Abstract: An improved method for forming a vehicle trim panel, such as a headliner, utilizes a zig zag path to deposit fibrous pieces onto a fibrous layer to form part of the trim panel. In one method, the fibrous pieces are laid down in a zig zag pattern that does not extend across the entire lateral width of the layer. In this way, the designer can easily achieve selected areas having a greater amount of fibrous pieces. This allows the designer to achieve selected high density or thicker portions in the layer without requiring the entire layer to have the same amount of fibrous pieces. This results in greater control over the design of the layer, and also reduces the amount of fiber which must be utilized to form the layer.

Abstract: A method of producing a mineral fibre element comprising a mineral fibre base layer having a surface coating in the form of a fibrous netting formed of a thermoplastic polymer material wherein such a surface coating is provided on at least a part of the surface of the base layer, wherein the surface coating is formed directly on the surface of the base layer and wherein the surface coating is formed by heating a thermoplastic polymer material so as to melt it and distributing the polymer melt obtained in the form of fibres and/or filaments on the surface of the base layer and cooling it to form a solid layer.

Abstract: A composite panel includes fibres adhered together by means of an adhesive binder to form a sheet having opposed planar faces and fibre reinforcement ribs imbedded in the sheet.

Abstract: A method, apparatus and filter unit product wherein filter media fibers are fed from a media supply source to a mat forming interchangeable and movable contoured surface to contour shape a filter media mat into a preselected form for subsequent movement to a transfer zone for further contour shaping and processing into filter unit products with preselected frame arrangements.

Abstract: A method of making a headliner assembly includes providing a porous member having first and second sides. A negative pressure is developed on the second side of the porous member, and particulate material is selectively deposited proximate the first side of the porous member to form a particulate layer having an outline that corresponds with a desired outline of the headliner assembly. The particulate material is drawn toward the first side of the porous member by the negative pressure developed on the second side of the porous member. The particulate layer is then thermoformed to form the headliner assembly.

Abstract: A system for producing three dimensional components by bonding together successive layers of a porous material with droplets of a binder material. A binder printhead has an array of nozzles which controllably supply jets of binder material droplets to the layers of porous material. The printhead is scanned in a raster scan fashion over each layer of porous material along a first scan axis in one direction to provide first fast scanning paths of droplets. The printhead is then moved laterally of such one direction and is then moved along the fast-scan axis in the opposite direction to provide second fast scanning paths of droplets which are interlaced with the first scanning paths. The supply of the droplets to the porous material can be controlled so as to control the overlapping thereof to produce various desired surface and interior characteristics of the components.

Abstract: A wood board of sufficient strength which demonstrates high dimensional stability and little warping can be obtained, while the production process therefor is simplified and may be carried out in less time and at a lower cost as compared to conventional methods by means of a method for producing a wood board comprising the steps of shaving lumber to produce wooden strands; applying a binder to the wooden strands; subjecting the binder coated wooden strands to a forming process to form a preformed material 1; and carrying out a steam injection pressing in which the preformed material 1 is subjected to thermal compression molding while being moisturized so as to obtain a molded material having a water content of 5 to 15%; as well as by means of a method for producing a wood board, comprising the steps of shaving lumber to produce wooden strands; applying a binder to the wooden strands after adjusting the water content of the wooden strands to 10 to 25%, or, alternatively, adding water when applying the binder t

Abstract: Methods for the continuous manufacture of board from lignocellulose-containing material are disclosed including disintegrating the lignocellulose material into particles or fibers, drying, coating with glue, forming the glued board into a mat, heating the mat with steam, compressing the heated mat to a predetermined thickness approximately equal to the final desired thickness of the board, and pressing the compressed mat into the board.

Abstract: A method for making shaped articles at room ambient temperatures without the addition of extraneous heat comprising the sequential steps:(1) forming a plurality of particles comprising a foamed admixture of starch, biodegradable polymer and water;(2) at room ambient temperature, applying to the surface of the particles finely divided drops of unheated water to effect wetting and softening of the outer surfaces of the particles;(3) without the addition of heat, compressing the surfaces of the surface softened particles to effect cohesion between the wetted outer surfaces of the particles, densification of the particles and formation of a shaped article; and(4) without the addition of heat, maintaining the particles under such compression for a time sufficient to render the outer surface of the particles nontacky by adsorption of water into the particles and by evaporation of water from the surface of the particles and(5) forming a protective skin on the outer surface of the compressed, non-tacky particles by h

Abstract: A polishing pad having a substantially uniform, continuously interconnected porous surface. The pad can be produced by pressure sintering powder compacts of thermoplastic polymer at a temperature above the glass transition temperature but not exceeding the melting point of the polymer. The sintering process is conducted in a mold at a pressure in excess of 100 psi (0.07 MPa). In a preferred version, a mixture of two polymer powders is used, where one polymer has a lower melting point than the other.

