Process for preparing molded porous articles and the porous articles prepared therefrom

A process for forming a porous article comprising:

• (a) providing a molding powder comprising polyethylene polymer particles, wherein the polyethylene polymer has a molecular weight within the range of about 800,000 g/mol to about 3,500,000 g/mol as determined by ASTM-D 4020, and wherein the particle size distribution of the particles of the polyethylene polymer are within the range of about 10 microns to about 1000 microns;
• (b) forming the molding powder into a desired shape;
• and
• (c ) heating the shape to a temperature within the range of about 140° C. and about 300° C. while maintaining the shape under pressure sufficient to maintain the volume of the shape and for a period of time sufficient to permit the polyethylene polymer to expand and soften;
• and
• (d) thereafter cooling the shape.