Isoporous Block Copolymer Membranes with Transition Layer
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Solution Overview
Problem
Existing mesoporous isoporous block copolymer materials often contain macrovoids, which lead to mechanical weakness and defects, and lack a transition layer, resulting in high protein adsorption and poor integration with porous supports.
Innovation Solution
Development of isoporous mesoporous block copolymer asymmetric materials with a transition layer and macrovoids, produced through a method involving dissolving diblock or multiblock copolymers in solvent-nonsolvent solutions, followed by evaporation and nonsolvent exposure to create a structure with low macrovoid density near the skin, enhancing mechanical integrity and integration with porous supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If macrovoids are present in mesoporous isoporous block copolymer materials, then high flux is enabled through the asymmetric structure, but mechanical weakness and defects occur
Solution Approach 1:
The patent applies local quality by creating different pore structures in different regions of the membrane. The asymmetric structure has macrovoids in certain regions to enable high flux, while the transition layer and controlled macrovoid density in other regions maintain mechanical strength. The skin layer maintains mesoporous isoporous structure for separation functionality while the support layer contains the asymmetric macrovoid structure for flux enhancement without compromising overall mechanical integrity.
Solution Approach 2:
The patent creates a composite material structure combining mesoporous isoporous skin layer with asymmetric macrovoid-containing support layer. This composite structure integrates the benefits of both configurations: the skin layer provides high-resolution separation through its uniform mesoporous structure, while the support layer provides high flux through its asymmetric macrovoid structure, achieving both high flux and maintained mechanical strength.
2Reliability
If a transition layer is added to reduce macrovoid density near the skin, then mechanical integrity and integration with porous supports are improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the membrane into distinct functional layers: a skin layer for separation and a support layer for mechanical strength and flux. The transition layer is positioned between these segments to gradually connect their different structures. This segmentation allows each layer to be optimized independently while the transition layer provides smooth structural connection, reducing overall complexity compared to attempting to create a uniformly complex structure throughout.
Solution Approach 2:
The transition layer acts as an intermediary between the skin layer and support layer, providing a gradual structural transition. This intermediary layer reduces the abrupt interface between the mesoporous skin and the asymmetric macrovoid-containing support, improving mechanical integrity and integration with porous supports while avoiding the need for complex interfacial structures.
3Ease of manufacture
If conventional solvent systems (DMF/THF) are used, then well-known manufacturing procedures are available, but macrovoids are formed that cause mechanical weakness
Solution Approach 1:
The patent modifies the solvent system parameters by replacing conventional DMF/THF mixtures with alternative solvent combinations such as dioxane/acetone or dioxane/tetrahydrofuran. These parameter changes in the solvent composition lead to different phase separation behaviors during membrane formation, enabling the creation of asymmetric structures with controlled macrovoid distributions that maintain mechanical strength while preserving ease of manufacture through simple casting and evaporation procedures.
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 materials exhibit remarkably low protein adsorption and effective integration with porous supports, reducing mechanical weaknesses and defects, while using fewer polymer materials for large-scale synthesis.
Implementation Method 1
dissolving diblock or multiblock copolymers in solvent-nonsolvent solutions
Implementation Method 2
followed by evaporation and nonsolvent exposure
Implementation Method 3
exposure to a nonsolvent causing precipitation of at least a portion of the dissolved polymer
Implementation Method 4
self-assembled diblock copolymer membranes
Data Source
AI summary
A mesoporous isoporous asymmetric material includes at least one diblock or multiblock copolymer, wherein the material has a transition layer having a thickness of at least 300 nm and a low macrovoid density, and the material has a sub-structure adjacent to said transition layer and said sub-structure comprises a high macrovoid density. A method for producing mesoporous isoporous asymmetric materials having macrovoids can include: dissolving at least one diblock or multiblock copolymer in a solution, the solution having one or more solvents and one or more nonsolvents, to form a polymer solution; dispensing the polymer solution onto a substrate or mold, or through a die or template; removing at least a portion of solvent and/or nonsolvent from the polymer solution to form a concentrated polymer solution; and exposing the concentrated polymer solution to a nonsolvent causing precipitation of at least a portion of the polymer from the concentrated polymer solution.