Method of making a water filter

DETAILED DESCRIPTION In the present invention, a satisfactory degree of filtration without undue inhibition of water flow is achieved by providing a cylindrical filter having an inner bonded 80 to 400 U.
S.
Mesh screen carbon particle shell, most preferably 80 to 325 U.
S.
mesh screen, and an outer shell of bonded 20 to 80 U.
S.
mesh screen and preferably 20 to 60 U.
S.
mesh screen carbon particles, which is also bonded to the inner charcoal shell so as to create an integral package.
This filter is made in accordance with a unique process whereby a separator sleeve is placed into a filter mold, a mixture of the smaller carbon particles and binder is placed on the inside of the separator sleeve and a mixture of the larger charcoal particles and binder is placed on the outside of the separator sleeve.
The separator sleeve is then removed and the mass is sintered and pressed to create a unitary carbon filter having two different particle size, integrally bonded layers.
In another aspect of the invention, the carbon particles are bonded together by means of a very low melt index polymer, which becomes tacky without becoming sufficiently liquid to substantially wet the carbon particle surface.
Deleterious diminution of the effective carbon surface area is minimized.
Further, this unique polymer binder, not heretofore suggested for use as such, facilitates binding layered masses of carbon particles, e.
g.
a two layer system, in that heating sufficiently to tackify and bond the innermost layer of particles can be achieved without wetting thoroughly the outer layer of particles.
These and other objects, advantages and features of the present invention will be more fully understood and appreciated by reference to the written specification and appended drawings.