CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No. 10/057,554, filed Jan. 23, 2002, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/263,894, filed on Jan. 24, 2001. This application also is based on and claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 60/536,899, filed on Jan. 16, 2004. The parent specifications each are incorporated herein by reference in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This development was supported in part by USPHS Research Grant DE11789 to the American Dental Association Foundation from the NIDCR. The United States or an agency thereof may have certain rights to the claimed invention.

BACKGROUND OF THE INVENTION

The various embodiments of the present invention relate to self-hardening calcium phosphate-containing and/or calcium-containing paste and cement compositions. The compositions may be used to form pastes for bone and tooth restoration and similar applications, where the paste will harden within a desired time after being delivered to a repair site.

Most conventional calcium phosphate cements are mixed with an aqueous solution immediately before application. In the clinical situation, the ability of the surgeon to properly mix the cement and then place the cement paste in the defect within the prescribed time is a crucial factor in achieving optimum results.

A self-hardening calcium phosphate cement (CPC), consisting of tetracalcium phosphate (Ca₄(PO₄)₂O, also referred to as â€œTTCPâ€ ) and dicalcium phosphate anhydrous (CaHPO₄, also referred to as â€œDCPAâ€ ), has been shown in clinical studies to be efficacious for repairing bone defects. The hardening time of such conventional cements is as long as about 30 minutes with water, although hardening time can be shortened if a phosphate solution is used as the cement liquid. Hydroxyapatite (Ca₅(PO₄)₃OH, also referred to as â€œHAâ€ ) is formed as the product. More recently, additional CPCs that do not contain TTCP, e.g., Î±-tricalcium phosphate (Î±-Ca₃(PO₄)₂, also referred to as â€œÎ±-TCPâ€ ) and CaCO₃or DCPA and Ca(OH)₂, have also been developed. These cements may harden in about 10 minutes when a phosphate solution is used as the cement liquid. They also form hydroxyapatite as the final product.

A premixed CPC paste containing the TTCP and DCPA powders and glycerol as the cement liquid has been used for root canal filling and sealing by injection techniques. The cement paste was found to be stable in a syringe but hardened only after being delivered into the root canal where it became exposed to water from the surrounding tissues. Because the cement paste was injected into a confined area, there was little concern of disintegration of the paste due to washout. Although the premixed CPC was shown to have improved biocompatibility with periapical bone tissue than a number of conventional root canal filling or sealing materials, the premixed CPC-glycerol paste did not exhibit a good washout resistance when it was applied to an open wet field.

The patent literature also describes at least one class of calcium phosphate cement compositions which are precursors for the formation of hydroxyapatite and are biologically compatible, and have two unique properties that are not attainable in other calcium phosphate biomaterials: (1) self-hardening to form a mass with sufficient strength for many medical and dental applications, and (2) when implanted in bone, the cement resorbs slowly and is completely replaced by new bone formation with no loss in the volume or integrity of the tissue that receives the implant. See U.S. Pat. Nos. Re. 33,221 and Re 33,161 to Brown and Chow, which teach preparation of calcium phosphate remineralization compositions and of finely crystalline, non-ceramic, gradually resorbable hydroxyapatite cement based on the same calcium phosphate compositions.

The major components of the calcium phosphate remineralizing slurries, pastes and cements taught in U.S. Pat. Nos. Re. 33,221 and Re. 33,161 are preferably tetracalcium phosphate (Ca₄(PO₄)₂O), and at least one other sparingly soluble calcium phosphate, preferably dicalcium phosphate anhydrous (CaHPO₄), or dicalcium phosphate dihydrate (CaHPO₄.2H₂O). These react in an aqueous environment to form hydroxyapatite, the principal mineral in teeth and bones, as the final product. Because of the apatitic nature of the set cement, it is highly compatible with soft and hard tissues. This material, if applied intraoperatively as a paste, subsequently sets to a structurally stable implant composed of microporous hydroxyapatite.

A virtually identical calcium phosphate system which consists of tetracalcium phosphate (TTCP) and monocalcium phosphate anhydrous (MCPA) or its monohydrate form (MCPM) was described by Constantz et al. (U.S. Pat. Nos. 5,053,212 and 5,129,905). This cement system is believed to involve conversion of the MCPA to dicalcium phosphate which reacts with TTCP and forms hydroxyapatite, the major mineral component of teeth and bone, as the end product.

