Porous media compositions and methods for producing the same
AssigneeAdvanced Materials Technology, Inc.
InventorsAndrew Scott Lawing, Timothy J. Langlois, Daniel Brian Messick, Jr., Brian M. Wagner
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Abstract
The present invention relates to porous substrate compositions and methods for producing such compositions. In one embodiment, the porous substrate composition of the present invention comprises sintered spherical particles of a substantially uniform size. The porous media compositions of the present invention comprise relatively randomly-ordered particles with a void fraction significantly higher than compositions with a more ordered, close-packed configuration. The present invention further relates to composite porous media compositions comprising two or more relatively discrete layers of sintered particles.
Claims24
A method of making a porous material comprising:
- providing a plurality of substantially spherical core particles having a diameter of at least 1 micron,
- contacting the core particles with a polymer such that at least a portion of the surface of the core particles is coated with the polymer,
- forming a plurality of core-shell particles by contacting the polymer-coated core particles with a plurality of shell particles, wherein the plurality of shell particles are bound to the polymer coated core particles,
- drying the core-shell particles, and
- sintering together the contact point of the shells of adjacent core-shell particles to form bonds between the adjacent core-shell particles, thereby forming a bonded porous material.
A method of making a porous material comprising the steps of:
- providing a plurality of substantially spherical core particles,
- contacting the core particles with a polymer such that at least a portion of the surface of the core particles is coated with the polymer,
- forming a plurality of core-shell particles by contacting the polymer-coated core particles with a plurality of shell particles, wherein the plurality of shell particles are bound to the polymer coated core particles,
- drying the core-shell particles, and
- sintering together the contact point of shells of adjacent core-shell particles to form bonds between the adjacent core-shell particles, thereby forming a bonded porous material wherein the degree of porosity of the bonded porous material is controlled by sintering.
A method of making a porous material comprising the steps of:
- providing a plurality of core-shell particles having a solid core comprising silica and one or more shell layers;
- wherein the one or more shell layers are selected so as to be sinterable at a lower temperature than the core, the one or more shell layers comprise shell particles smaller than the core particles to provide the lower sinterable temperature of the one or more shell layers;
- and
- sintering together the contact point of shells of adjacent core-shell particles to form bonds between the adjacent core-shell particles, thereby forming a bonded porous material.
Dependencies are inferred from the claim text.