Apparatuses, systems, and associated methods for forming porous masses for smoke filter

摘要

A system for producing porous masses may include a mold cavity disposed along the material path, at least one hopper before at least a portion of the mold cavity for feeding a matrix material to the material path, a heat source in thermal communication with at least a first portion of the material path, and a cutter disposed along the material path after the first portion of the material path.

主权项

1. A method comprising:
continuously introducing a matrix material into a mold cavity, wherein the matrix material comprises an active particle and a binder particle, and wherein the binder particles have a melt flow index of less than about 3.5 g/10 min at 190° C. and 15 kg according to ASTM D1238, a bulk density of about 0.1 to about 0.5 g/cm3, and either (1) a molecular weight of about 300,000 to less than 1,000,000 and an average particle size of about 5 microns to about 500 microns or (2) a molecular weight of about 1,000,000 to about 6,000,000 and an average particle size of about 200 microns to about 500 microns; disposing a release wrapper as a liner of the mold cavity; heating at least a portion of the matrix material to about 175° C. to about 300° C., so as to bind the matrix material at a plurality of contact points thereby forming a porous mass length having an encapsulated pressure drop of about 10 mm of H2O/mm of porous mass length or less; and cutting the porous mass length radially thereby yielding a porous mass.