3m Innovative Properties Company

Eric C Pemberton

Mark R Stouffer

Mark A Stouffer

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.

Composite blocks with void spaces

A filter medium comprises: a) 55 to 80 percent by weight of activated carbon particles having a Dof 70 to 130 micrometers and a Dof 25 to 50 micrometers; b) 5 to 20 percent by weight of first catalytic activated carbon particles having a D50 in a range of 20 to 40 micrometers and a Dof 2 to 20 micrometers; and c) 10 to 30 percent by weight of a thermoplastic binder that binds at least the activated carbon particles and the catalytic activated carbon particles into a porous unitary body, wherein the percent by weight of components a)-c) is based upon a total weight of components a)-c). A water filtration system including the filter medium is also disclosed.

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Southington, CT, United States of America

Eric C Pemberton