SYSTEMS AND METHODS FOR MAKING POROUS ARTICLES
Multiple processes for preparing porous articles are described. The porous articles can be in a wide array of shapes and configurations. The methods include providing a soluble material in particulate form and forming a packed region from the material. The methods also include contacting a flowable polymeric material with the packed region such that the polymeric material is disposed in voids in the packed region. Also described are systems for performing the various processes.
1 . A method comprising:
vibrating a mesh frame to form a packed region within a soluble material passing through the mesh frame, the packed region having a plurality of voids, wherein dimensions of a spacer between the mesh frame and the soluble material corresponds to a desired thickness of particulates within the soluble material; and
contacting a flowable polymeric material with at least a portion of the packed region of the soluble material such that at least a portion of the flowable polymeric material is disposed in at least a portion of the plurality of voids of the packed region.
2 . The method of claim 1 , further comprising solidifying a portion of the flowable polymeric material to thereby form a composite material.
3 . The method of claim 2 , further comprising converting the composite material into a porous article.
4 . The method of claim 1 , wherein contacting the flowable polymeric material with at least a portion of the packed region of the soluble material includes:
providing a polymeric film;
contacting the polymeric film with a layer of the soluble material in particulate form; and
heating the polymeric film to a temperature sufficient to transform the polymeric film into the flowable polymeric material.
5 . The method of claim 1 , wherein contacting a flowable polymeric material with at least a portion of the packed region of the soluble particulate material includes:
providing polymeric particulates;
contacting the polymeric particulates with the soluble material in particulate form;
and heating the polymeric particulates to a temperature sufficient to transform the polymeric particulates to a flowable polymeric material.
6 . The method of claim 5 , wherein the polymeric particulates are in a fibrous form, a tubular form, or a spherical form.
7 . The method of claim 1 , wherein the contacting includes injecting at least one polymeric material in flowable form into the packed region of particulate material.
8 . The method of claim 7 , wherein the injecting includes:
a first injection of a first polymeric material; and
a second injection of a second polymeric material, the second injection performed after the first injection.