Synthesis of high-strength tissue invasive bone substitute materials by unidirectional freezing and development of control method of their porous structure

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Organic slurry containing hydroxyapatite (HAP) particles or tricalcium phosphate (TCP) particles was prepared. Then HAP or TCP monolith was synthesized by unidirectional freezing of the organic slurry, freeze-drying, and calcination in air. In the case where resorcinol-formaldehyde (RF) gel was used as organic slurry, the pore size and compressive strength of monolith are 0.1mm and 2.3MPa. However, the compressive strength was not enough for a practical use.When t-butanol and polyvinylpyrrolidone were used as solvent and binder, it was possible to produce HAP or TCP monolith having pore size of more than 0.1mm and a compressive strength of more than 10MPa. In addition, a method controlling the porous structure of the monolith was proposed with the help of unidirectional freezing simulation.