Abstract: A method for producing a patterned shaped article includes the steps of disposing on a base surface a retainer having a plurality of particle-retaining spaces; filling the spaces with pre-filling particles having a particle size of not more than 600 .mu.m and easy to remove; removing the pre-filling particles from part of the spaces to form at least one empty space; filling the at least one empty space with shaped article-forming particles; repeating the step of removing the pre-filling particles and the step of filling the shaped article-forming particles until the shaped particle-forming particles are substituted for all the pre-filling particles, the shaped article-forming particles including at least two kinds of particles; removing the retainer to form a pattern course on the base surface; and allowing the pattern course to set into an integral mass.

Abstract: A method of producing a sintered body (1) having different cross-sections along a main axis (5), in particular a toothed-belt or chain wheel, by compression moulding a sintering powder in the direction of the main axis (5) and subsequent sintering. At least two partial bodies (6, 7), which can be form-fitted into each other in the direction of the main axis (5), are pressed from sintering powder, which partial bodies each form an axial portion of the sintered body (1) with different cross-sections, and that the separately pressed and possibly presintered partial bodies (6, 7) are jointly sintered after joining them together.

Abstract: A packaging material comprising a plurality of flexible strips of material intertwined with and bondably connected to one another so as to form a cohesive cushioning unit and method for forming same is provided. The strips of material have a bonding material disposed thereon for bondingly connecting the strips of material to one another and enabling the strips of material to be bondingly connected to a container and an article.

Abstract: A process and installation for the continuous production of boards of wood-based material, includes the steps of forming on a continuously moving scattering belt, a pressed material mat includes an initial mixture of chips and/or fibers from a scattering station and mixed with binder; precompacting and preheating the pressed material mat between the scattering station and a main pressing region; and bringing into an end form and curing the pressed material with the application of pressure and heat in a main pressing regions. The moisture level of the pressed material mat is less on entry into the main pressing region than the moisture level of the initial mixture in the scattering of the pressed material mat, part of the moisture imparted to it in the scattering being extracted again by hot-air preheating.

Abstract: A method for producing a laminated object repeats a depositing step and an irradiating step alternatively. The irriating step comprises the operations of: covering a deposited layer with a mask having a pattern configuration for penetrating the laser beam; and scanning the lader beam on the desposited layer covered with the mask in such a manner that the laser beam depicts an irradiated continous wave trace being wider than the pattern configuration of the mask, by moving the laser beam in the Y-direction with a Y-rotating mirror, while repeating oscillations of the laser beam in the X-direction with a X-rotating nirror, The laminated object may be a casting mold.

Abstract: An absorbent core for use in an absorbent article for absorbing discharged bodily fluid comprises a first absorbent material dispersed throughout the core, and a second absorbent material provided in a discrete strip, and substantially surrounded by the first absorbent material. An apparatus and method for producing such cores comprises a mold support advanceable in a predetermined direction and having at least one mold therein, and a tubular conduit for the second material alignably positioned such that a portion of the conduit will pass through at least a portion of the mold as the mold support is advanced. The mold support may comprise a forming drum or a forming belt. The tubular conduit has a distal end through which the second absorbent material may be expelled.

Abstract: A decorative construction material such as a glass tile is produced from recycled glass granulate, and exhibits a smooth, external surface substantially free from defects on one side of the tile. One or two layer tiles may be produced. A binder, together with control of the maximum temperature and temperature gradient in the layers, if applicable, is used during manufacture to ensure a substantially flawless outer surface.

Abstract: A method for making a resilient cushion includes providing a particulate polymer, discrete pieces of foam and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.

