SYSTEMS AND METHODS OF MAKING MOLDED COMPOSITE BLOCKS

Abstract

Provided are filtration matrixes formed from adsorptive media, such as activated carbon, and polymeric binder for use in water filtration systems. A first aspect of the invention provides methods of making a filtration matrix comprising: mixing an adsorptive media with a polymeric binder to form a mixture; impulse filling a mold with the mixture; and processing the mixture to form the filtration matrix. Filtration matrixes formed from this method are also provided. Another aspect includes methods of making a filtration matrix comprising: mixing adsorptive media with a polymeric binder to form a mixture; filling a mold with the mixture; and applying heat and pressure the mixture to form the filtration matrix, wherein the step of applying pressure to the mixture comprises compressing the mixture until a desired final shape of the filtration matrix is obtained.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

In describing embodiments of the invention, reference is made to the various Figures wherein like reference numerals indicate like features and in which:

FIG. 1 is a schematic representation of a representative prior art material compressing apparatus useful with molds during the manufacture of composite blocks; and

FIG. 2 is a schematic representation of a representative material compressing apparatus useful with molds during the manufacture of composite blocks in accordance with the present disclosure.

Claims

1. A method of making a filtration matrix comprising: mixing an adsorptive media with a polymeric binder to form a mixture;impulse filling a mold with the mixture; andheating the mixture to form the filtration matrix.

2. The method of claim 1, wherein the step of impulse filling comprises administering impulses at a rate in the range of 6 to 120 impulses per minute.

3. The method of claim 2, wherein the rate is about 20 impulses per minute.

4. The method of claim 1, wherein the mixture has a maximum uncompressed density, and the mold is filled to at least 90% of the maximum uncompressed density.

5. The method of claim 4, wherein the mold is filled to at least 95% of the maximum uncompressed density.

6. The method of claim 1, wherein the processing step comprises compressing the mixture until a desired final shape of the filtration matrix is obtained.

7. The method of claim 1, wherein the processing step comprises heating the mold to a temperature in the range of 160° C. to 250° C.

8. The method of claim 1, further comprising providing a mold that is tapered to facilitate removal of the filtration matrix from the mold.

9. The method of claim 1, wherein the adsorptive media comprises activated carbon.

10. The method of claim 9, wherein the adsorptive media further comprises a lead-removal media.

11. The method of claim 1, wherein the binder comprises ultra high molecular weight polyethylene.

12. The method of claim 1, wherein the impulse filling is used to fill a plurality of molds, and wherein a plurality of filtration matrixes is formed.

13. The method of claim 12, wherein a standard deviation of the average weight of the plurality of filtration matrixes is no greater than 10% of the average weight.

14. The method of claim 13, wherein the standard deviation is no greater than 5% of the average weight.

15. A method of making a filtration matrix comprising: mixing adsorptive media with a polymeric binder to form a mixture;filling a mold with the mixture; andapplying heat and pressure the mixture to form the filtration matrix wherein the step of applying pressure to the mixture comprises compressing the mixture until a desired final shape of the filtration matrix is obtained.

16. The method of claim 15, wherein the steps of applying heat and pressure are done substantially simultaneously.

17. The method of claim 15, wherein the step of applying heat occurs before the step of applying pressure.

18. The method of claim 15, wherein the step of applying pressure occurs before the step of applying heat.

19. The method of claim 15, wherein the step of applying pressure comprises applying compressive force axially to the mixture.

20. The method of claim 15, further comprising providing a mold that is tapered to facilitate removal of the filtration matrix from the mold.

21. A filtration matrix made according to the method of claim 1.

22. The filtration matrix of claim 21, comprising a VOC capacity according to NSF-53 of 20 gal/in3 or greater.

23. The filtration matrix of claim 21, comprising a VOC capacity according to NSF-53 of 30 gal/in3 or greater.

24. The filtration matrix of claim 21, comprising a VOC capacity according to NSF-53 of 40 gal/in3 or greater.

25. The filtration matrix of claim 21, wherein the binder is present in an amount of no greater than 30% of the total weight of the matrix.

26. A method of making a filtration matrix comprising: mixing an adsorptive media with ultra high molecular weight polyethylene to form a mixture comprising the adsorptive media in an amount in the range of 65 to 90% by weight and ultra high molecular weight polyethylene in an amount in the range of 35 to 10% by weight;impulse filling a mold with the mixture;heating the mold to a temperature in the range of 160° C. to 200° C.;compressing the mixture until a fixed length of the filtration matrix is obtained; andcooling the mold.