在的摩擦力，在导轨侧发生了明显的金属磨损。这种磨屑（Abrieb）不能或者仅仅不充分地在进行外科手术时从伤口上除去。因此，这种磨屑会进而变成感染源，和特别会导致患者的过敏反应。因此，重要的是充分减少所述的磨屑，并且特别地，当在潜在过敏症患者情况下通过使用陶瓷股骨部件来进行植入反应时应当避免这种情况。
根据现今的认知，大部分金属磨屑是通过在切割模板中的导轨磨损而产生的。在切割模板在膝盖模板植入过程中使用了大约20-40次后，该导轨表现出增加了大约0.5-1.5mm的导轨间隙。结果，该切割模板的引导精度明显降低。对于外科医生，结果是不再能进行锯条的精确切割，股骨切割表面的对准和平坦度背离得越来越多。这导致了切割表面和股骨部件之间较大的间隙。所述的间隙必须通过比在其它通常情况下更大体积的骨水泥在外科手术过程中填充，这会对所述系统的使用寿命产生不利影响。
本发明目标是消除现有技术的切割模板/切割块的缺点，和特别是：
Figure 436640DEST_PATH_IMAGE001
减少金属磨屑，其中力争将金属磨屑相对于迄今的金属熔体减少至多90%；
延长切割模板的使用寿命和因此节约成本；
减少过敏的风险和感染的风险。
本发明的目标令人惊讶地通过陶瓷制成的、具有独立权利要求的特征的切割模板/切割块(下文中，术语烧结模制体(Sinterformkörper)或者烧结体(Sinterkörper)也用于本发明的切割模板/本发明的切割块)来实现的。优选的实施方案可以在从属权利要求中找到。已经令人惊讶地发现给定目标的解决方案需要具有非常特定组成的烧结模制体：
70-90体积份的铬掺杂的氧化铝(Al2O3：Cr)，
12-22体积份的Y稳定的氧化锆(ZrO2：Y)，和
1-5体积份的式SrAl12-xCrxO19的铝酸锶，具有可变的Cr掺杂。
根据本发明的教导，相对于迄今的金属制成的切割模板或者切割块，金属磨屑减少了至多90%。本发明的切割模板或者切割块的使用寿命得到显著延长，这是因为在该切割模板上仅仅发生了很少的磨损。这降低了成本。此外，降低了患者过敏或者过敏反应的风险和感染的风险。
在本发明的一种实施方案中，将成分氧化锆和铝酸锶嵌入到氧化铝基质中。
优选地，该铝酸锶的存在形式是小片状微晶和/或片状体(Platelet)。
在本发明的一种实施方案中，该切割模板的材料另外散布(durchsetzen)有由合适材料形成的晶须和/或纤维或者网状结构或者织物(Gewebe)。
该切割模板优选用于医疗技术领域，特别是用于处理骨头的外科手术中，在优选的方式中用于膝盖模板植入中。
本发明的陶瓷切割模板或者制造其的陶瓷的优点是：
Figure 499382DEST_PATH_IMAGE001
该切割模板表现出极低的磨损。
Figure 253712DEST_PATH_IMAGE001
该材料是生物相容性的。
Figure 928406DEST_PATH_IMAGE001
如果本发明的切割模板是通过激光标记的，则该模板是清楚可见的和易读的，并因此能够降低该切割模板使用过程中的误操作。
该切割模板具有非常好的摩擦学性能。
已经令人惊讶地发现具有下面的材料组成的切割模板非常适用于医疗技术领域中。
材料组成 式 体积份
铬掺杂的氧化铝 Al2O3：Cr 70%-90%
Y稳定的氧化锆 ZrO2：Y 12%-22%
铝酸锶(具有可变的Cr掺杂) SrAl12-xCrxO19 1%-5%
这样的切割模板的主要微结构成分是氧化铝。因此，性能决定的特征例如硬度，弹性模量和热导率与纯氧化铝的性能密切相关。将成分氧化锆和铝酸锶嵌入氧化铝基质中。该铝酸锶形成了特征的小片状微晶，片状体，这明显有助于强度的升高。
成分氧化锆和铝酸锶导致了断裂韧度的提高，其比纯氧化铝的情况高大约60%。通过这些增强的组分，强度提高到几乎2倍，并且与此同时，提高了损坏公差，即，该切割模板这样的能力，即，甚至在可能的损坏的情况中保持高残余强度的能力。
