Patent ID: 8658039

Claim:
A method for manufacturing a porous composite particulate material, comprising: providing a plurality of acid-base-resistant core particles and a plurality of acid-base-resistant shell particles; applying at least one polymer material/shell particle bilayer comprising: coating at least a portion of the plurality of acid-base-resistant core particles, at least a portion of the plurality of acid-base-resistant shell particles, or combinations thereof with polymer material; adhering a portion of the plurality of acid-base-resistant shell particles to each of the plurality of acid-base-resistant core particles with the polymer material to form a plurality of composite particles, wherein at least a portion of the plurality of acid-base-resistant core particles comprises at least one member selected from the group consisting of diamond, graphitic carbon, glassy carbon, silicon carbide, boron nitride, tungsten carbide, niobium carbide, zirconia, noble metals, acid-base-stable highly cross-linked polymers, titania, alumina, and thoria; and applying sonic energy to the core particles during application of the at least one polymer material/shell particle bilayer to narrow a particle size distribution of the resulting composite particulate material than otherwise would be produced absent application of the sonic energy.