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Porous Structure and Methods of Making Same
| Content Provider | The Lens |
|---|---|
| Abstract | The present disclosure provides methods to improve the properties of a porous structure formed by a rapid manufacturing technique. Embodiments of the present disclosure increase the bonding between the micro-particles 5 on the surface of the porous structure and the porous structure itself without substantially reduce the surface area of the micro-particles. In one aspect, embodiments of the present disclosure improves the bonding while preserving or increasing the friction of the structure against adjacent materials. |
| Related Links | https://www.lens.org/lens/patent/009-793-990-495-356/frontpage |
| Language | English |
| Publisher Date | 2019-11-07 |
| Access Restriction | Open |
| Content Type | Text |
| Resource Type | Patent |
| Jurisdiction | United States of America |
| Date Applied | 2019-07-16 |
| Applicant | Smith & Nephew Inc |
| Application No. | 201916513259 |
| Claim | A method comprising the step of: forming a porous structure by rapid manufacturing technique utilizing a metallic material, wherein the rapid manufacturing technique is selected from group consisting of direct metal fabrication, direct metal laser sintering, and solid free-form fabrication; treating the porous structure with a thermal treatment to increase the bond strength between a plurality of micro-particles attached to said porous structure and said porous structure without substantially reducing the surface area of the porous structure; and selecting a time and temperature for the thermal treatment, wherein the time is between 30 minutes to 300 minutes and the temperature is between about 800 degrees C. and about 1200 degrees C. The method of claim 1 , wherein the thermal treatment provides average micro-particle diameter to neck diameter ratio greater than 1 and less than 5. The method of claim 1 , wherein the thermal treatment is selected from the group consisting of high vacuum furnace treatment, resistive heat treatment, radiative heat treatment, electron beam scanning, laser beam scanning, and a combination thereof. The method of claim 1 , wherein the selection step is configured to improve the bonding between said plurality of micro-particles and said porous structure while at least substantially preserving a desired roughness and friction of said porous structure. The method of claim 1 , wherein the selection step is configured to improve the bonding between said plurality of micro-particles and said porous structure while increasing the roughness of said porous structure. The method of claim 1 , wherein the plurality of micro-particles comprises a powder selected from the group consisting of metal, ceramic, metal-ceramic (cermet), glass, glass-ceramic, polymer, composite and combinations thereof. The method of claim 1 , wherein the metallic material is selected from the group consisting of titanium, titanium alloy, zirconium, zirconium alloy, niobium, niobium alloy, tantalum, tantalum alloy, nickel-chromium (e.g., stainless steel), cobalt-chromium alloy and combinations thereof. The method of claim 7 , wherein the porous structure comprises titanium alloy, the temperature of the thermal treatment of the titanium alloy structure is between greater than about 800 degrees C. and about 1200 degrees C. The method of claim 1 , wherein the porous structure is thermally treated from about 30 minutes to 300 minutes. The method of claim 1 , wherein the thermal treatment is performed in a vacuum or inert gas furnace below atmospheric pressure. The method of claim 1 , wherein the thermal treatment is performed in a vacuum or inert gas furnace with oxygen partial pressure below about 0.02 torr. The method of claim 1 , wherein the time and temperature of the thermal treatment is determined based at least on the size of the plurality of micro-particles and the solid-state diffusion coefficient of the plurality of micro-particles. The method of claim 1 , wherein the time and temperature of the thermal treatment is determined based at least on the desired aspect ratio of the porous structure. The method of claim 1 , wherein the time and temperature of the thermal treatment is determined based at least on the desired friction of a surface of the porous structure. The method of claim 1 , wherein the selecting step comprises determining a friction value of said porous structure prior to treatment, determining a friction value of said porous structure subsequent to treatment, adjusting the time and temperature