Process for the production of materials and materials produced by the process

Claim 2

A porous composite article comprising: a plurality of primary particles having relatively high softening temperatures, said particles having a diameter between about 0. 1 and about 3000 micrometers; and a matrix of from 3 to 30% by weight of a substantially continuous thermoplastic binder phase supporting and emeshing said primary particles, said continuous binder phase being formed from binder particles having a diameter of between about 0.1 to about 150 micrometers, said binder particles being substantially incapable of fibrillation under normal conditions into micro fibers of less than 10 micrometers diameter at room temperature and having a softening temperature substantially below the softening temperature of the primary particles, and where such primary particles are consolidated into a uniform matrix with the continuous binder material present as a dilute material within the pores between the primary particles, the remainder of the pore volume comprising a continuous volume of voids and said binder material being forced into macropores and exterior voids of individual primary particles having such macropores and exterior voids.

Claim 3

The composition of claim 1 wherein said binder material is present in an amount between about 4% to about 8% by weight of the composition.

Claim 4

The composition of claim 1 wherein said primary particles are metal.

Claim 5

The composition of claim 3 wherein said metal is ferromagnetic.

Claim 6

The composition of claim 4 wherein said metal is a steel.

Claim 7

The composition of claim 5 wherein said metal is a stainless steel.

Claim 8

The composition of claim 3 wherein said binder material is present in an amount between about 4% to about 8% by weight of the composition.

Claim 9

The composition of claim 1 wherein said primary particles comprise a silica gel.

Claim 10

The composition of claim 1 wherein said primary particles are sawdust.

Claim 11

The composition of claim 1 wherein said primary particles are sand.

Claim 12

The composition of claim 1 wherein said primary particles comprise an ion-exchange resin.

Claim 13

The composition of claim 11 wherein said primary particles comprise a ferromagnetic metal.

Claim 14

The composition of claim 12 wherein said metal is a stainless steel.

Claim 15

The composition of claim 11 wherein said primary particles comprise organic fibers.

Claim 16

The composition of claim 14 wherein said organic fibers are cellulose.

Claim 17

The composition of claim 14 wherein said organic fibers are acrylic.

Claim 18

The composition of claim 1 wherein said primary particles comprise a diatomaceous earth.

Claim 19

The composition of claim 17 wherein said primary particles comprise organic fibers.

Claim 20

The composition of claim 8 wherein said organic fibers are cellulose.

Claim 21

The composition of claim 19 wherein said organic fibers are acrylic.

Claim 22

The composition of claim 1 wherein said primary particles comprise abrasives.

Claim 23

The composition of claim 21 wherein said primary particles comprise a glass.

Claim 24

The composition of claim 21 wherein said primary particles comprise an abrasive selected from the group consisting of silicon carbide or alumina.

Claim 25

The composition of claim 21 wherein said primary particles comprise a silica.

Claim 26

The composition of claim 1 wherein said primary particles comprise an ion complexing material.

Claim 27

The composition of claim 25 wherein said primary particles comprise organic fibers.

Claim 28

The composition of claim 26 wherein said fibers are cellulose.

Claim 29

The composition of claim 26 wherein said fibers are acrylic.

Claim 30

The composition of claim 25 wherein said primary particles comprise a ferromagnetic metal.

Claim 31

The composition of claim 29 wherein said metal comprises a stainless steel.

Claim 32

The composition of claim 1 wherein said primary particles comprise carbon.

Claim 33

The composition of claim 31 wherein said primary particles comprise an activated carbon.

Claim 34

The composition of claim 1 wherein the binder material forming the matrix is a crystalline thermoplastic polymer selected from the group consisting of polyolefins, polyvinyls, polyvinyl esters, polyvinyl ethers, polyvinyl sulfates, polyvinyl phosphates, polyvinyl amines, polyoxidiazoles, polytriazols, polycarbodiimides, ethylene-vinyl acetate copolymers, polysulfones, polycarbonates, polyethers, polyarylene oxides, and polyesters.

Claim 35

The composition of claim 33 wherein the binder material is polyethylene.

Claim 36

The composition of claim 33 wherein the binder material is polypropylene.

Claim 37

The composition of claim 33 wherein the binder material is polybutene-1.

Claim 38

The composition of claim 33 wherein the binder material is poly-4-methylpentene-1.

Claim 39

The composition of claim 33 wherein the binder material is polyvinyl chloride.

Claim 40

The composition of claim 33 wherein the binder material is polyvinyl fluoride.

Claim 41

The composition of claim 33 wherein the binder material is polyvinylidene chloride.

Claim 42

The composition of claim 33 wherein the binder material is polyvinyl acetate.

Claim 43

The composition of claim 33 wherein the binder material is polyvinyl proprionate.

Claim 44

The composition of claim 33 wherein the binder material is polyvinyl pyrrolidone.

Claim 45

The Composition of claim 33 wherein the binder material is a polysulfone.

Claim 46

The composition of claim 33 wherein the binder is a polycarbonate.

Claim 47

The composition of claim 33 wherein the binder material is polyethylene oxide.

Claim 48

The composition of claim 33 wherein the binder material is polymethylene oxide.

Claim 49

The composition of claim 33 wherein the binder material is polypropylene oxide.

Claim 50

The composition of claim 33 wherein the binder material is a polyarylate.

Claim 51

The composition of claim 33 wherein the binder material is polyethylene terephthalate.

Claim 52

The composition of claim 33 wherein the binder material is a polyimide.

