WO2011082905A1

WO2011082905A1 - Open-cell titanium metal foams and method for producing same

Info

Publication number: WO2011082905A1
Application number: PCT/EP2010/068723
Authority: WO
Inventors: Jörg ADLER; Gisela Standke; Peter Quadbeck; Ralf Hauser; Günter Stephani
Original assignee: Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
Priority date: 2009-12-14
Filing date: 2010-12-02
Publication date: 2011-07-14
Also published as: DE102009054605B8; DE102009054605B3

Abstract

The invention concerns the field of materials science and relates to open-cell metal foams made of titanium, as can be used, for example, for medical implants. The aim of the invention is therefore to specify open cell titanium metal foams in which the adhesion of ingrowing tissue is improved. Said aim is achieved by means of open cell titanium metal foams consisting of a three-dimensional network of interconnected webs, wherein the enveloping surface thereof consists of titanium and the smooth web surfaces have roughnesses R_a of < 2 μm. Said aim is further achieved by means of a method in which an open cell polymer foam is coated once with a suspension, wherein the suspension contains at least 75 mass % titanium powder particles of a mean particle size of < 25 μm and the total powder mixture has a particle size distribution having a d₉₅ value < 30 μm, the coated polymer foam is subsequently dried, the polymer is removed and the titanium powder structure remaining is sintered.

Description

Open-cell titanium metal foams and process for their preparation

The invention relates to the field of materials science and relates to open-cell metal foams of titanium, as they can be used for example for medical implants, and a method for their preparation.

The production and use of open-cell foams as an implant material, in particular as a bone replacement material has long been known, because the open-cell foam structure images the skeletal structure in an ideal manner and can be well interspersed with newly formed tissue at a certain cell size. Open cell foam ceramics of hydroxyapatite, tricalcium phosphate and bioglass ceramics are known. Also known are open-cell metal foams of titanium and titanium alloys, as well as of tantalum (LD Zardiackas et al .: J. Biomed., Mater., Res 58 180-187, 2001). For metal implant applications, the metals titanium and tantalum, as well as alloys with a high titanium or tantalum content are particularly preferred, because these metals are considered to be tried and inert in the human body.

Furthermore, the "Schwartzwalder method" (US Pat. No. 3,090,094 B1) has long been known, after which a polyurethane is foamed and reticulated, the open-celled polymer foam is coated with a ceramic or metal particle suspension, and subsequently the polyurethane is burned out and the ceramic or metal particles are sintered. The resulting foam is a scaffold of a plurality of ridges (1) which delimit the cells of the foam (see Fig. 1) .This method is used for the production of open-celled titanium foams as a bone implant material (WO 02/066693, JPLi et al .: J.Biomed. Mat. Res 73A No2 (2005) 223-233).

This method is the powder technology or powder technologies zugeord net, in which from metallic particles (powders) by a shaping process and a subsequent thermal treatment (sintering), a metallic molded part is produced.

Titanium and tantalum open-cell metal foams are also known to be made by a CVD or CVI process in which the metal is deposited on an inert framework, usually open-cell carbon. In this case, a crystalline layer of the metal or the metal alloy grows on and forms a rough surface on the webs. The use of such foams as a bone implant material is known since these foams are produced commercially (tantalum foam - Zimmer Zimmer, Trabecular Metal brand, titanium foam - Wright Medical Technology, brand name BioFoam). A disadvantage of the production of such foams by means of CVD is that they require a high expenditure on apparatus and only allow limited sample sizes and uniformity.

An idealized foam cell (see (2) in Fig. 2) is characterized by its diameter (cell diameter) which corresponds to the diameter of a sphere approximately enclosed by it. In addition, a foam cell forms so-called window openings (cell windows, see (5) in FIG. 2) to the neighboring cells which are in approximately enclose a circle whose diameter is about one third of the mean diameter of the foam cell. In the case of average cell width plots, the number of cells and cell windows cut by a measurement line are counted on a surface intersection and reported as number per length, typically in units of pores per inch (ppi) or pores per cm.

