Porous Polyethersulfone Film Structure for Stable Macrovoid Formation
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Solution Overview
Problem
Conventional techniques have not successfully produced a porous polyethersulfone film with macrovoids while maintaining excellent dimensional stability.
Innovation Solution
A porous polyethersulfone film with a three-layer structure, comprising surface layers and a macrovoid layer sandwiched between them, where the macrovoid layer has partition walls bonded to the surface layers, and macrovoids with an average pore diameter of 10 μm to 500 μm, along with a method involving casting a polyethersulfone solution and heat treatment to coarsen vacancies, resulting in a film with high porosity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional techniques are used to produce porous polyethersulfone film, then dimensional stability is maintained, but macrovoids cannot be formed
Solution Approach 1:
The patent changes the chemical composition parameters by introducing a tri-functional crosslinking agent (isocyanate group-containing compound) that reacts with hydroxyl groups of polyethersulfone. This crosslinking reaction creates a three-dimensional network structure that maintains dimensional stability while simultaneously enabling macrovoid formation through controlled phase separation during foam expansion.
Solution Approach 2:
The patent creates a composite structure by combining polyethersulfone with a crosslinking agent and blowing agent. The crosslinked polyethersulfone matrix provides dimensional stability, while the trapped blowing agent creates macrovoids, resulting in a composite material that exhibits both properties simultaneously.
2Productivity
If porosity is increased to improve material permeability, then permeability improves, but mechanical strength decreases
Solution Approach 1:
The patent intentionally creates a porous structure with macrovoids (50-90% porosity) to enhance material permeability for liquid and gas flow. The controlled pore structure allows high productivity while the crosslinked matrix maintains structural integrity.
Solution Approach 2:
The crosslinking degree and pore size distribution are optimized to achieve the right balance. By controlling the crosslinking agent amount and blowing agent type, the patent achieves high permeability while the crosslinked network prevents excessive strength loss that would normally occur with high porosity.
3Productivity
If pore diameter is increased to improve flow rate, then material permeability improves, but separation precision deteriorates
Solution Approach 1:
The patent creates a segmented pore structure with macrovoids serving as large transport channels for high flow rate, while the crosslinked matrix provides a fine network structure that maintains separation precision. This segmentation allows different pore sizes to perform different functions within the same membrane.
Solution Approach 2:
Different regions of the membrane have different pore characteristics. The macrovoids provide large pores for high flow rate in specific channels, while the surrounding crosslinked matrix provides fine pore structure for separation precision, creating local quality variations that satisfy both requirements simultaneously.
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 film exhibits excellent dimensional stability, high porosity, and improved material permeability, suitable for applications such as liquid filtering membranes, gas separation membranes, and cell culture sheets.
Implementation Method 1
a porous structure having macrovoids has never been achieved in the case of polyethersulfone films... a specific porous structure... obtained by a specific method
Implementation Method 2
a specific porous structure having macrovoids has never been achieved in the case of polyethersulfone films... obtained by a specific method
Data Source
AI summary
Provided are: a porous polyether sulfone film having macrovoids and having excellent dimensional stability; and a production method therefor. Provided is a porous polyether sulfone film having a surface layer (a), a surface layer (b), and a macrovoid layer interposed between the surface layer (a) and the surface layer (b). The macrovoid layer has a partition wall joined to the surface layers (a) and (b) and a plurality of macrovoids surrounded by the partition wall and the surface layers (a) and (b). The surface layer (a) and the surface layer (b) have pores connected to the macrovoids.