Abstract: In a rapid prototyping system, a part is formed by depositing a bead of slurry that has a sufficient high concentration of particles to be pseudoplastic and almost no organic binders. After deposition the bead is heated to drive off sufficient liquid to cause the bead to become dilatant.

Abstract: Fibrous structures containing immobilized particulate matter and processes for making them are disclosed. These structures may be used for filters and for fabrics including chemical defense garments and others. The fibrous structures have webs containing composite fibers having a lower melting component and a higher melting component. The particles are distributed into the interior of the web and fused to the low melting component of the individual fibers without substantially reducing the available surface area of the particle. A fibrous structure of a composite staple having a nylon sheath and a polyester core, with activated carbon particles bonded to the sheath is specifically disclosed. The processes for producing such a fibrous structure include carding a web of staple fibers and distributing particulate matter therein, air laying a web of staple fibers and particulate from a suspension thereof between two wet formed layers of staple fibers.

Abstract: A composite friction assembly is disclosed which comprises at least one friction member and a support member. Each of the friction member and the support member have a composition comprising a thermosettable resin and a filler material. The friction member and the support member each have a planar surface, with the respective planar surfaces being joined at their interface, so as to define a boundary layer. The composition of each member is substantially confined to separate sides of the boundary layer whereby the composition of the friction member does not substantially penetrate beyond the boundary layer into the composition for the support member and the composition for the support member does not substantially penetrate beyond the boundary layer into the composition for the friction member. Among the disclosed embodiments of the present invention is a brake pad, such as that used in vehicular brakes. The present invention further relates to a method of making such a composite friction assembly.

Abstract: Flexible graphite sheet is made by compressing a mixture of fine particle of intercalated, exfoliated, expanded natural graphite with fine particles of intercalated, unexpanded, expandable particles of natural graphite, the unexpanded particles being more finely sized than the expanded particles. The resulting sheet of flexible graphite exhibits improved fire retardant and sealability properties.

Abstract: The device according to the invention is used for conducting a fluid between a space at least partly bounded by a solid surface through which a fluid can flow and a duct, a high surface continuity of the fluid flow through the surface being achieved with a relatively small differential pressure. The device comprises a coarsely porous shaped part (3), which has on the surface areas through which a flow is to take place a finely porous surface layer (4). The pores of the surface layer (4) are open at the surface and progress continuously into the shaped part (3). The shaped part (3) and surface layer (4) together form a one-piece part of a cured plastic, in that in the vicinity of the shaped part are incorporated larger particles and in the vicinity of the surface layer (4) smaller particles, e.g. aluminium particles, in such a way that the particles represent a larger proportion of the weight than the plastic.

Abstract: An apparatus and method for uniform granulation is disclosed. The method involves the use of an initial feedstock having particle size of -150 mesh and 90% or greater particle size of 200 mesh. The feedstock may be contacted in a pan granulator which includes a minor amount of nucleating material of about -35 mesh. Binder is introduced into the pan granulator to progressively layer the feedstock material onto the nucleating to form a final product having a size distribution -8 mesh to +4 mesh. The method is designed to be interruptible and is particularly useful for forming granules having a plurality of layers of differing material. The method has marked improvement over the prior art methods since a particularly fine granule can be formed in a relatively expedient process to result in a granule having high commercial value and high break strength. These factors are achievable in addition to 100% product usage with no waste.

Abstract: Flexible graphite sheet is made by compressing a mixture of fine particle of intercalated, exfoliated, expanded natural graphite with fine particles of intercalated, unexpanded, expandable particles of natural graphite, the unexpanded particles being more finely sized than the expanded particles. The resulting sheet of flexible graphite exhibits improved fire retardant and sealability properties.

Abstract: A method and apparatus for forming a laminated object using a laser-discharging means a laser beam, a material capable of forming a solid layer by receiving the laser beam, and a mask for interrupting the laser beam. The method includes the steps of: forming a layer of the material on a surface, covering the material with the mask, and discharging the laser beam onto the material covered with the mask to solidify the material and form the solid layer on the surface. The above cycle is repeated to produce a laminated object. The method and the apparatus are characterized in the adjusting at least one of a distance from the laser-discharging means to the mask and a distance from the mask to the material, so that the extent of the laser beam is adjusted and the dimension of the laminated object is adjusted.

