Multilayer Sorbent Membrane Continuous Coextrusion
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Solution Overview
Problem
Existing multilayer sorbent polymeric membranes face challenges with poor productivity and performance due to complex manufacturing processes, low strength, and residual solvents, which affect the sorbability and porosity of sorbent materials.
Innovation Solution
A continuous single-step method for producing multilayer sorbent polymeric membranes through coextrusion of layer-forming compositions containing sorbent materials and a diluent, followed by cooling and diluent extraction, resulting in a membrane with high sorbability, porosity, and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a discrete multistep process is used to manufacture multilayer sorbent polymeric membranes, then adhesion between layers can be improved through surface treatment and adhesives, but productivity decreases and the interface is altered or contaminated
Solution Approach 1:
The patent combines multiple discrete manufacturing steps into a single continuous extrusion process. The multilayer membrane is formed by coextruding multiple polymer streams with sorbent materials in one continuous operation, eliminating the need for separate lamination, surface treatment, and adhesive application steps. This integration maintains layer adhesion through direct polymer bonding while dramatically improving manufacturing productivity.
Solution Approach 2:
The patent incorporates sorbent materials and functional additives into the polymer matrix during the extrusion process itself, before the membrane is formed. This preliminary incorporation ensures uniform distribution of sorbent particles throughout the membrane structure and eliminates subsequent processing steps that would alter or contaminate the interface between layers.
2Reliability
If multiple components and processes are involved in manufacturing filled membranes, then functional performance can be enhanced, but productivity decreases due to process complexity
Solution Approach 1:
The patent integrates multiple functional components (polymer matrix, sorbent materials, porous formers, and additives) into a single continuous extrusion process. All components are fed simultaneously through separate hoppers and mixed in the extruder, then formed into the final multilayer membrane structure in one operation. This maintains complex functional performance while eliminating sequential processing steps that reduce productivity.
3Ease of manufacture
If residual solvents are retained in processed membranes, then manufacturing complexity is reduced, but sorbability and porosity of sorbent materials decrease
Solution Approach 1:
The patent uses a porous former material (such as salt particles or porous beads) as a temporary substitute for solvent-based porogen. This porous former is incorporated into the polymer matrix during extrusion, then extracted in situ through a simple wash or extraction step, leaving behind a porous structure that maintains sorbent material accessibility. This approach eliminates residual solvents that would otherwise block sorbent pores while keeping the manufacturing process simple.
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 method enhances productivity and performance by maintaining initial sorbability and porosity of sorbent materials, achieving superior sorption kinetics, permselectivity, and mechanical strength with minimal pressure drop, while eliminating residual solvents.
Implementation Method 1
cooling the multilayer coextrudate on a cast roll to form a multilayer film
Implementation Method 2
extracting the diluent from the multilayer film with an extractant
Data Source
AI summary
Provided is a novel continuous single-step method of manufacturing a multilayer sorbent polymeric membrane having superior productivity, properties and performance. At least one layer of the polymeric membrane comprises sorbent materials and a plurality of interconnecting pores. The method includes: (a) coextruding layer-forming compositions to form a multilayer coextrudate; (b) casting the coextrudate into a film; (c) extracting the film with an extractant; and (d) removing the extractant from the extracted film to form the multilayer sorbent polymeric membrane. The sorbent membrane of this disclosure can find a wide range of applications for use in filtration, separation and purification of gases and fluids, CO2 and volatile capture, structural support, vehicle emission control, energy harvesting and storage, device, protection, permeation, packaging, printing, and etc.