Furthermore, the webs of foams have cracks (7), cavities (6) and pores (8) (FIG. 3), in particular if they have been produced by the Schwartzwalder process, wherein the pores (8) do not interfere with the web material match the cells of the foam and may be confused.

The enveloping surface (4) of the webs in their entirety forms the geometrical outer surface of a foam that is directly accessible for roughness measurements (see Figures 3 and 4). In the context of this invention, this is to be understood below as the enveloping surface.

A determination of the enveloping surface may e.g. by image evaluation of metallographic bevels and is based on the outer volume of the sample or its weight. By external volume is meant the volume calculated from the external dimensions of the foam sample.

By contrast, the so-called specific surface, which is usually determined by gas adsorption and based on the weight (or volume) of a sample, is the sum of all the surface area of the foam which can be assigned to a sample gas, i. includes both the above mentioned enveloping surface and the surface of the accessible cracks, pores and cavities in the webs, i. the specific surface is always higher than the enveloping surface. The determination of the specific surface is also carried out by known methods, which are also described in DIN ISO 9277 (3003-05).

The surface properties of the webs is of particular importance when it interacts with a filling or through-flow medium. In the case of medical implants, this is especially the ingrowth tissue, in bone replacement materials the bone tissue. The setting of a high roughness of the surface of metallic implants is necessary and advantageous for tissue ingrowth and mechanical anchoring in bone (Ronold et al .: Biomaterials 24 (2003), 4599-4564; Martin et al., J. Biomed Mat. Res. 29, 389-401 (1995)). As a result, open-cell foams with the highest possible roughness of the webs have also been developed. According to JPLi et al .: J. Biomed. Mat. Res 73A No2 (2005) 223-233 is a roughness of R _a = 3.4 ± 0.3 μιτι the webs of open-cell foam known as a special property and advantage. Furthermore, from "Biofoam Technical Monograph MI023-109 the Fa. WMT" high adhesion of the CVI titanium foam due to the special surface structuring known to be particularly advantageous.

The roughness is caused in particular by the surface structure formed in the coating and heat treatment or by vapor deposition, and in part by pores on the surface of the metal webs of the foam.

With regard to the characterization of the surface roughness of materials, various DINs are known (DIN 4760 (DIN 4768 (1990) Determination of roughness values R _a , R _z , Rmax with electric styli burrs, terms and measurement conditions, DIN EN ISO 4287 (1998) Surface finish, stylus method , Designations, definitions and characteristics of the surface texture), which describe both the terms and the measuring methods.

The surfaces of ceramic or metallic materials have in most cases no regular structure, but contain shape deviations, which are divided into roughness, waviness and shape shape. Important parameters are R _a = average roughness and R _z = roughness depth.

The average roughness R _a is a calculated average of all deviations of the roughness profile from the middle line of the defined reference path. R _a theoretically corresponds to the distance between several lines that form when the mountains are above the midline and the valleys below the midline would be transformed into equal size rectangles.

The roughness depth R _z is the mean value of single roughness depths of five consecutive individual measuring sections in the roughness profile. The extreme values in each measuring section are added together and the span is divided by the number of measuring sections.

A disadvantage of a high roughness on the surface of medical implants, however, is that the high roughness at the same time implies the possibility that individual metal particles are detached from the surface of the metal webs under mechanical stress and unfavorably transported fine metal particles in the body and deposited elsewhere in the body tissue become. This mechanical stress can occur during handling of the implant materials before and during the operation or during the ingrowth phase or when the bone is heavily loaded during or after the healing phase.

Furthermore, high roughness also implies a high number of so-called notches in the surface. These notches are detrimental to the action of Tensile stresses perpendicular to the notch, which manifests itself in the strength and especially the fatigue strength of the metallic components.

Furthermore, the roughness is also directly proportional to the o.g. specific surface of the foams, i. a high roughness leads to a high specific surface area. This can lead to an increased interaction with corrosive liquids, which can also adversely affect the life of the metallic components.