Abstract: A method, die apparatus and product wherein a layered web of melt blown fibrous filter media is produced by a unitary die including several die sources with facing layers of the fibrous filter media being attenuated by opposed fluid streams at preselected included angles and with the fiber layers being free from bonding together and with the fibers in each layer being minimally bonded.

Abstract: The invention relates to a process for manufacturing an article of a high-density carbon. To produce an un-fired compact, binderless, self-sintering, fine-grained carbon powder, particularly carbon mesophases, with a powder density of more than 1 g/cm.sup.3, particularly more than 1.4 m/cm.sup.3, and an average grain size of between 5 and 20 .mu.m, is precompacted at a low pressure and is pressed in a mold to at a pressure of between 50 and 150 MPa, particularly at approximately 100 MPa. After pressing, the contact pressure is slowly lowered. Then, the un-fired compact is carbonized in a temperature gradient of maximally 20 K/min. The temperature is held constant at a holding temperature of between 500 and 700.degree. C. for a defined holding time and is subsequently raised to a maximal temperature of between 800 and 1,200.degree. C., particularly approximately 1,000.degree. C. Finally, the carbonized compact is graphitized at an end temperature of between 2,500-3,000.degree. C.

Abstract: A process for the production of compacted bodies of powdered medicament is disclosed, the process comprising the steps of:a) positioning expansible means along the longitudinal axis of the mold;b) placing loose powdered medicament in the mold; andc) expanding the expansible means perpendicularly to the longitudinal axis of the mold. An apparatus for use in the process according to the invention and medicament compacts formed by the process are also disclosed.

Abstract: A rapid prototyping method utilizing a powder sintering process and an apparatus for fabricating a product, utilizing the method. The rapid prototyping method includes steps of slicing an image of a product to be fabricated into a number of layers, preparing a mold sheet for each of the slices of the product with a cavity adapted to the profile of the corresponding slice, laying the mold sheet in place on a one-on-the-other basis, feeding the cavity of the mold sheet with a powdery material, pressurizing the material, repeating the preceding steps for each slide to form a multilayer structure for a complete product, and sintering the multilayer structure to produce a finished product. The rapid prototyping method according to the invention provides major advantages over comparable known methods in terms of cost, processing time, and profiling accuracy.

Abstract: A water soluble dicarboxylic acid or an alkali metal salt thereof acts as a mold release agent for salt pellets when a salt-contacting surface of a roll-type briquetting press is coated with from about 0.02 to about 5 mg/cm.sup.2 of a powder of the acid or alkali metal salt just prior to a charge of salt. The coating is achieved by spraying an air stream entraining the powder onto the press rolls or by spraying a solution of the release agent onto the rolls and evaporating the solvent to leave the powder on the rolls. The acid has from 6 to 10 carbon atoms; adipic acid being preferred. Salt pellets having a layer of the powder on their surface may be used in water softening systems wherein the pellets sit in a brine reservoir and supply salt for the recharging of an ion exchange resin. There is no formation of an unsightly scum on the surface of the brine and on the sides of the reservoir.

Abstract: A laminated composite structure of alternating metal powder layers, and layers formed of an inorganic bonding media powder, and a method for manufacturing same are discosed. The method includes the steps of assembling in a cavity alternating layers of a metal powder and an inorganic bonding media of a ceramic, glass, and glass-ceramic. Heat, with or without pressure, is applied to the alternating layers until the particles of the metal powder are sintered together and bonded into the laminated composite structure by the layers of sintered inorganic bonding media to form a strong composite structure. The method finds particular application in the manufacture of high performance magnets wherein the metal powder is a magnetic alloy powder.

Abstract: A structural panel, board, or beam and method of making same, with straw that is oriented is provided. The straw is preferably oriented such that strands are parallel oriented in one or more directions. The straw strands are chopped, split, and a binder such as MDI is added.

Abstract: A process for the manufacture of porous structures comprises forming a dry mixture comprising a component providing primary separation capability, a component providing green strength reinforcement capability and, a component providing binding capability and selected from the group consisting of thermoplastic and thermosetting polymers; delivering the mixture to a suitable surface and building a desired thickness thereof; densifying the mixture into tile form desired for the porous structure; removing the densified porous structure from the surface; binding the component providing the primary separation capability by melting the mixture to a temperature of up to about 20.degree. C. higher than the melting point of any thermoplastic component providing binding capability.

