Method of forming a composition and the composition formed therefrom

A method of making a composition, the method comprising:

• forming a solvent mixture comprising a polymer and a solvent;
• combining the solvent mixture with a non-solvent to precipitate a composition comprising a plurality of filler particles in a fibrillated polymer matrix, wherein the composition is in a form of a particulate, wherein the filler particles are mechanically bonded by one or more polymer fibers to at least one or more filler particles across an interstitial spaces within the formed particulates, and where the polymer fibers are caused to deposit in an elongated form within the interstitial space among the filler particles having bonded filament connections to at least one other particle, wherein at least one of the solvent and the non-solvent comprises the filler particles prior to the precipitating;
• removing greater than or equal to 95 percent of the solvent and the non-solvent from the composition after precipitating the composition in less than or equal to 15 seconds;
• and
• reducing a volume of the interstitial spaces between the dispersed filler particles, resulting in a decreasing of the interstitial spaces existing within the plurality of the dispersed filler particles;
• wherein the produced composition is porous and has a void content of 40 to 99 volume percent and comprises a filler content of greater than or equal to 90 volume percent based on the total volume of the composition, where the filler particles are attached to the polymer or are embedded within the composition and wherein the filler surface area exposure to a pore is greater than or equal 50 area percent;
• wherein the composition comprises greater than or equal to 90 weight percent of the filler particles and 1 to 10 weight percent of the fibrillated polymer matrix based on the total weight of the composition minus any solvent;
• and
• wherein the average filler particle diameter is less than or equal to 100 micrometers and the polymer filaments have an average diameter of 5 to 50% of the filler particle diameter.