Constantz et al. U.S. Pat. Nos. 4,880,610 and 5,047,031 describe another cement system that consists of a mixture of solid phosphoric acid crystals, calcium carbonate, and calcium hydroxide as the cement powder and a 7.4 mol/L NaOH solution (4.5 g NaOH in 15 mL of water) as the cement liquid. Data on the physical and chemical properties (compressive strength, hardening time, nature of end product, pH of the cement fluid, heat of mixing etc.) of this cement have not been located in the patent or scientific literature.

BRIEF SUMMARY OF THE INVENTION

The various embodiments of the present invention comprise compositions and means for formulating calcium phosphate cement pastes that are stable in a package, resistant to washout and harden within a desired time after being delivered to a defect or implant site. Solutions are provided for promoting rapid setting of calcium phosphate cements upon blending of a solution with a calcium phosphate cement powder. The solutions and powders are stable and, when blended together, yield cement slurries having reduced hardening times.

Numerous solutions may be used in accordance with the present invention, however, the solutions each are capable of accelerating cement setting reactions upon blending with a calcium phosphate cement powder. In one embodiment, one or more calcium phosphate salts are present in a relatively reactive form, which accelerates cement setting reactions by acting as â€œseedsâ€ to promote more rapid formation of hydroxyapatite and, thus, hardening of the cement. The solution can be an acidic calcium phosphate solution. The solution also can be a concentrated acidic solution. Dissolution of a calcium phosphate cement powder in such solutions results in precipitation of a calcium phosphate compound from solution. The precipitated compound is very reactive and enhances cement setting reactions to reduce cement hardening times.

In another embodiment, solutions of one or more salts that are not calcium salts can be mixed with calcium phosphate cement powders to increase the solution phosphate concentration and accelerate formation of hydroxyapatite. The solution can be a salt: (a) where the cationic component is not calcium and one or more of the anionic components form strong calcium complexes in solution, or (b) the cationic component is not calcium and one or more of the anionic components form insoluble salts with calcium. Dissolution of a calcium phosphate cement powder in the solution results in an increase in the phosphate concentration in the solution, which enhances cement setting reactions to reduce cement hardening times.

Another embodiment of the invention is a method of preparing a cement paste from a slurry for bone and tooth restoration. The method includes preparing a cement slurry from a solution and a calcium phosphate powder. The cement slurry hardens relatively rapidly into a formable paste that can be shaped before it hardens into a cement.

Still another embodiment of the invention is a method of repairing bone and tooth defects. The method includes blending the solutions and powders described above to provide a cement paste and filling a defect with the cement paste before it hardens substantially into a cement.

The invention further contemplates the improved calcium phosphate cement mixtures prepared by this method, the cement component(s) provided to the user in a pre-manufactured kit or delivery device, the methods of using the improved cement, and the biological implants made from the cement. A rapid-hardening industrial cement is also contemplated.

The invention includes a method for preparing calcium phosphate cement compositions, which self-harden substantially to hydroxyapatite at ambient temperature when in contact with an aqueous medium, the method including combining one or more calcium phosphate salts or calcium salts with a solution that is (1) an acidic calcium phosphate solution saturated with respect to more or more calcium phosphate compounds, (2) a concentrated acid solution, or (3) salt solutions with a cationic component other than calcium.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the solubility phase diagram of the 3-component system, Ca(OH)₂â€”H₃PO₄â€”H₂O, showing the acidic and concentrated region of the phase diagram for the system;

FIG. 2A is a three-dimensional solubility phase diagram for the Ca(OH)₂â€”H₃PO₄â€”H₂O system;

FIG. 2B is a projection of the diagram of FIG. 2A along the log[Ca] axis; and

FIG. 2C is a projection of the diagram of FIG. 2A along the log[P] axis.

DETAILED DESCRIPTION OF THE INVENTION

Calcium phosphate cement compositions are prepared that yield a product that self-sets at ambient temperatures (i.e., room or body temperature) to hydroxyapatite (HA). The calcium phosphate cement compositions include a liquid solution and a powder composition. The use of certain calcium phosphate precursor cement slurry compositions results in a cement which sets reliably and quickly to HA. The setting rate can be adjusted for various end uses, and may be quite rapid if desired. The resulting hydroxyapatite cement is believed to be both biocompatible and resorbable (biodegradable) with bone replacement when in contact with living bone.

The calcium phosphate cement pastes can be used in bone graft and similar medical repair applications. The calcium phosphate cements can be mixed and/or shaped prior to delivery to a bone or tooth defect site. The pastes also can be provided in an injectable form for delivery to the bone or tooth defect site. The calcium phosphate cements harden relatively rapidly to form HA.

