Solvent-Free Polymer Membrane Manufacturing Via Aqueous Particle Extraction
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Solution Overview
Problem
Existing methods for manufacturing polymer membranes are disadvantageous due to the use of solvents, stretching processes, and limitations in scalability and versatility, particularly for large-area membranes.
Innovation Solution
A solvent-free manufacturing process for porous polymer membranes involving the steps of forming shaped articles with a polymer matrix and particles, converting them into a non-porous film, and removing the particles using an aqueous composition to create a porous membrane, without stretching or phase separation, allowing for continuous production of large-area membranes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solvent removal is used to manufacture membranes, then porosity is achieved, but environmental harm and process complexity increase
Solution Approach 1:
The invention extracts the harmful solvent from the manufacturing process entirely. Instead of using solvents to create pores and then removing them, the process uses a solvent-free extrusion method where pores are formed directly during the extrusion process through the interaction of immiscible polymer phases, eliminating environmental harm while achieving the desired porosity
Solution Approach 2:
The invention replaces the chemical solvent removal process with a mechanical extrusion process. The porous structure is created mechanically during extrusion through phase separation of immiscible polymers, substituting the need for chemical solvents and their subsequent removal with a purely mechanical forming process
2Manufacturing precision
If stretching process is used to create porous structure, then porosity is achieved, but process complexity and manufacturing time increase
Solution Approach 1:
The invention performs the pore-forming action during the extrusion process itself rather than as a subsequent step. The immiscible polymer phases separate and form porous structures while the material is being extruded, integrating the pore-formation action into the primary manufacturing process and eliminating the need for separate stretching operations
Solution Approach 2:
The invention merges the extrusion process with the pore-formation process. By using immiscible polymer phases that separate during extrusion, the manufacturing of the membrane and the creation of the porous structure occur simultaneously in a single integrated process step, reducing overall process complexity
3Reliability
If organic solvents are used for plasticizer removal, then membrane properties are improved, but production cost and environmental impact increase
Solution Approach 1:
The invention extracts organic solvents from the manufacturing process entirely. The desired membrane properties are achieved through the careful selection and formulation of immiscible polymer phases that naturally separate to create the required porous structure, eliminating the need for expensive and environmentally harmful organic solvent treatments
Solution Approach 2:
The invention changes the fundamental parameters of the system by using immiscible polymer phases instead of polymer-plasticizer-solvent systems. This parameter change allows pore formation through phase separation of polymers with different densities or compatibilities, achieving reliable membrane properties without requiring organic solvent interventions
4Manufacturing precision
If medical implant process is transferred to large-scale production, then porosity is achieved, but scalability is limited
Solution Approach 1:
The invention creates a universal extrusion process that can produce porous membranes at any scale. The same immiscible polymer phase extrusion technique that works for medical implants can be scaled up continuously for large-area membrane production, making the process universally applicable from small to large scales without fundamental changes
Solution Approach 2:
The invention implements continuous extrusion processing that maintains the pore-forming mechanism throughout the entire production run. The immiscible polymer phases continuously separate and form porous structures as the material moves through the extrusion and cooling process, enabling uninterrupted large-scale production while maintaining consistent porosity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process is versatile, reliable, and cost-effective, enabling the production of large-area membranes with high porosity and permeability, suitable for applications in breathable textiles and other advanced materials.
Implementation Method 1
removing said particles (4) from said film (2) by contacting said film with an aqueous composition (6)
Data Source
AI summary
The invention relates to the manufacturing of porous polymer membranes by (a) providing pellets comprising a polymer matrix and particles in the ratio 90:10 to 10:90, (b) converting said pellets into a non-porous film by a solvent-free process; (c) removing said particles from said film with an aqueous composition to thereby obtain said membrane. The invention further relates to pellets useful in such manufacturing process as well as porous polymer membranes obtainable or obtained by such manufacturing process as well as textile materials and articles containing such membranes; to the use of such pellets, membranes, and articles.