APPARATUSES, SYSTEMS, AND ASSOCIATED METHODS FOR FORMING POROUS MASSES FOR SMOKE FILTERS
High-throughput production apparatuses, systems, and associated methods may include pneumatic dense phase feeding. For example, a method may involve feeding via pneumatic dense phase feeding a matrix material into a mold cavity to form a desired cross-sectional shape, the matrix material comprising a binder particle and an active particle; heating (e.g., via microwave irradiation) at least a portion of the matrix material so as to bind the matrix material at a plurality of contact points thereby forming a porous mass length; cooling the porous mass length; and cutting the porous mass length radially thereby producing a porous mass. In some instances, the matrix material may include a plurality of active particles, a plurality of binder particles (optionally having a hydrophilic surface modification), and optionally a microwave enhancement additive.
1 . A method comprising:
feeding via pneumatic dense phase feeding a matrix material into a mold cavity to form a desired cross-sectional shape, the matrix material comprising a plurality of binder particles and a plurality of active particles;
heating at least a portion of the matrix material so as to bind at least a portion of the matrix material at a plurality of sintered contact points, thereby forming a porous mass length; and
cooling the porous mass length.
2 . The method of claim 1 , wherein at least some of the of binder particles have a hydrophilic surface treatment.
3 . The method of claim 1 , wherein the porous mass is a hollow cylinder.
4 . The method of claim 1 , wherein the porous mass is a sheet.
5 . The method of claim 1 , wherein the porous mass has a rectangular cross-sectional shape.
6 . The method of claim 1 , wherein the porous mass has an ovular cross-sectional shape.
7 . The method of claim 1 , wherein the porous mass has a circumference of about 5 mm to about 785 mm.
8 . The method of claim 1 , wherein the binder particles are fibrous.
9 . The method of claim 1 , wherein the porous mass has a void volume of about 40% to about 90%.
10 . The method of claim 1 , wherein the binder particles comprise ultrahigh molecular weight polyethylene, and wherein the active particles comprise carbon.
11 . A fluid filter comprising:
a porous mass that comprises a plurality of binder particles mechanically bound to a plurality of active particles at a plurality of sintered contact points, wherein the binder particles have a hydrophilic surface treatment.
12 . The fluid filter of claim 11 , wherein the porous mass is a hollow cylinder.
13 . The fluid filter of claim 11 , wherein the porous mass has a rectangular cross-sectional shape.
14 . The fluid filter of claim 11 , wherein the porous mass has an ovular cross-sectional shape.
15 . The fluid filter of claim 11 , wherein the porous mass is a sheet.
16 . The fluid filter of claim 11 , wherein the porous mass has a circumference of about 5 mm to about 785 mm.
17 . The fluid filter of claim 11 , wherein the porous mass has a length less than a diameter.
18 . The fluid filter of claim 11 , wherein the porous mass has a void volume of about 40% to about 90%.
19 . The fluid filter of claim 11 , wherein the binder particles comprise ultrahigh molecular weight polyethylene, and wherein the active particles comprise carbon.
20 . A method comprising:
introducing a matrix material into a mold cavity, the matrix material comprising a plurality of binder particles and a plurality of active particles, wherein at least some of the binder particles comprise ultrahigh molecular weight polyethylene and have a hydrophilic surface treatment;
heating at least a portion of the matrix material so as to bind the matrix material at a plurality of sintered contact points, thereby forming a porous mass having a void volume of about 40% to about 90%; and
cooling the porous mass.
21 . A method comprising:
introducing a matrix material into a mold cavity having a circumference of about 5 mm to about 785 mm, the matrix material comprising a plurality of binder particles and a plurality of active particles, wherein at least some of the binder particles have a hydrophilic surface treatment;
heating at least a portion of the matrix material so as to bind the matrix material at a plurality of sintered contact points, thereby forming a porous mass having a void volume of about 40% to about 90%; and
cooling the porous mass.