Formation of HA from the calcium phosphate cement slurries can be greatly accelerated by use of the inventive solutions that, when mixed with any one or more of a wide variety of calcium phosphate cement powders to form a slurry composition, results in: (1) an increase in phosphate concentration in the slurry composition and/or (2) an increase in the pH of the slurry composition. Without wishing to be bound by any theories, it is believed that the cement solutions provide effective means to accelerate the HA formation in the slurry systems because of the formation of intermediate compounds and/or calcium complexes either of which will precipitate more readily than HA at the lower solution pH. Such intermediate compounds and complexes are less soluble than HA at lower pH (below a pH of about 4), whereas HA is the least soluble phase at a pH of about 4 and greater.

FIG. 1 is a solubility phase diagram for the Ca(OH)₂â€”H₃PO₄â€”H₂O, in which both the solid phase and the saturated solution contain only those ions or non-charged species that are derived from the three components, Ca(OH)₂, H₃PO₄, and H₂O. FIG. 1 shows the acidic and concentrated region of the phase diagram. Each solid line in the diagram is referred to as a solubility isotherm and represents the compositions (expressed in terms of H₃PO₄mass % and Ca(OH)₂mass %) of a series of solutions that are saturated with respect to the indicated solid, i.e., MCPM, DCPD, or DCPA. The point where two isotherms meet is referred to as a singular point, where the solution is saturated with respect to both solids. In FIG. 1, those solution compositions that are to the left of an isotherm are super saturated with respect to the solid, and those to the right of the isotherm are under saturated. The vertical axis represents H₃PO₄solution concentrations.

The dashed lines are used to illustrate the changing solution compositions that occur when HA dissolves into H₃PO₄solutions of different concentrations. By way of example, it can be seen that when HA dissolves into a 10% H₃PO₄solution, the dissolution line will first cross the DCPA isotherm, at which point the solution becomes saturated with respect to DCPA. Being an anhydrous salt, DCPA does not always readily precipitate, allowing the HA dissolution line to cross the DCPD isotherm. Further HA dissolution will lead to DCPD precipitation. Similarly, when HA dissolves into a 30% H₃PO₄solution, the dissolution line will cross the DCPA isotherm and then the MCPM isotherm, resulting in precipitation of DCPA or MCPM or both. In contrast, dissolution of HA into a 50% or 70% H₃PO₄solution will lead to MCPM precipitation only. The above illustrates how the phase diagram of FIG. 1 can be used to predict the phases that would form as a result of dissolution of HA in any solution composition covered in the diagram. A similar analysis is possible with any other calcium phosphate, e.g., tetracalcium phosphate, tricalcium phosphate, dicalcium phosphate, etc., as the dissolving compound.

The lower left corner of the phase diagram, sometimes referred to as the â€œwater corner,â€ represents the region of the solubility phase diagram for the Ca(OH)₂â€”H₃PO₄â€”H₂O system where the pH is about 4 or above. Because the Ca and P concentrations of the solutions for this region are much lower than those in the acidic region, another solubility phase diagram that employs logarithmic scales is used to illustrate the relative stability of the various calcium phosphate phases, which is the major driving force for phase transformation reactions, as a function of pH. FIG. 2A is a three-dimensional solubility phase diagram showing the solubility isotherms of the various calcium phosphate phases that are stable in the pH range of 4 to 12. FIGS. 2B and 2C illustrate the projections of the three-dimensional diagram along the log[P] and log[Ca] axes, respectively. In FIGS. 2B and 2C, those solutions that are below an isotherm are undersaturated with respect to the indicated solid phase and those above the isotherms are supersaturated with respect to the indicated solid phase.

It can be seen in the figures that among all calcium phosphate salts, HA is the least soluble in a wide range of solution pHs, ranging approximately from 4.5 to 14. Thus, within this pH range, any other calcium phosphate or mixture of calcium phosphates has the tendency to dissolve and reprecipitate as HA. However, in general the rate of HA formation is very slow such that a slurry of DCPD, DCPA, octacalcium phosphate (Ca₈H₂(PO₄)₆.5H₂O, or â€œOCPâ€ ), amorphous calcium phosphate (Ca₃(PO₄)₂, or â€œACPâ€ ), Î±-tricalcium phosphate (Î±-Ca₃(PO₄)₂, or â€œÎ±-TCPâ€ ), Î²-tricalcium phosphate (Î²-Ca₃(PO₄)₂, or â€œÎ²-TCPâ€ ), or a mixture of these salts does not produce a setting cement or act as an effective remineralizing agent.

