US 7,361,300 B2
Method of making extended area filter
William R. Kelly, Prospect, Conn. (US); and Larry Moore, Hamden, Conn. (US)
Assigned to MOTT Corporation, Farmington, Conn. (US)
Filed on Aug. 12, 2003, as Appl. No. 10/639,367.
Prior Publication US 2005/0035052 A1, Feb. 17, 2005
Int. Cl. B22F 7/06 (2006.01)
U.S. Cl. 419—2  [419/6] 34 Claims
OG exemplary drawing
 
1. 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; and
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.