Method of producing a multilayer body by coalescence and the multi-layer body produced

Abstract

A method of producing a multilayer body by coalescence, characterised in that the method comprises the steps of a) filling, a pre-compacting mould with a start material in the form of powder, pellets, grains and the like, b) pre-compacting the start material at least once and c) compressing the material in a compression mould by at least one stroke, where a striking unit emits enough kinetic energy to form the body when striking the material inserted in the compression mould, causing coalescence of the material, d) at least one further material being inserted into the mould in the form of powder, pellets, grains and the like, either in step a), after compacting in step b) or after compressing the first material in step c), e) if necessary, further pre-compacting and/or compressing being performed after the insertion of the at least one further material.

1 . A method of producing a multilayer body by coalescence, characterised in that the method comprises the steps of 
 a) filling a pre-compacting mould with a start material in the form of powder, pellets, grains and the like,    b) pre-compacting the material at least once and    c) compressing the material in a compression mould by at least one stroke, where a striking unit emits enough kinetic energy to form the body when striking the material inserted in the compression mould, causing coalescence of the material,    d) at least one further material being inserted into the mould in the form of powder, pellets, grains and the like, either in step a), after compacting in step b) or after compressing the start material in step c),    e) if necessary, further pre-compacting and/or compressing being performed after the insertion of the at least one further material.    
     
     
         2 . A method according to  claim 1 , characterised in that the pre-compacting mould and the compressing mould are the same mould.  
     
     
         3 . A method according to any of the preceding claims, characterised in that the material is pre-compacted with a pressure of at least about 0.25×10 8  N/m 2 , in air and at room temperature.  
     
     
         4 . A method according to  claim 3 , characterised in that the material is pre-compacted with a pressure of at least about 0.6×10 8  N/m 2 .  
     
     
         5 . A method according to any of the preceding claims, characterised in that the method comprises pre-compacting the material at least twice.  
     
     
         6 . A method of producing a multilayer body by coalescence, characterised in that the method comprises compressing a solid body of a start material in a compression mould by at least one stroke, where a striking unit emits enough energy to cause coalescence of the material in the body, at least one further material being inserted in the mould, either in the form of powder, pellets, grains and the like or in the form of a solid body, the at least one further material also being struck by the striking unit, either in the first stroke or in a later stroke so that the at least two materials form an integral body.  
     
     
         7 . A method according to any of claims  1 - 5  or  claim 6 , characterised in that the compression strokes emit a total energy corresponding to at least 100 Nm in a cylindrical tool having a striking area of 7 cm 2 in air and at room temperature.  
     
     
         8 . A method according to  claim 7 , characterised in that the compression strokes emit a total energy corresponding to at least 300 Nm in a cylindrical tool having a striking area of 7 cm 2 .  
     
     
         9 . A method according to  claim 8 , characterised in that the compression strokes emit a total energy corresponding to at least 600 Nm in a cylindrical tool having a striking area of 7 cm 2 .  
     
     
         10 . A method according to  claim 9 , characterised in that the compression strokes emit a total energy corresponding to at least 1000 Nm in a cylindrical tool having a striking area of 7 cm 2 .  
     
     
         11 . A method according to  claim 10 , characterised in that the compression strokes emit a total energy corresponding to at least 2000 Nm in a cylindrical tool having a striking area of 7 cm 2 .  
     
     
         12 . A method according to any of claim  1 - 5  or  claim 6 , characterised in that the compression strokes emit an energy per mass corresponding to at least 5 Nm/g in a cylindrical tool having a striking area of 7 cm 2  in air and at room temperature.  
     
     
         13 . A method according to  claim 12 , characterised in that the compression strokes emit an energy per mass corresponding to at least 20 Nm/g in a cylindrical tool having a striking area of 7 cm 2 .  
     
     
         14 . A method according to  claim 13 , characterised in that the compression strokes emit an energy per mass corresponding to at least 100 Nm/g in a cylindrical tool having a striking area of 7 cm 2 .  
     
     
         15 . A method according to  claim 14 , characterised in that the compression strokes emit an energy per mass corresponding to at least 250 Nm/g in a cylindrical tool having a striking area of 7 cm 2 .  
     
     
         16 . A method according to  claim 15 , characterised in that the compression strokes emit an energy per mass corresponding to at least 350 Nm/g in a cylindrical tool having a striking area of 7 cm 2 .  
     
     
         17 . A method according to any of the preceding claims, characterised in that the multilayer body is compressed to a relative density of at least 60%, preferably 65%.  
     
     
         18 . A method according to  claim 17 , characterised in that the multilayer body is compressed to a relative density of at least 70%, preferably 75%.  
     
     
         19 . A method according to  claim 18 , characterised in that the multilayer body is compressed to a relative-density of at least 80%, preferably at least 85% and especially at least 90% up to 100%.  
     
     
         20 . A method according to any of the preceding claims, characterised in that the method comprises a step of post-compacting the body at least once after the compression step.  
     
     
         21 . A method according to any of the preceding claims, characterised in that the materials in the multilayer body are chosen from the group comprising metallic, ceramic and polymeric materials..  
     
     
         22 . A method according to  claim 21 , characterised in that one of the materials in the multilayer body contains a reinforcing phase which is chosen from the group comprising carbon, glass, metal, polymeric and ceramic material.  
     
     
         23 . A method according to  claim 21 , characterised in that the multilayer materials are chosen from the group comprising UHMWPE, PMMA, nitrile rubber, aluminium alloys and titanium.  
     
     
         24 . A method according to any of the preceding claims, characterised in that the body produced is a medical implant, such as a skeletal or tooth prosthesis.  
     
     
         25 . A method according to any of the preceding claims, characterised in that the method comprises a step of post-heating and/or sintering the body any time after the compression or the post-compacting.  
     
     
         26 . A method according to any of the preceding claims, characterised in that the body produced is a green body.  
     
     
         27 . A method of producing a body according to  claim 27 , characterised in that the method also comprises a further step of sintering the green body.  
     
     
         28 . A method according to any of the preceding claims, characterised in that the materials are a medically acceptable materials.  
     
     
         29 . A method according to any of the preceding claims, characterised in that the at least one of the materials comprises a lubricant and/or a sintering aid.  
     
     
         30 . A method according to  claim 6 , characterised in that the method also comprises deforming the body.  
     
     
         31 . A product obtained by the method according to any of claims  1 - 30 .  
     
     
         32 . A product according to  claim 31 , characterised in being a medical device or instrument.  
     
     
         33 . A product according to  claim 31 , characterised in being a non medical device.