Acceleration of HA formation can be achieved using the present solutions with calcium phosphate cement powders because of increased phosphate concentration and/or increased solution pH. The intermediate compounds will form initially. As the cement setting reactions proceed, the solution pH increases and the compounds will begin to dissolve. The formation of HA and dissolution of the more soluble intermediate compounds are responsible for the hardening of the cement. Preferably, the pH of the prepared cement paste systems increases with time to be in the range of approximately 4.5 to 14, the range in which HA is the most stable phase. With these conditions, more rapid HA formation and subsequent cementation can occur.

A variety of solutions can be used in accordance with the invention. Generally, the solutions can be grouped based on the mechanism by which the solutions accelerate cement setting reactions.

In one embodiment, one or more calcium phosphate salts in the cement solutions are generally very reactive with respect to hydroxyapatite formation, thereby promoting more rapid formation of hydroxyapatite and reducing hardening time of the cements. Without wishing to be bound by any theories, it is believed that the calcium phosphate salts act as â€œseedsâ€ that promote hydroxyapatite formation. That is, the calcium phosphate salts precipitate to form reactive particles that provide the foundation from which hydroxyapatite forms. At least initially, when the solution is at a lower pH, the calcium phosphate particles are not highly soluble in the non-aqueous solutions or water. The phosphate concentration of the paste is not expected to increase by any significant amount if exposed to an aqueous environment. The calcium phosphate â€œseedsâ€ provide a template for growth of hydroxyapatite crystal growth, which enhances the rate of formation of hydroxyapatite and provides more rapid hardening of the cement.

In a first group of solutions, the solutions are acidic calcium phosphate solutions that are saturated with respect to monocalcium phosphate monohydrate (Ca(H₂PO₄)₂H₂O, or â€œMCPMâ€ ) or monocalcium phosphate anhydrous (Ca(H₂PO₄)₂, or â€œMCPAâ€ ). These solutions generally have a pH between about 0 to about 1.9, a Ca(OH)₂content from about 0.3% to about 8.5%, and a H₃PO₄content of about 30% to about 80% (see the solid curve for MCPM in FIG. 1). They are not supersaturated with respect to other calcium phosphate phases, and are stable as a result. When the solution is mixed with a calcium phosphate cement powder, the powder dissolves and the solution pH increases. As described previously, dissolution of the cement components leads to increases in pH and calcium and phosphate concentrations. The solution will become supersaturated with respect to MCPM or MCPA, and MCPM or MCPA will precipitate from the respective solutions. The MCPM and MCPA formed in situ are highly reactive. The precipitate acts as â€œseedsâ€ that accelerate cement setting reactions and reduce cement hardening time.

In a second group of solutions, the solutions are acidic calcium phosphate solutions that are saturated with respect to dicalcium phosphate dihydrate (CaHPO₄.2H₂O, or â€œDCPDâ€ ) or dicalcium phosphate anhydrous (CaHPO₄, or â€œDCPAâ€ ). These solutions generally have a pH between about 1.9 to about 4.3, a Ca(OH)₂content from about 0.05% to about 8.5%, and a H₃PO₄content of about 0.1% to about 30% (see the solid curves for DCPA and DCPD in FIG. 1). The DCPA saturated solutions are not supersaturated with respect to other calcium phosphate phases, and are stable as a result. The DCPD saturated solutions are not supersaturated with respect to other calcium phosphate phases except DCPA, but DCPA does not readily precipitate from these solutions. The solutions thus are expected to be stable for longer periods, e.g., about 1 year or more. When the solution is mixed with a calcium phosphate cement powder, the powder dissolves and the solution pH and calcium and phosphate concentrations increase. As the solution becomes supersaturated with respect to DCPD or DCPA, DCPD or DCPA will precipitate from the respective solutions. The DCPD and DCPA formed in situ are highly reactive. The precipitate acts as â€œseedsâ€ that accelerate cement setting reactions and reduce cement hardening time.

In third group of solutions, the solutions are concentrated acid solutions. Suitable solutions include hydrochloric acid (HCl), nitric acid (HNO₃), phosphoric acid (H₃PO₄), glycerolphosphoric acid ((HOCH₂)₂CHOPO(OH)₂), and acetic acid (CH₃COOH). The pH of these solutions is highly acidic. When the solution is mixed with a calcium phosphate cement powder, the powder dissolves. MCPM, MCPA, DCPD, DCPA and combinations thereof will precipitate according to the acid strength and concentration. That is, MCPM and MCPA are expected to precipitate in a stronger acid solution, and DCPD and DCPA are expected to precipitate in a weaker acid solution. The MCPM, MCPA, DCPD and DCPA formed in situ are highly reactive. The precipitate acts as â€œseedsâ€ that accelerate cement setting reactions and reduce cement hardening time.