Abstract: A method of constructing multi-layer products for absorbing fluids is disclosed. In the methods of the present invention, two or more layers of materials chosen to vary in recovery are compressed such that an absorption gradient forms through the continuous intimately associated layers. A first layer preferably remains densified while a second layer "blooms" to form an open, absorptive layer, which acts as a reservoir, drawing absorbed fluids into the densified layer, where they are retained.

Abstract: A method of making glass-silicate tiles includes pouring an input raw material containing glass granulate into a heat-proof mold, wetting the input raw material and making an initial blank thereby, heat treating of the blank by gradual heating and by gradual cooling by stages with holding period between the stages wherein a first heating stage is performed predominantly by heating a bottom side of the blank with higher speed of heating of a lowering layer than of an upper layer of the blank to accelerate gases to release the blank through the upper layer up to reach of the temperature of beginning of glass granulate sintering (T.sub.f) in the lower layer, and the temperature not exceeding a glass granulate transformation temperature (T.sub.g) in the upper layer, a first holding period at these condition to expel generated gases, and heating the upper layer with higher speed than the lower layer until a Littleton temperature is reached in the lower layer.

Abstract: In a method for the continuous production of a running mat (6) of stocked particles (2) of different dimensions by the use of a conveyor spreading method, for the production of wood material boards or similar boards by subsequent pressing of the mat, for the solution of the problem of having a well-defined supporting plane for the spread material independently of the rotary speed of the spreading rolls, it is proposed that, during the conveyor spreading action (11), at first holdouts be formed deliberately and continuously over the entire spreading width and the entire spreading length of the conveyor spreading mechanism, out of which individual spreading is done for the continuous formation of the advancing mat (6); at the same time an apparatus is proposed for the practice of the method for the performance of the already-named tasks.

Abstract: A pressurized feed shoe for delivering particulate materials to fill a die cavity is provided. The feed shoe includes a feed shoe body comprising a vessel for receiving a quantity of particulate material. The feed shoe body has at least one bottom egress opening for registering with the die cavity and a top ingress opening for receiving particulate material. A pressure generator for generating supra-atmospheric pressures within the vessel and the die cavity is also provided. The pressure generator communicates with the vessel via a conduit sealingly engaged thereto. A shuttle selectively moves the feed shoe body to and from a position whereby the bottom egress opening registers with the die cavity.

Abstract: An arrangement for fibre-laying on a moving air-permeable conveyor path (2) fibre bodies which are comprised of at least two different layers. The arrangement includes for each fibre layer a succession of air-laying units disposed sequentially in the direction of movement of the conveyor path, wherein each of the units includes elements (6, 7) for passing a stream of air-borne fibres to a region above the moving conveyor path (2), elements (3, 4) for generating a subpressure beneath the air-permeable conveyor path in the proximity of the region in which the stream of air-borne fibres is delivered, and elements (6, 7) for shielding the stream of air-borne fibres from ambient air.

Abstract: Method and apparatus of forming an air laid paper web. Superabsorbing powder is introduced at an intermediate stage between the initial supply of the fibers to the air laying unit and the final formation of the web. A first coarse distribution of the powder is effected in a compulsory manner, independently of the initial supply of fiber material while the final distribution of powder is effected by means of the same air flows which cause the final distribution of the fiber material for forming the even web layer. In this manner the powder is effectively mixed evenly into the fiber material.

Abstract: A foamed aqueous dispersion of a mixture of particulate plastics material is formed when the fibers are between 5% and 35% of the volume of the mixture, where no more than about 7% of the volume of the mixture is conductive fibers between about 7 and 20 mm long, and where any other fibers are reinforcing fibers with a high modulus of elasticity and between about 7 and about 50 mm long. A web is formed from the foamed dispersion using a wet laying process. The web is dried and compacted under heat and pressure. The compacted web is cooled to form a consolidated element in which the conductive fibers extend as a conductive lattice. The resulting element can be formed or molded into shielding to provide attenuation of electrical or magnetic fields.

