Filter cartridge containing reticulated foam fluid treatment media

A filter assembly for removing contaminants from a fluid, the filter assembly operably connected to a supporting structure, the filter assembly comprising:

• a filter housing having an inlet, an outlet and a chamber extending through the filter housing;
• a filter cartridge positioned in the chamber of the filter housing, the filter cartridge constructed from a fibrous material used to filter contaminants from a fluid;
• and
• a substantially flexible reticulated foam fluid treatment media embedded within the filter cartridge, wherein the reticulated foam fluid treatment media comprises a flexible porous polyurethane substrate having surfaces including pore walls, and particles secured to the surfaces of the porous polyurethane substrate via a binder, the particles being substantially uniformly distributed throughout the porous polyurethane substrate via sonic vibration of the porous polyurethane substrate and particles.

A method for producing flexible reticulated foam fluid treatment media for removing contaminates from fluids, the method comprising the steps of:

• providing a flexible porous polymeric substrate;
• coating the flexible porous polymeric substrate with a binder compatible with the flexible porous polymeric substrate;
• compressing the coated flexible porous polymeric substrate using a roller or pair of rollers to press the binder into pores of the flexible porous polymeric substrate, to remove excess binder from the pores of the flexible foam substrate, and to allow re-expansion of the flexible porous polymeric substrate to provide a coated flexible porous polymeric substrate having tacky surfaces;
• applying an effective amount of particles on a first face of the coated flexible porous polymeric substrate and applying sonic vibration to substantially uniformly distribute the particles throughout the porous polymeric substrate and uniformly coat the tacky surfaces of the coated flexible porous polymeric substrate with the particles, thereby providing a particle coated flexible porous polymeric substrate, the particles being selected from the group consisting of metal particles, metal oxide particles, rare earth particles, carbon particles and combinations thereof.