Solution concentrations should be sufficiently high enough so that MCPM, MCPA, DCPD, and/or DCPA will form when using solutions of the third group. For example, the H₃PO₄concentration preferably is at least about 0.015 M. The minimum concentrations of other acid solutions in the third group are likely somewhat higher because they do not contain phosphate ions. It is anticipated that the effectiveness of the acid solutions in providing a rapidly setting cement generally will decrease with decreasing acid concentration. Thus, for a given acid solution, it is anticipated that there will be a particular concentration range that will provide a desired setting time.

In another embodiment, the solutions are solutions of a salt where the cationic component(s) is not calcium and one or more of the anionic component(s) form strong calcium complexes in the solution. Suitable solutions of this type include sodium acetate, sodium lactate, sodium cacodylate and the like. Alternatively, the solutions are solutions of a salt where the cationic component(s) is not calcium and one or more of the anionic components form insoluble salts with calcium. Suitable solutions of this type include sodium fluoride, potassium oxalate, sodium sulfate and the like. When solutions of either of these types are mixed with a calcium phosphate cement powder, the concentration of the free, or uncombined, form of the anionic component(s) in the solution and the concentration of the free calcium in the solution decrease, as a result at least in part, of complex formation or precipitation. Correspondingly, the concentration of phosphate in the solution increases to maintain the electroneutrality in the solution. An increased concentration of phosphate accelerates cement setting reactions. The pH of the solution may vary but should promote at least some degree of solubility of the calcium phosphate powders. Preferably, the pH is selected to promote a higher degree of powder solubility.

The cement compositions also include one or more cement powders. Powders that can be mixed with any of the above solutions to yield a rapid-hardening cement include (1) one or more calcium phosphate salts, or (2) one or more calcium phosphate salts and one or more calcium salts. Suitable calcium phosphate salts include (in the order of increasing calcium to phosphate ratio) but are not limited to MCPM, MCPA, DCPD, DCPA, OCP, ACP, Î±-TCP, Î²-TCP, HA, carbonated HA, calcium-deficient HA, poorly crystalline HA, tetracalcium phosphate (TTCP), and precipitated or high temperature products that are homogeneous mixtures of one or more of the above salts. Suitable calcium salts are sparingly to moderately soluble calcium-containing compounds, which include but are not limited to calcium oxide (CaO), calcium hydroxide (Ca(OH)₂), calcium carbonate (CaCO₃), calcium glycerophosphate, calcium gluconate, calcium lactate, and calcium sulfate.

The particle sizes of the powders preferably are in the range of between about 0.05 Î¼m to about 500 Î¼m, more preferably between about 1 Î¼m to about 100 Î¼m. The crystallinity of the powders can range from very low (amorphous) to high.

The compositions also may include one or more additives to enhance the properties of the compositions, such as when used in clinical applications. Additives may include medicaments, filler materials, crystal adjustors, viscosity modifiers, gelling agents, pore forming agents, resorbable and nonresorbable fibers and meshes, osteoinductive factors, bone morphogenic proteins, other proteins, and combinations thereof.

The cement compositions may include one or more non-toxic gelling agents to enhance paste cohesiveness and washout resistance. The gelling agent may include hydroxypropyl methylcellulose, carboxylmethylcellulose, starch, proteoglycans, glycoproteins, chitosan and chitosan derivatives, collagen, gum, gelatin, and alginate, and combinations thereof. Use of a gelling agent can increase the rate of hardening of the cement.

Filler materials can be added in amounts effective for enhancing the strength of the cement. Suitable filler materials include but are not limited to non-toxic biocompatible natural or synthetic polymers, non-toxic biocompatible metals, and other non-toxic biocompatible organic and inorganic materials. Fillers can be in the form of granules, fibers, rods, sheets, grids or other suitable forms.

Pore forming agents can be selected to form pores having diameters effective to result in vascularization of tissue that infiltrates the composition. Preferably, the pore diameter ranges between about 30 Î¼m to about 500 Î¼m, or more preferably, between about 100 Î¼m to about 350 Î¼m. The pore forming agents are selected from materials that are sufficiently insoluble in the cement pastes to enable incorporation of the pore forming agents into the hardened cement but that are sufficiently soluble to be substantially removed by dissolution in physiological fluids or resorbed by actions of cells after implantation. Alternatively, the agents can be removed after hardening of the cement using solvents or heating. Suitable solvents include water, ethanol, acetone, ether, and any other organic solvent in which the pore forming agent dissolves. If heated, the temperature should be sufficiently high enough to remove the pore forming agent by decomposition, sublimation, evaporation, combustion, etc. Preferably, the cement is heated to a temperature range of from about 100Â° C. to about 1200Â° C., although other heating temperatures also may be employed. The pore forming agents may include sugar, sodium bicarbonate and phosphate salts. Phosphate salts are effective pore forming agents because the use of concentrated phosphate solutions in the cement makes them relatively insoluble in the cement. A particularly useful phosphate salt is disodium phosphate.

