Artificial bone and joint compositions and methods of use and manufacture
The present invention provides a ceramic porous body for in-vitro and in-vivo use comprising a composition comprising a calcium aluminate (CA) containing phase and optionally at least one of an accelerator, a retarder, a surfactant, a foaming agent, a reactive alumina, water, a fiber, and a biologically active material, and combinations thereof. Ceramic compositions are provides as well as method of using the ceramic compositions and methods of manufacturing a ceramic porous body. The ceramic porous bodies of this invention may be used as artificial bones, joints, in-vitro support structures, and in-vivo support structures for cells, tissues, organs, and nerve growth and regeneration.
1. An artificial prosthesis for in vitro and in vivo use consisting essentially of an unfired hydrated composition consisting essentially of:
a calcium aluminate (CA) containing phase that results from the interaction of C n A y and C n A y -hydrates, wherein n is an integer from about 1 to about 12, and y is an integer from about 1 to about 24, and wherein C is CaO and A is Al 2 O 3 , and wherein greater than 98 weight percent of said calcium aluminate phase having a particle size ranging from −325 mesh to +10 mesh.
2. The artificial prosthesis of claim 1 wherein said composition further consisting essentially of an organic fiber.
3. The artificial prosthesis of claim 1 wherein said calcium aluminate containing phase is one or more phases, analogs, and derivatives of calcium aluminate.
4. The artificial prosthesis of claim 1 having a porosity suitable for achieving vascularity.
5. The artificial prosthesis of claim 1 capable of being functionalized for use with biologic processes.
6. The artificial prosthesis of claim 5 wherein said biologic processes include accommodation of protein building blocks and binding sites.
7. The artificial prosthesis of claim 1 further consisting essentially of a biologically active material.
8. The artificial prosthesis of claim 1 that is an in-situ patch for repairing a bone void of a patient.
9. The artificial prosthesis of claim 1 that is selected from the group consisting of an artificial bone, artificial joint, in-vitro support structure, and an in-vivo support structure.
10. The artificial prosthesis of claim 9 wherein said in-vitro support structure and said in-vivo support structure are a scaffold matrix for support of cell, tissue, organ and nerve growth.
11. A method of making an artificial prosthesis comprising:
mapping a patient's identified bone structure,
creating a three dimensional pattern of said identified bone structure from said mapped bone structure,
creating a mold or negative of said identified bone structure from said pattern,
casting said mold employing a composition comprising a calcium aluminate containing phase (CA) that results from the interaction of C n A y and C n A y -hydrates, wherein n is an integer from about 1 to 12, and y is an integer from about 1 to about 24, and wherein C is CaO and A is Al 2 O 3 , and wherein greater than 98 weight percent of said calcium aluminate phase having a particle size ranging from −325 mesh to +10 mesh.
12. The method of claim 11 including wherein said composition includes a fiber.
13. The method of claim 11 wherein said casting includes employing vibrational, slip or gel casting.
14. The method of claim 11 wherein said composition further includes water.