Composite blocks with void spaces

摘要

A composite block that includes activated carbon particles bonded to one another with a polymeric binder. The block includes a tortuous porous network extending through the block article, the tortuous porous network having a plurality of void spaces interspersed throughout the network with the majority of void spaces each having an average diameter greater than the average diameter of the remainder of the porous network. A filter incorporates the composite block as a part thereof. A process of making a composite block includes mixing activated carbon, polymeric binder and pore forming material to provide a moldable mixture; placing the moldable mixture in a mold cavity; heating the mold cavity and the moldable mixture to melt the polymeric binder; cooling the mold to re-solidify the polymeric binder to form the composite block; and removing the composite block from the mold cavity.

主权项

1. A composite block comprising:
a plurality of activated carbon particles bonded to one another with a polymeric binder forming a plurality of pores between the bound carbon particles, the plurality of pores forming a tortuous porous network extending throughout the composite block; the tortuous porous network further comprising a plurality of void spaces, wherein the plurality of void spaces includes first void spaces and second void spaces, wherein the first void spaces are located within an internal structure of the composite block and are spaced apart from an outer surface of the composite block, and wherein the second void spaces are located along the outer surface of the composite block and are separate from said first void spaces; and wherein a majority of the plurality of first void spaces each have an average diameter greater than the average diameter of the plurality of pores in the tortuous porous network, and wherein the plurality of first void spaces have an average diameter of at least about 1 millimeter.