The object of the invention is therefore to provide open-cell titanium metal foams, in which the adhesion to coatings of the surface, in particular of einwachsendem tissue, improved and the risk of particle delivery is reduced, and in the statement of a simple and inexpensive process for their preparation.

The object is achieved by the invention specified in the claims. Advantageous embodiments are the subject of the dependent claims.

The open-cell titanium metal foams according to the invention consist of a three-dimensional network of interconnected webs, wherein at least their enveloping surface essentially consists of titanium and the substantially smooth web surfaces have roughnesses R _a of <2 μm.

Advantageously, the open-cell titanium metal foams are produced by the Schwartzwalder process.

Further advantageously, the webs have a smooth surface with roughness R _a of <1 pm.

Also advantageously, the surface area of the webs consists of at least 8 5% titanium, the remainder being titanium compounds and / or titanium alloy constituents. And also advantageously titanium alloys Ti6AI7Nb and Ti6AI4V are present.

It is also advantageous if the webs have cavities in the interior.

It is also advantageous if the webs have cracks and pores in their walls.

It is also advantageous if the enveloping surfaces of the webs have pores, the proportion of which is <5%, based on the area.

And it is also advantageous if the pores in the enveloping surface of the webs have maximum dimensions of <1 μητι.

In the process according to the invention for producing open-cell titanium-metal foams, an open-celled polymer foam is coated once with a suspension, the suspension containing at least 75% by weight of titanium powder particles having an average particle size of <25 μm and the entire powder mixture having a particle size distribution with a d ₉₅ Value <30 μm, followed by drying the coated polymer foam, removing the polymer and sintering the remaining titanium powder framework in the form of a three-dimensional network.

Advantageously, titanium powder particles are used in the suspension, which have an average particle size of <20 pm and a d ₉ 5 value of <25 pm.

Also advantageously, the suspension is applied only once to the polymer foam.

And also advantageously particles of pure titanium and / or titanium compounds and / or titanium alloys are used as titanium powder particles.

With the solution according to the invention, open-cell titanium metal foams can be produced whose webs have a comparatively smooth, enveloping surface Nevertheless, they nevertheless achieve a good adhesion to coatings, in particular of ingrowing tissue, and in the case of which the risk of undesired particle delivery is markedly reduced.

Contrary to the general view of the art regarding the nature of bone substitute moldings and in particular their surface open-cell titanium metal foams are given as Knochenersatz- molded parts with the solution according to the invention, the webs have just no rough, but a relatively smooth enveloping surface.

According to the prior art, it is known that in addition to the biocompatibility, the bone substitute moldings should have a high porosity and a porous structure, similar to the human bone structure. This also includes a rough outer surface of the webs. According to JPLi et al .: J.Biomed. Mat. Res 73A No2 (2005) 223-233 surface roughnesses of 3.4 + 0.4 pm (R _a ) are achieved, wherein the pores in the rough surface of the webs are referred to as micropores and their size in the range of 1 to 10 pm is specified.

In contrast, the substantially smooth, enveloping web surfaces according to the invention have roughnesses R _a of <2 μm.

These low roughnesses are achieved above all by the fact that in the open-cell titanium metal foams according to the invention produced by powder technology, titanium powders are used as starting powders which have significantly smaller particle diameters than the powders used in the solutions of the prior art. According to JPLi et al .: J.Biomed. Mat. Res 73A No2 (2005) 223-233, titanium alloy powders having an average particle diameter of 45 μm are etched. The mean particle diameter of a powder is understood to mean the d ₅ o value of the particle size distribution function. The low roughnesses are inventively also achieved in that the main component of the powder, that is, 75% of the particles have a mean particle diameter <25 pm, but especially by the fact that the coarse fraction of titanium powder, characterized by the d ₉₅ value < is pm, ie 95% of the particles from the particle distribution curve are smaller than 30 pm. These particle distribution curves are measured by the known method of laser diffraction. Furthermore, the smooth enveloping surfaces of the webs according to the invention are also achieved in that only a coating of the polymer foam in the production of titanium metal foams is carried out with a titanium powder-containing suspension.