Preferably, the precipitated calcium phosphate seeds that form in the slurry compositions are an acidic calcium phosphate compound. Such compounds include, inter alia, DCPA, DCPD, MCPA, MCPM, ACP and HA. Preferably, the compound is DCPD or MCPM, and combinations thereof.

The particle size of the calcium phosphate seeds can vary. By way of example, nanometer-size particles of calcium phosphate compounds will promote hydroxyapatite formation.

The compositions may be employed as rapid-hardening cement pastes in a variety of medical and dental procedures for repairing or restoring missing or defective bone or tooth tissue. The cement pastes may be applied to the defect site using any suitable methods, including injecting with a syringe or depositing with a spatula, and also molded or sculpted in vivo as desired. When the solutions are mixed with the cement powders, the resulting slurry compositions will harden relatively rapidly.

For most clinical applications, a cement hardening time of more than 60 minutes is too long. Additionally, if the cement sets too rapidly, the time to sculpt the paste into the desired shape and deposit it at the defect site may not be sufficient. The cement composition in accordance with the various embodiments of the present invention will have a hardening, or setting, time of no more than about 35 minutes, preferably no more than 20 minutes and even more preferably between about 5 to about 15 minutes.

EXAMPLES

The following examples further illustrate preferred embodiments of the present invention but are not be construed as in any way limiting the scope of the present invention as set forth in the appended claims.

Various cement paste systems were prepared. Setting times and other properties of the pastes were evaluated.

Preparation of Cement Powders: TTCP, Î±-TCP and Î²-TCP are prepared using conventional methods known to those of skill in the art and described below. DCPA, DCPD, HA, CaCO₃, and Ca(OH)₂are commercially available reagent grade chemicals, such as available from J.T. Baker Chemical Co., Phillipsburg, N.J.

TTCP is prepared by heating an equimolar mixture of commercially obtained DCPA (Baker Analytical Reagents, J.T. Baker Chemical Co., Phillipsburg, N.J.) and CaCO₃(J.T. Baker Chemical Co.) at about 1500Â° C. for about 6 hours in a furnace and quenched at room temperature. Alternatively, appropriate amounts of DCPA and CaCO₃are used to obtain a Ca/P molar ratio of between about 1.8 to about 2.2 if it is desired to have TTCP in the final product and minor amounts of other phases including Î±-TCP, HA, and CaO. Î±-TCP is prepared by heating a mixture that contains about 2 mol of DCPA and about 1 mol of CaCO₃to about 1500Â° C. for about 6 hours and then quenching in air. Alternatively, appropriate amounts of DCPA and CaCO₃are used to obtain a Ca/P molar ratio of between about 1.5 to about 1.7 if it is desired to have Î±-TCP in the final product and various amounts of HA. Î²-TCP is similarly prepared, except that the mixture is heated to about 1200Â° C. and allowed to cool to room temperature in the furnace. The powders are ground individually in a planetary ball mill in cyclohexane, ethanol, or without a liquid to obtain the median particle sizes indicated in the tables below. When not indicated in the tables, the median particle size of TTCP is about 17 Î¼m, A-TCP is about 5 Î¼m, DCPA is about 1 Î¼m, CaCO₃is about 4 Î¼m, and Ca(OH)₂is about 2 Î¼m.

Preparation of Solutions: The various cement solutions are prepared by dissolving appropriate amounts of the indicated compounds in distilled water to obtain the concentrations indicated below. Solutions of Examples 1 and 2 are prepared using conventional methods known to those of skill in the art and described in the literature. All other solutions are prepared by dissolving appropriate amounts of the indicated compounds in distilled water to obtain the concentrations indicated in the tables below.

Test Methods: The selected solutions and powders are blended at a mass ratio of between about 0.25 to about 0.5 to form a smooth paste composition. The paste is placed in a mold, and the mold is maintained at a temperature of about 37Â° C. and 100% humidity to simulate expected conditions at a defect site.

Cement setting time is measured with a Gilmore needle apparatus using a heavy Gilmore needle (453.5 g load, 1.06 mm diameter). The cement is considered set when the needle fails to leave a visible indentation when placed over the surface of the cement. Compressive strength measurements are performed on 24-hour, wet specimens using a computer-controlled Universal Testing Machine (Instron, United Calibration Corp., Garden Grove, Calif.). Powder X-ray diffraction analysis (Rigaku, Danvers, Mass., USA) is used to identify the phases that are present in 24-hour cement samples.

