Method of making extended area filter
AssigneeMott Corporation
InventorsWilliam R. Kelly, Larry Moore
Life of this patent
Estimating the term…
Abstract
Methods are provided for making a porous filter that is useful in polymer melt spinning. The methods include pressing particles, such as a metal powder, to form a filter having a filter body integrally formed with a top cap and a bottom cap. The filter body and caps are formed as a single component or, alternatively, are formed as two or three separate parts that are fitted and pressed together to form a single component having blind inlet and outlet cavities. After pressing, the component is sintered to form the porous filter. The particles are pressed and cohere to form the caps and filter body without the use of a polymeric binder, and the inlet and outlet cavities are formed substantially without machining.
Claims34
A method of making a porous filter, the filter having a filter body integrally formed with a top cap and a bottom cap, the method comprising:
- (a) introducing a first plurality of particles into a first mold having a desired shape for the top cap, the shape defining a plurality of spaced inlet openings;
- (b) applying pressure to the first mold, thereby causing the first plurality of particles to cohere and form a green top cap;
- (c) introducing a second plurality of particles into a second mold having a desired shape for the bottom cap integrally formed with the filter body, the shape defining a plurality of spaced outlet openings extending into a plurality of spaced outlet cavities, and a plurality of blind inlet cavities with a spacing corresponding to the spacing of the inlet openings in the top cap;
- (d) applying pressure to the second mold, thereby causing the second plurality of particles to cohere and form a green integral bottom cap and filter body;
- (e) fitting the green top cap together with the green integrally formed bottom cap and filter body, whereby the inlet cavities are aligned with the inlet openings;
- (f) compressing the green fitted top cap and integral filter body and bottom cap, thereby causing the fitted top cap and integral filter body and bottom cap to cohere and form a single green component, the single component defining a plurality of blind inlet cavities and a plurality of blind outlet cavities;
- and
- (g) sintering the green component to form the porous filter, wherein the filter is a single-component uniform porous body having an integral structure with substantially uniform pore structure and density;
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- wherein the first and second pluralities of particles are pressed and cohere to form the top cap and the integral bottom cap and filter body without the use of a polymeric binder, and wherein the inlet and outlet cavities are formed substantially without machining.
A method of making a porous filter, the filter having a filter body integrally formed with a top cap and a bottom cap, the method comprising:
- (a) introducing a first plurality of particles into a first mold having a desired shape for the top cap, the shape defining a plurality of spaced inlet openings;
- (b) applying pressure to the first mold, thereby causing the first plurality of particles to cohere and form a green top cap;
- (c) introducing a second plurality of particles into a second mold having a desired shape for the bottom cap, the shape defining a plurality of spaced outlet openings;
- (d) applying pressure to the second mold, thereby causing the second plurality of particles to cohere and form a green bottom cap;
- (e) introducing a third plurality of particles into a third mold having a desired shape for the filter body, the shape defining a plurality of cavities with a spacing corresponding to the spacings of the inlet openings and the outlet openings;
- (f) applying pressure to the third mold, thereby causing the third plurality of particles to cohere and form a green filter body;
- (g) fitting the green top cap, green filter body, and green bottom cap together, whereby the cavities are aligned with the inlet openings and outlet openings;
- (h) compressing the green fitted top cap, filter body, and bottom cap, thereby causing the fitted top cap, filter body, and bottom cap to cohere and form a single green component, the single component defining a plurality of blind inlet cavities extending into the filter body from the inlet openings in the top cap, and a plurality of blind outlet cavities extending into the filter body from the outlet openings in the bottom cap;
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- (i) sintering the green component to form the porous filter, wherein the filter is a single-component uniform porous body having an integral structure with substantially uniform pore structure and density;
- and
- wherein the first, second, and third pluralities of particles are pressed and cohere to form the top cap, filter body, and bottom cap without the use of a polymeric binder, and wherein the inlet and outlet cavities are formed substantially without machining.
Dependencies are inferred from the claim text.