of said treatment until the friction value prior to treatment is at least substantially the same as the friction value subsequent to treatment. The method of claim 1 , wherein the selecting step comprises determining a friction value of said porous structure prior to treatment, determining a friction value of said porous structure subsequent to treatment, adjusting the time and temperature of said treatment until the friction value subsequent to treatment is higher than said friction value prior to treatment. The method of claim 1 , wherein the selected time and temperature for said treatment results in the friction value prior to treatment being within about 0% to less than about 15% of the friction value subsequent to treatment. The method of claim 17 , wherein the friction value comprises a coefficient of friction when said porous structure is articulated against an analogue component. The method of claim 17 , wherein the friction and/or roughness of structure is measured using an inclined plane method or using a pin-on-disk testing apparatus. A method comprising the step of: forming a titanium alloy porous structure formed by rapid manufacturing technique, wherein the rapid manufacturing technique is selected from group consisting of direct metal fabrication, direct metal laser sintering, and solid free-form fabrication; treating the porous structure with a thermal treatment to increase the bond strength between a plurality of micro-particles attached to said porous structure and said porous structure without substantially reducing the surface area of the porous structure, wherein the thermal treatment is performed in a vacuum or inert gas furnace below atmospheric pressure; and selecting a time and temperature for the thermal treatment, wherein the time is between 30 minutes to 300 minutes and the temperature is between than about 800 degrees C. and about 1200 degrees C., and wherein the time and temperature of the thermal treatment is determined based at least on the desired friction of a surface of the porous structure. |
| CPC Classification | 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 LIME; MAGNESIA;SLAG;CEMENTS;COMPOSITIONS THEREOF; e.g. MORTARS; CONCRETE OR LIKE BUILDING MATERIALS;ARTIFICIAL STONE ;CERAMICS ;REFRACTORIES;TREATMENT OF NATURAL STONE CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS SHAPING OR JOINING OF PLASTICS;SHAPING OF MATERIAL IN A PLASTIC STATE; NOT OTHERWISE PROVIDED FOR;AFTER-TREATMENT OF THE SHAPED PRODUCTS; e.g. REPAIRING ADDITIVE MANUFACTURING; i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION; ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING; e.g. BY 3-D PRINTING; STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING WORKING METALLIC POWDER;MANUFACTURE OF ARTICLES FROM METALLIC POWDER;MAKING METALLIC POWDER ;APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER Climate Change Mitigation Technologies In The Production Or Processing Of Goods INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B; B29C OR B29D; RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR |
| Extended Family | 040-335-271-612-339 197-630-244-138-702 125-397-570-608-087 010-963-174-689-923 161-126-772-660-087 154-741-622-500-548 159-662-873-248-347 069-762-881-898-599 122-268-807-873-429 106-516-111-885-499 093-404-121-691-499 113-795-173-085-284 067-707-633-116-119 117-799-373-546-798 118-129-948-613-028 052-244-752-189-879 070-893-649-201-705 082-110-967-686-834 118-187-999-092-766 143-126-678-591-078 009-793-990-495-356 |
| Patent ID | 20190337055 |
| Inventor/Author | Scott Marcus L Gan Lu Pawar Vivek D Tsai Stanley |
| IPC | B22F3/11 A61L27/04 A61L27/56 B22F3/105 B22F3/24 B29C64/153 B29C65/00 B33Y40/00 C22F1/18 |
| Status | Pending |
| Owner | Smith & Nephew Inc |
| Simple Family | 040-335-271-612-339 197-630-244-138-702 125-397-570-608-087 010-963-174-689-923 161-126-772-660-087 154-741-622-500-548 159-662-873-248-347 069-762-881-898-599 122-268-807-873-429 106-516-111-885-499 093-404-121-691-499 113-795-173-085-284 067-707-633-116-119 117-799-373-546-798 118-129-948-613-028 052-244-752-189-879 070-893-649-201-705 082-110-967-686-834 118-187-999-092-766 143-126-678-591-078 009-793-990-495-356 |
| CPC (with Group) | A61L27/56 A61L27/04 C04B2235/6026 C04B2235/6584 C04B2235/665 C22F1/18 B29C64/153 B33Y80/00 B33Y70/00 B22F3/1146 B22F10/25 B22F10/28 B33Y40/20 B22F10/64 B22F10/36 Y02P10/25 B22F3/105 B22F3/24 B22F2003/248 B29C66/72 B29K2101/00 B29K2105/04 |
| Issuing Authority | United States Patent and Trademark Office (USPTO) |
| Kind | Patent Application Publication |