Example 1

In this example, a MCPM-forming solution having a pH of about 1, a calcium concentration of about 0.66 M, and a phosphorus concentration of about 7.6 M is used as the cement liquid. This solution is prepared by stirring an excess amount of MCPM in a solution of H₃PO₄(about 6.3 M) until equilibrium, followed by filtration.

The powders also are mixed with water to provide comparative setting times.

TABLE 1SettingSettingtime (min):Productstime (min):MCPMFormedPowderwatersolution(after 24 hours)TTCP and DCPA30<1290% HAÎ±-TCP and DCPA30<1590% HADCPA and Ca(OH)₂does not set<20TTCP(Ca: P = 1.9)(17 Î¼m)does not set<10Î±-TCP (17 Î¼m)does not set<3020% HAÎ±-TCP (5 Î¼m)does not set<40

This example illustrates that the inventive solutions promote relatively rapid hardening and that the cements do not harden as a result of the cement powders contacting an aqueous solution (water alone).

Example 2

In this example, a DCPD-forming solution having a pH of about 2.1, a calcium concentration of about 1.5 M and a phosphorus concentration of about 4.4 M is used as the cement liquid. The solution is prepared by stirring an excess amount of DCPD in a solution of H₃PO₄(about 2.9 M) until equilibrium, followed by filtration. The powders also are mixed with water to provide comparative setting times.

TABLE 2SettingSetting TimeProductsTime (min):(min): DCPDCompressiveFormedPowderwatersolutionStrength (MPa)(after 24 hours)TTCP and DCPA30<10â€‚80% HAÎ±-TCP and CaCO₃does not set<20100% HADCPA and Ca(OH)₂does not set<25â€‚50% HATTCP(Ca: P = 2) (17 Î¼m)does not set30â€‚80% HATTCP(Ca: P = 2) (5 Î¼m)does not set<40â€‚9.2 (n = 3)â€‚98% HATTCP(Ca: P = 1.95)does not set<2580-90% HA(20 Î¼m)TTCP(Ca: P = 1.9) (15 Î¼m)does not set3018.9â€‚80% HATTCP(Ca: P = 1.9) (5 Î¼m)does not set<1510.4 (n = 2)poorly HATTCP(Ca: P = 1.67)does not set<1321.7 (n = 3)poorly HA(5 Î¼m)Î±-TCP (5 Î¼m)does not set<2522.5 (n = 3)â€‚80% HA, 20%DCPDÎ²-TCP (17 Î¼m)does not set28Î²-TCP (5 Î¼m)does not set27â€ƒ0% HA, 20%DCPDHA (from Fisher)does not set20â€‚30% DCPD

Example 3

In this example, concentrated acid solutions are used as the cement liquid.

The powders also are mixed with water to provide comparative setting times.

TABLE 3Products formedPowderLiquidSetting time (min)(after 24 hours)TTCP and DCPAwater30â€‚90% HATTCP and DCPA0.016 N HCl<25â€‚95% poorly HATTCP and DCPA0.063 N HCl<20TTCP and DCPA1.0 N HCl<15TTCP and DCPA0.016 N HNO₃<25â€‚95% poorly HATTCP and DCPA0.032 N HNO₃15â€‚95% poorly HATTCP and DCPA1.0 N HNO₃<15â€‚95% poorly HATTCP and DCPA0.004 M H₃PO₄25â€‚90% HATTCP and DCPA0.008 M H₃PO₄25â€‚90% HATTCP and DCPA0.016 M H₃PO₄22â€‚90% HATTCP and DCPA0.078 M H₃PO₄20â€‚90% HATTCP and DCPA1.0 M H₃PO₄15â€‚90% HATTCP and DCPA0.016 M acetic acid<25â€‚97% HATTCP and DCPA0.063 M acetic acid<20HATTCP and DCPA0.01 M acetic acid<17HATTCP and DCPA1M acetic acid<17â€‚97% HATTCP and DCPA0.016 M lactic acid25â€‚90% HATTCP and DCPA0.063 M lactic acid20â€‚90% HATTCP and DCPA1M lactic acid20â€‚90% HATTCP and DCPA3 M glycerol<2phosphoric acidTTCP and DCPA0.75 M glycerol5phosphoric acidTTCP and DCPA0.19 M glycerol10phosphoric acidTTCP and DCPA0.05 M glycerol25phosphoric acidDCPA and Ca(OH)₂waterdoes not setDCPA and Ca(OH)₂1N HNO₃27â€‚65% HADCPA and Ca(OH)₂1M H₃PO₄<60â€‚35% HAÎ±-TCP and CaCO₃waterdoes not setÎ±-TCP and CaCO₃1N HCl25100% poorly HAÎ±-TCP and CaCO₃1M H₃PO₄<12â€‚60% HA, 40% DCPAÎ±-TCP and DCPAwater35Î±-TCP and DCPA1N HCl<20â€‚70% poorly HAÎ±-TCP and DCPA1M H₃PO₄20â€‚30% HA, 20% DCPD, 50%DCPAÎ±-TCP (5 Î¼m)waterdoes not setÎ±-TCP (5 Î¼m)1N HN0₃<15100% poorly HAÎ±-TCP (5 Î¼m)1N HCl<20100% poorly HAÎ±-TCP (5 Î¼m)1M H₃PO₄<20â€‚60% HA, 40% DCPDTTCP(Ca: P = 1.9)(5 Î¼m)waterdoes not setTTCP(Ca: P = 1.9)(5 Î¼m)1M H₃PO₄<25100% poorly HAÎ²-TCP (5 Î¼m)waterdoes not setÎ²-TCP (5 Î¼m)1M H₃PO₄70