According to the solutions of the prior art, multiple coatings are favored, since this improves the mechanical properties (EP 1329229). Furthermore, after repeated coatings similar mechanical properties of the materials are achieved as in human bones (J.P.Li et al: J. of Mat. Sic. 17 (2006) 179-185).

A repeated coating, however, necessarily means that the suspensions for the repeated coatings may contain less and less coating material, since with repeated coatings, the cell dimensions are getting smaller and with the lower proportions of coating material in the suspensions, a closure of the cells must be prevented (see also JP Li et al .: J. of Mat. Sic. 17 (2006), Table 1).

The lower proportion of coating material in the suspension leads to a lower packing density of the particles after the drying of the coating, which in turn leads after sintering to a higher porosity and higher roughness of the outer surface. This leads to a repeated coating but also that a rougher enveloping surface of the webs is achieved, which is indeed desired in the prior art.

In contrast, according to the invention, with a significantly finer titanium powder as the starting material and with only a single coating, a demonstrably much smoother enveloping surface of the webs is achieved, which, surprisingly, shows good adhesion of the tissue growing in.

In the context of this invention, titanium metal foams are to be understood as meaning foams with a predominant proportion of titanium. This also implies that in addition to titanium, it is also possible to use typical titanium alloys, such as Ti6Al7Nb and Ti6Al4V, which contain alloying elements in small amounts (<15%). Furthermore, very small amounts (<5%) of titanium compounds with other elements (eg oxides, nitrides, carbides, etc.) may be contained in the microstructure. All titanium metal foams produced from these starting materials are to be understood by the term titanium metal foams according to the invention. Essentially, however, the titanium metal foams according to the invention should comply with the technically standardized purities and alloy constituents.

In the prior art, open-cell titanium metal foams can also be produced by means of CVD processes. However, these processes are very complicated and expensive, and the resulting titanium metal foams differ, inter alia, from the titanium metal foams according to the invention in that the webs of the open-cell network according to the invention are hollow in each case since the polymer foam has been removed there.

The titanium powders deposited by means of CVD processes are present on a substrate, mostly of carbon, which may likewise be an open-cell foam, but at the end of the CVD process the substrate is retained in each case, so that the webs are filled in the entire volume ( See, for example, LD Zardiackas et al .: J. Biomed., Mater., Res., 58, 180-187, 2001).

In addition, the reaction of the titanium with the substrate may not be completely prevented by the CVD method, so that the area of the web surfaces does not essentially consist of titanium or can exist.

In addition, forms at the interface between carbon substrate and titanium layer, a reaction layer of titanium carbide, which can lead to an undesirable embrittlement of the foam.

The invention will be explained in more detail below with reference to two exemplary embodiments.

Show Fig. 1 is a schematic representation of an open-cell foam

Fig. 2 is the idealized schematic representation of a cell of an open-cell

foam

Fig. 3 shows the idealized schematic representation of the cross section of a web of an open-cell foam

Fig. 3 schematic diagram of webs with associated enveloping

surface

example 1

A water-based suspension is produced which contains a metal powder based on the TiAl6V4 alloy with an average particle size d ₅ o of 15 pm and d ₉₅ of 25 μm. As a binder, 5% of a polysaccharide preparation is added and the suspension is stirred for 10 minutes at a speed of 200 s-1. It then has a solids content of 84% by mass.

To produce the titanium metal foam molded parts made of reticulated polyurethane foam of average cell diameter (2 in Fig. 2) 1200 pm impregnated with the suspension. For subsequent homogenization and separation of excess material, the moldings are centrifuged. For a sample of dimensions 27x19x1 1 mm ³ , the coating weight is 4 g. The body is then dried and the polyurethane burned out to a temperature of 600 ° C under an argon atmosphere. The remaining titanium powder framework is sintered in a high vacuum of about 10 ^-3 Pa at a temperature of 1350 ° C. During the sintering, the sample linearly shrinks by 12% so that the final dimensions are 24 × 16 × 10 mm ^3. The mean geometric density of the sintered body is 1, 1 g / cm ³ and the compressive strength is 57 MPa The average roughness R _a on the enveloping surface of the titanium metal foam is 1.2 μm and the roughness R _{z is} 5 μm. Example 2

