Inorganic shaped bodies and methods for their production and use

Abstract

Shaped, preferably porous, inorganic bodies are provided which are prepared from a reactive blend. In accordance with one preferred embodiment, the solution is absorbed into a porous sacrificial substrate such as a cellulose sponge. The solution-saturated substrate is heated and an oxidation-reduction reaction occurs thereby forming an inorganic solid. A shaped, inorganic body is formed in situ. Optional, but preferred additional thermal treatment of the shaped, inorganic body removes the organic substrate, leaving an inorganic body that faithfully mimics the porosity, shape, and other physical characteristics of the organic substrate. Inorganic substrates may also be used to good effect. Large varieties of shaped bodies can be prepared in accordance with other embodiments of the invention and such shapes find wide use in surgery, laboratory and industrial processes and otherwise. The invention also provides chemically and morphologically uniform powders, including those having uniformly small sizes.

1 . A shaped body for restoring or repairing bone in an animal comprising a material having a total pore volume of at least about 30%, said material being a combination of calcium phosphate and hydroxyapatite, the calcium phosphate having macro-, meso- and microporosity.  
     
     
         2 . The shaped body of  claim 1  wherein the calcium phosphate has a crystallite size less than 1 μm.  
     
     
         3 . The shaped body of  claim 1  wherein the calcium phosphate is tricalcium phosphate.  
     
     
         4 . The shaped body of  claim 1  wherein the calcium phosphate is beta-tricalcium phosphate.  
     
     
         5 . The shaped body of  claim 1  wherein the total pore volume is at least about 50%.  
     
     
         6 . The shaped body of  claim 1  wherein the total pore volume of at least about 80%.  
     
     
         7 . A shaped body for restoring or repairing bone in an animal comprising a material having a total pore volume of at least about 30%, said material being a combination of calcium phosphate and a stable polymeric compound, the calcium phosphate having macro-, meso-, and microporosity.  
     
     
         8 . The shaped body of  claim 7  wherein the stable polymeric compound is lactate.  
     
     
         9 . The shaped body of  claim 7  wherein the stable polymeric compound is gelatin.  
     
     
         10 . The shaped body of  claim 7  wherein the stable polymeric compound is wax.  
     
     
         11 . The shaped body of  claim 7  wherein the stable polymeric compound is polylactate.  
     
     
         12 . A shaped body for restoring or repairing bone in an animal comprising a material having a total pore volume of at least about 80%, said material being a combination of 
 calcium phosphate having macro-, meso- and microporosity and a crystallite size less than 1 μm; and    a medicament.    
     
     
         13 . The shaped body of  claim 12  wherein the medicament is a growth hormone, antibiotic, or a cell signaling material.  
     
     
         14 . An inorganic anisotropic membrane comprising a calcium phosphate material having substantially uniform macro-, meso-, microporosity together with a pore volume of at least about 30%.  
     
     
         15 . The inorganic anisotropic membrane of  claim 14  wherein said pore volume is at least about 50%.  
     
     
         16 . The inorganic anisotropic membrane of  claim 14  wherein said pore volume is at least about 70%.  
     
     
         17 . The inorganic anisotropic membrane of  claim 14  wherein said pore volume is at least about 80%.  
     
     
         18 . The inorganic anisotropic membrane of  claim 14  wherein said pore volume is at least about 90%.  
     
     
         19 . The inorganic anisotropic membrane of  claim 14  wherein said membrane is in the shape of a cylinder, core, truncated cone, sleeve, or concavo-convex surface.  
     
     
         20 . The inorganic anisotropic membrane of  claim 14  wherein the shaped body is in the shape of a mammalian bone.  
     
     
         21 . The inorganic anisotropic membrane of  claim 14  wherein the shaped body is in the shape of a human bone.  
     
     
         22 . The inorganic anisotropic membrane of  claim 14  wherein the shaped body is in the shape of a vertebra.  
     
     
         23 . The inorganic anisotropic membrane of  claim 14  wherein the calcium phosphate comprises tri-calcium phosphate.  
     
     
         24 . The inorganic anisotropic membrane of  claim 14  wherein the calcium phosphate comprises beta-tri-calcium phosphate.  
     
     
         25 . The inorganic anisotropic membrane of  claim 14  wherein said pore volume is at least about 90% and the calcium phosphate comprises beta-tri-calcium phosphate.  
     
     
         26 . A catalytically impregnated reactor comprising a ferrous-containing material and calcium phosphate material having substantially uniform macro-, meso-, microporosity together with a pore volume of at least about 30%.  
     
     
         27 . The reactor of  claim 26  further comprising at least one housing containing said ferrous-containing materials and said calcium phosphate.  
     
     
         28 . The reactor of  claim 26  wherein said calcium phosphate material has a pore volume of at least about 80%.  
     
     
         29 . The reactor of  claim 26  wherein said calcium phosphate has a crystallite size less than 1 μm.  
     
     
         30 . The reactor of  claim 26  wherein said calcium phosphate comprises tricalcium phosphate.  
     
     
         31 . The reactor of  claim 26  wherein said calcium phosphate comprises beta tricalcium phosphate.