Example 4

In this example, salt solutions that form calcium-complexes or insoluble calcium salts are used as the cement liquid. The powders also are mixed with water to provide comparative setting times.

TABLE 4Setting timeProducts formedPowderLiquid(min)(after 24 hours)TTCP and DCPAwater30â€‚90% HATTCP and DCPA2% NaF10â€‚70% HATTCP and DCPA1 M NaF13â€‚95% HATCCP and DCPA1 M KF7â€‚95% HATTCP and DCPA1 M Na acetate13â€‚60% HATTCP and DCPA1 M C₂K₂O₄13â€‚85% HATTCP and DCPA0.016 M Na₂SO₄<25â€‚85% HATTCP and DCPA0.063 M Na₂SO₄17â€‚85% HATTCP and DCPA1 M Na₂SO₄12â€‚85% HATTCP and DCPA1 M Na cacodylate20DCPA and Ca(OH)₂waterdoes not setDCPA and Ca(OH)₂2% NaF<15100% poorly HADCPA and Ca(OH)₂1M NaF<13100% poorly HADCPA and Ca(OH)₂1M KF<7100% poorly HADCPA and Ca(OH)₂1M Na₂SO₄<20100% poorly HADCPA and Ca(OH)₂1M Na cacodylate23â€‚65% HADCPA and Ca(OH)₂1M C₂K₂O₄<15100% poorly HAÎ±-TCP and DCPA1M NaF10â€‚60% HAÎ±-TCP and DCPA1M Na acetate30â€‚60% HA, 40% DCPATTCP(Ca: P = 1.9) (5 Î¼m)waterdoes not setTTCP(Ca: P = 1.9) (5 Î¼m)1.0 M NaF50100% poorly HATTCP(Ca: P = 1.9) (5 Î¼m)1.0 M C₂K₂O₄15100% poorly HAÎ±-TCP (5 Î¼m)waterdoes not setÎ±-TCP (5 Î¼m)1.0 M NaF90100% poorly HAÎ±-TCP (5 Î¼m)1.0 M Na acetate80100% poorly HAÎ±-TCP (5 Î¼m)1.0 M C₂K₂O₄17100% poorly HAÎ±-TCP (5 Î¼m)1.0 M Na₂SO₄35100% poorly HA

Example 5

This example illustrates the effects of the solutions of Example 4 on the phosphate concentration of cement liquid during setting.

Method and Materials: Approximately 0.4 g of an equimolar TTCP (median size=17 Î¼m) and DCPA (1 Î¼m) mixture is mixed with 1 mL of the various test solutions for the times set forth in Table 5. Phosphate concentration in the solution phase is determined.

TABLE 5LiquidMixing time (min)Phosphate conc.Water30.61Water150.401.0 M NaF32961.0 M NaF153301.0 M Na₂SO₄361.0 M Na acetate36

When the solutions of Example 4 are used as the cement solutions, the phosphate concentrations in solution are significantly higher than when water is used. These results provide further support the mechanism of accelerated setting reaction postulated above when the solutions of Example 4 are used.

Although particular embodiments of the present invention have been described and illustrated, it should be understood that the invention is not limited thereto as modifications may be made by persons skilled in the art. The present application contemplates any and all modifications that fall within the spirit and scope of the underlying invention disclosed herein.