Self-Assembly Polymer Membrane Without Drying-Induced Porosity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing high-density polymer membranes, such as solution casting and non-solvent induced phase separation, face challenges like lengthy processing times, energy-intensive drying processes, and the formation of cloudy, uneven porous structures.
Innovation Solution
A method involving the preparation of a polymer solution with an ionized polymer and an organic solvent with a boiling point of 150°C or higher, followed by coating the solution on a substrate and immersing it in a non-solvent without drying, to form a non-porous, dense, and transparent polymer membrane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solution casting is used to produce dense polymer membranes, then membrane density and transparency are improved, but processing time and energy consumption increase due to lengthy drying processes
Solution Approach 1:
The patent changes the solvent boiling point parameter to above 150°C, which fundamentally alters the drying kinetics. This high boiling point allows the solvent to evaporate more gradually and completely, forming a dense membrane structure without requiring excessively long drying times or high vacuum conditions, thus resolving the contradiction between membrane density and processing time
Solution Approach 2:
The patent performs preliminary optimization of the polymer-solvent system selection before the drying process. By carefully selecting solvents with appropriate high boiling points and optimizing the polymer concentration in the solution, the membrane forms a dense structure more efficiently during drying, reducing the overall processing time while maintaining high density
2Manufacturing precision
If high-boiling solvents are used in solution casting, then membrane density is improved, but energy consumption increases due to multi-stage high-temperature vacuum treatment
Solution Approach 1:
The patent optimizes the drying temperature parameter by using solvents with boiling points above 150°C, which allows the drying process to proceed at more moderate temperatures compared to using lower boiling point solvents that would require higher temperatures and vacuum conditions to achieve complete solvent removal and dense membrane formation, thus reducing energy consumption
Solution Approach 2:
The patent replaces the need for high-vacuum mechanical systems with a simplified drying approach. By selecting solvents with appropriate high boiling points, the membrane can be dried under atmospheric or mild vacuum conditions without requiring complex multi-stage high-vacuum equipment, significantly reducing energy consumption while maintaining membrane density
3Loss of time
If non-solvent induced phase separation is used, then processing time is reduced, but membrane quality deteriorates due to phase separation and cloudiness
Solution Approach 1:
The patent changes the fundamental parameter of solvent boiling point to above 150°C, which prevents phase separation during the drying process. The high boiling point ensures that the solvent remains in the liquid phase longer during drying, maintaining polymer-solvent interaction and preventing premature phase separation, thus achieving both rapid processing and high membrane transparency without cloudiness
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
This method saves time and energy by eliminating the drying process, prevents phase separation and cloudiness, and produces membranes with properties similar to those obtained through conventional solution casting, resulting in efficient and high-quality polymer membranes.
Implementation Method 1
unlike solution casting (SC), time and energy are saved by not going through a drying process after polymer solution coating
Implementation Method 2
when the polymer solution was immersed in a non-solvent, phase separation occurred, forming an asymmetric porous membrane, and causing the membrane become cloudy
Data Source
AI summary
An embodiment relates to a method for producing a self-assembly polymer membrane by non-solvent induced film formation (NIFF), the method including: (a) preparing a polymer solution by mixing an ionized polymer with an organic solvent, (b) preparing a substrate on which a polymer solution coating layer is formed by coating the polymer solution on a substrate and (c) forming an ionized polymer membrane by immersing the substrate on which the polymer solution coating layer is formed in a non-solvent without going through a drying process under elevated temperature conditions. Accordingly, it is possible to produce a nonporous, dense polymer membrane in an efficient way that saves time and energy.