A water-based suspension is produced which contains 40% of a metal powder based on the TiAl6Nb17 alloy with a mean particle size of 15 pm and 60% of a metal powder of the same composition with an average particle distribution of 6.5 μm. The d _g5 value of the powder mixture is 22 μm. As binder, 7% of a binder mixture of polyvinyl alcohol and polysaccharide is added and the suspension is stirred for 10 minutes at a speed of 400 s-1. It then has a solids content of 87% by mass.

To produce the titanium metal foam molded parts of reticulated polyurethane foam of average cell diameter 1 000 pm are impregnated with the prepared suspension. For subsequent homogenization and separation of excess material, the moldings are passed through a roller mill. For a sample of dimensions 75 × 75 × 20 mm ³ , a coating weight of 80 g results. The body is then dried and the polyurethane burned out to a temperature of 600 ° C under an argon atmosphere at a pressure of 70 mbar. The remaining titanium powder framework is sintered in a high vacuum of about 10 ^-3 Pa at a temperature of 1250 ° C. During the sintering, the sample linearly fuses 1 1% so that the final dimensions are 67 × 67 × 18 mm ^3. The mean geometric density of the The sintered body is 0.7 g / cm ³ and the compressive strength is measured at 62 MPa The average roughness R _a at the enveloping surface of the titanium foam is 0.85 μm and the roughness depth R _{z is} 3.9 μm The area fraction of the pores at the surface of the webs is determined by light microscopy to be 4%, and the average diameter of the pores is 0.8 μm.

LIST OF REFERENCE NUMBERS

1 foam bar

2 foam cell, cell diameter

3 connection point of various foam webs

4 enveloping surface

5 cell windows

6 cavity in the bridge

7 cracks in the bridge

8 pores in the bridge

9 bar diameter

Claims

claims

1. open-cell titanium metal foams consisting of a three-dimensional network of interconnected webs, wherein at least their enveloping surface consists essentially of titanium and the substantially smooth web surfaces roughness R _a of <2 μιτι have.

2. open-cell titanium metal foams according to claim 1, which are produced by the Schwartzwalder- method.

3. open-cell titanium metal foams according to claim 1, wherein the webs have a smooth surface with roughness R _a of <1 μιτι.

4. Open-cell titanium metal foams according to claim 1, wherein the surface region of the webs consists of at least 85% titanium, the remainder being titanium compounds and / or titanium alloy constituents.

5. Open-cell titanium metal foams according to claim 1, in which titanium alloys Ti6AI7Nb and Ti6AI4V are present as titanium alloys

6. open-cell titanium metal foams according to claim 1, wherein the webs have cavities in the interior.

7. open-cell titanium metal foams according to claim 1, wherein the webs in their walls have cracks and pores.

8. open-cell titanium metal foams according to claim 1, wherein the enveloping surfaces of the webs have pores, wherein the proportion is <5%, based on the area.

9. open-cell titanium metal foams according to claim 8, wherein the pores in the enveloping surface of the webs have maximum dimensions of <1 μιτι.

1

10. A process for the preparation of open-celled titanium metal foams in which an open-cell polymer foam is coated once with a suspension, wherein the suspension contains at least 75% by mass of titanium powder particles having an average particle size of <25 μm and the total powder mixture has a particle size distribution a dgs value <30 μιτι, subsequently dried the coated polymer foam, the polymer removed and the remaining titanium powder scaffold is sintered in the form of a three-dimensional network.

1 1. A method according to claim 10, wherein the titanium powder particles are used in the suspension, which have a mean particle size of <20 μιτι and a DGS value of <25 μιτι.

12. The method of claim 10, wherein the suspension is applied only once to the polymer foam.

13. The method according to claim 10, wherein particles of pure titanium and / or titanium compounds and / or titanium alloys are used as titanium powder particles.

2