Abstract: Fiber reinforced composite products of enhanced interlaminar ply strength and processes of producing same. In forming the products, layers of fibrous reinforcing material and resinous matrix material are established. The matrix material contains unset resin and short fibers of an average particle length of 0.2-0.6 mm in a weight ratio of short fibers to resin in the range of 0.4-1. The reinforcing material comprises fibers of a length substantially greater than the length of the short fibers in the matrix material. The fiber and matrix layers are integrated in order to cause the resin and short fibers which comprise the strengthened matrix material to enter into the interstitial spaces of the longer fiber reinforcing material. Thereafter, the matrix resin is solidified in order to arrive at the fiber reinforced composite product.

Abstract: A method of processing refuse wherein layers of resin-coated pulverized refuse are cross-blended, compressed, heated, recompressed, shaped and cured to form useful structural members.

Abstract: A process is described for the manufacture of tannin-bonded particle- and fiberboard wherein the binding of wood chips and fibers is accomplished by obtaining the formaldehyde necessary for the cross-linking of tannin by the hydrolytic decomposition of the binder present in old particle- or fiberboard. The formaldehyde obtained by hydrolytic decomposition is cross-linked with the tannin by high temperature and moisture during pressing.

Abstract: A high density fiber product is made from natural lignin containing plant fibers. Plant fibers ranging in size below about 3000 microns in diameter are used. Binding agents and other additives may be mixed with the fibers to enhance product or process performance. The plant fibers or mixture of fibers and additives are heated to between about 50 degrees C. to about 140 degrees C. The heated fibers are compressed in a mold to an average density of about 50 pounds per cubic foot to about 100 pounds per cubic foot. Compression pressures of about 500 psi to about 2500 psi are used to achieve product densities within this range. The compressed fibers are cured under these temperature and pressure conditions. After the curing time has elapsed, the compressed fiber product is released from the mold and the mold may be reused. A high density product made from small plant fibers is provided.

Abstract: As a paper-made stampable sheet having a high rigidity and, if necessary, improved adhesiveness and non-permeability and a light weight stampable sheet shaped body made from this sheet and a method of producing the same, there are proposed a paper-made stampable sheet obtained by paper-making a mixture of thermoplastic resin and reinforcing fibers to obtain a sheet-like web, piling a thermoplastic resin film of a single layer or multi layer or an organic fiber nonwoven fabric having at least one excellent property selected from rigidity, non-permeability and adhesiveness on at least one-side surface of the sheet-like web in accordance with use purpose, compressing them under heating above a melting point of the thermoplastic resin constituting the web, cooling and solidifying at a compressed state as well as a light weight stampable sheet shaped body made from this sheet and a method of producing the same.

Abstract: The present invention is directed to a method of forming a heteroconstituent nonwoven web including a mixture of different filament types simultaneously formed into the same web. The filament types may differ as to polymer composition, additive loadings, fiber size, fiber shape, and/or degree of crimping. The invention is also directed to a method of forming a multilayered nonwoven structure in which different filament types constituting different layers are simultaneously formed.

Abstract: A method for forming a tool such as a mold includes the steps of initially selecting a cooling channel configuration for the mold. The initial selected cooling channel is evaluated utilizing a computer program. The program analyzes whether there would be local hot or cool spots in the mold with the initially selected channel. The channel is then modified based upon this evaluation. The modified channel is again subjected to the evaluation. This iterative process continues until an acceptable cooling channel configuration is achieved. The invention utilizes a generally helical cooling channel.

Abstract: A woody group material and cement are combined to form a construction material. The material has an aggregate of finely split pieces formed by splitting wood, bamboo or the like in a fiber direction. The split pieces are formed in one or more layers and are surrounded by, and buried in, a mortar. A construction material can be provided which is fire resistant and has a strength comparable to a lumbered product such as wood material obtained by cutting raw wood. The finely split pieces of wood, bamboo or the like are very strong and tough because they closely adhere to the mortar. Moreover, it is possible to use a fiber structure of raw material. Since the finely split pieces can use a small diameter wood, lumbering byproducts, and other waste material, it is possible to achieve effective use of forest resources and low manufacturing costs.

Abstract: An integrated filter and sleeve assembly has an annular non-porous sleeve having opposing open ends and an outer circumferential wall with an inner surface. The integrated filter and sleeve assembly also has a filtration block disposed within the annular sleeve between the open ends. The filtration block includes a mixture of filtration media and a binder. A seal is formed between the inner surface and the filtration block by applying heat to the annular non-porous sleeve and the filtration block.