在本发明的切割模板上具有高机械负荷的情况下，令人惊讶地，激活了这样的机理，其例如抑制或者阻止了裂纹蔓延。最重要的机理是氧化锆从四方晶相向单斜晶相的应力诱导转化。由该转化所产生的氧化锆的体积增加导致形成了局部压应力，其对抗外拉伸负荷，因此抑制了裂纹的蔓延。
该嵌入的片状体令人惊讶地偏转了裂纹路径，这样在裂纹蔓延过程中吸收了另外的能量。
被认为是本发明切割模板的特定特征的是所述的两种机理它们相互强化，这样断裂韧度的有效提高甚至比通过简单的单个机理相加更高。
切割模板的制造是通过常规的陶瓷技术来进行的。
基本的方法步骤是：
a) 将根据规定组成的粉末混合物置入水中，使用液化器来防止沉降。
b)在溶解器(高速搅拌器)中均化。
c)在搅拌球磨机中研磨，其中提高该粉末混合物的比表面积(=粉碎)。
d)加入有机粘合剂。
e)喷雾干燥，由此产生具有界定性能的自由流动的颗粒。
f)用水润湿该颗粒。
g)轴向或者等静压加压。
h) 切削生坯机加工，其中由于烧结收缩，基本形成了最终的轮廓。
i)预烧，其中收缩到理论密度的大约98%。仍然剩余的残留孔朝外密封。
j)在高温和高气压下热静等压，由此实质上完成最终的致密化。
k)所谓的烧除(Weiβbrand)；由此平衡了陶瓷中在热静等压过程中产生的氧离子的不平衡。
l)通过研磨和抛光来硬机加工。
m)回火(Tempern)。
该切割模板的性能仍然可以通过嵌入来提高。在该切割模板脱模之前可以将晶须和/或纤维混入到所述材料中或者将网状结构或者织物混入到生坯状态的材料中。该晶须、纤维或者网或者织物必须由这样的材料制成，该材料不与陶瓷材料以这样的方式相互作用，即，发生了陶瓷材料性能的劣化。此外，该材料在烧结过程中不得以这样的方式变化，即，该材料发生损坏。
本发明的切割模板令人惊讶地在每种情况中结合了纯氧化铝和氧化锆的最佳性能：硬度，耐老化性，被水润湿的行为和高热导率是由氧化铝制成的烧结模制体已知的性能；高强度和高断裂韧度，即，损坏容限是由氧化锆制成的烧结模制体已知的性能。
图1-4以不同视图表示了陶瓷制成的本发明的切割模板1。图5表示了常规的金属制成的切割模板的构造和在外科手术中的使用。
图1-4表示了本发明的切割模板1，其也称作切割块。这样的切割模板1用于在人造膝关节植入过程中引导外科手术锯条。
该切割模板是由基体2组成的，其带有狭缝状凹进3，用于插入和精确引导板状锯条，其中该狭缝状凹进3具有对置的引导表面4。在该锯割过程中，锯条(参见图5)紧贴着这些引导表面4。通孔5施加到基体2中，该通孔用于将切割模板1螺纹连接到股骨上。
在本发明上下文中，术语烧结模制体/烧结体表示切割模板或者切割块形式的陶瓷，或者表示用作切割模板或者切割块的陶瓷。

Claims (6)

1. 切割模板，特征在于所述切割模板包含70-90体积份的铬掺杂的氧化铝(Al2O3：Cr)，12-22体积份的Y稳定的氧化锆(ZrO2：Y)和1-5体积份的式SrAl12-xCrxO19的铝酸锶，该铝酸锶具有可变的Cr掺杂。
2. 根据权利要求1的切割模板，特征在于将该成分氧化锆和铝酸锶嵌入到氧化铝基质中。
3. 根据权利要求1或者权利要求2的切割模板，特征在于该铝酸锶的存在形式是小片状微晶和/或片状体。
4. 根据权利要求1-3任一的切割模板，特征在于该材料另外的散布有由合适的材料形成的晶须和/或纤维或者网状结构或者织物。
5. 根据权利要求1-4任一的切割模板的用途，其用于医疗技术领域中，特别是用于处理骨头的外科手术中。
6. 根据权利要求5的切割模板的用途，其用于膝盖模板植入中。
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EP2413986A2 (de) 2012-02-08
WO2010112589A2 (de) 2010-10-07
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