Claim 53

The composition of claim 44 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 54

The composition of claim 3 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 55

The composition of claim 6 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 56

The composition of claim 8 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 57

The composition of claim 9 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 58

The composition of claim 10 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 59

The composition of claim 11 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 60

The composition of claim 13 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 61

The composition of claim 15 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 62

The composition of claim 16 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 63

The composition of claim 17 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 64

The composition of claim 19 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 65

The composition of claim 20 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 66

The composition of claim 21 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 67

The composition of claim 22 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 68

The composition of claim 23 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 69

The composition of claim 24 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 70

The composition of claim 25 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 71

The composition of claim 27 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 72

The composition of claim 28 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 73

The composition of claim 30 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 74

The composition of claim 31 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 75

The composition of claim 32 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 76

The composition of claim 8 wherein the binder material is polyethylene.

Claim 77

The composition of claim 8 wherein the binder material is polyethylene oxide.

Claim 78

A porous composite article comprising: a plurality of primary particles having relatively high softening temperatures, said particles having a diameter between 0.1 and 3000 micrometers; and a matrix of from 3 to 30% by weight of a thermoplastic binder material having a softening temperature substantially below the softening temperature of the primary particles, said matrix being formed from binder particles having a diameter of from about 0.1 to about 150 micrometers; wherein the primary particles are consolidated into a uniform matrix with melted and resolidified binder matrix present as forced point-bonds between the primary particles, wherein binder material is forced into macropores and exterior voids of individual primary particles to form physical connections between particles having such macropores and exterior voids.

Claim 79

A porous composite article comprising: a plurality of primary particles having relatively high softening temperatures, said particles having a diameter between 0.1 and 3000 micrometers; and a matrix of from 3 to 30% by weight of a thermoplastic binder material having a softening temperature substantially below the softening temperature of the primary particles, said matrix being formed from binder particles having a diameter of from about 0.1 to about 150 micrometers; wherein the primary particles are consolidated into a uniform matrix with melted and resolidified binder matrix present as forced point-bonds between the primary particles, wherein binder material is forced into macropores and exterior voids of individual primary particles to form physical connections between particles having such macropores and exterior voids.

Claim 80

The composition of claim 77 wherein the binder material is a resin that is resistant to conversion.

Claim 81

The composition of claim 77 wherein the binder material is a resin selected from the group consisting of acrylic and nylon resins.

Claim 82

A composite composition of claim 77 wherein the binder material is a noncrystalline or amorphous polymer.

Claim 83

The composition of claim 77 wherein the primary particles are granular or powdered carbon.

Claim 84

The material of claim 81 wherein the binder material is an ethylene polymer selected from the group consisting of polyethylene or an ethylene-vinyl acetate copolymer.

Claim 85

The material of claim 77 wherein the primary particles are stainless steel.

Claim 86

The material of claim 79 wherein the primary particles are stainless steel.

Claim 87

The material of claim 80 wherein the primary particles are stainless steel.

Claim 88

The composition of claim 1 wherein the binder material is an amorphous or non-crystalline polymer selected from the group consisting of polystyrenes, acrylonitrile-styrene copolymers, and styrene-butadiene copolymers.

Claim 89

A porous composite material comprising: a plurality of primary particles; and a webbing matrix of polytetrafluoroethylene supporting and enmeshing said primary particles and where such primary particles are consolidated into a uniform matrix with polytetrafluoroethylene webbing present within the pores remaining between the primary particles; said composite material produced according to a process comprising: providing a quantity of first particles of a polytetrafluorethylene binder material, said first particles having diameters between about 0.1 and 150 micrometers; providing from 3 to 30% by weight of second particles of a primary material having a softening temperature substantially greater than the softening temperature of said polytetrafluorethyleen binder material, said second particles having diameters between about 0.1 and about 3000 micrometers; combining the first and second quantities of particles in a substantially uniform mixture; heating said substantially uniform mixture, in the absence of pressure or shear sufficient to convert the polytetrafluoroethylene binder particles into a continuous phase through the composite material, to a temperature substantially above the softening temperature of said binder material but to a temperature less than the softening temperature of said primary material; thereafter applying pressure and shear to the heated mixture sufficient substantially immediately to convert at least a portion of the polytetrafluoroethylene binder material particles into a substantially continuous webbing structure through the composite material; and substantially immediately after formation of said continuous binder structure, rapidly cooling said mixture to below the softening point of the polytetrafluoroethylene binder material to retain said converted binder material in its continuous webbing structure condition to produce the composite material.

Claim 90

A porous composite material comprising: a plurality of primary particles; and a webbing matrix of polytetrafluoroethylene supporting and enmeshing said primary particles and where such primary particles are consolidated into a uniform matrix with polytetrafluoroethylene webbing present within the pores remaining between the primary particles; said composite material produced according to a process comprising: providing a quantity of first particles of a polytetrafluorethylene binder material, said first particles having diameters between about 0.1 and 150 micrometers; providing from 3 to 30% by weight of second particles of a primary material having a softening temperature substantially greater than the softening temperature of said polytetrafluorethyleen binder material, said second particles having diameters between about 0.1 and about 3000 micrometers; combining the first and second quantities of particles in a substantially uniform mixture; heating said substantially uniform mixture, in the absence of pressure or shear sufficient to convert the polytetrafluoroethylene binder particles into a continuous phase through the composite material, to a temperature substantially above the softening temperature of said binder material but to a temperature less than the softening temperature of said primary material; thereafter applying pressure and shear to the heated mixture sufficient substantially immediately to convert at least a portion of the polytetrafluoroethylene binder material particles into a substantially continuous webbing structure through the composite material; and substantially immediately after formation of said continuous binder structure, rapidly cooling said mixture to below the softening point of the polytetrafluoroethylene binder material to retain said converted binder material in its continuous webbing structure condition to produce the composite material.