Porous Polymer Membranes with Controlled Pore Size
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Solution Overview
Problem
Current filtration membranes face challenges in achieving precise and uniform pore size, desired surface functionalization, and reduced solvent consumption during manufacturing, while also needing to be applicable on various supports.
Innovation Solution
A porous material composed of polymer particles assembled by a block copolymer, where the block copolymer includes immiscible and miscible polymer sequences, is used to create a network of particles with controlled size distribution, stabilized by a block copolymer, allowing for the formation of membranes with specific mechanical and chemical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If PVDF is intimately mixed with block copolymer to increase hydrophilic nature, then water resistance is improved, but manufacturing precision of pore size deteriorates
Solution Approach 1:
The membrane is segmented into distinct components: PVDF particles (30-1000 nm diameter) and block copolymer molecules. The block copolymer itself is segmented into hydrophobic blocks (interacting with PVDF) and hydrophilic blocks (facing pores). This segmentation allows each component to perform its specific function without compromising the other, achieving both hydrophilicity and pore size precision.
Solution Approach 2:
Different regions of the membrane have different properties: the bulk contains PVDF particles for mechanical strength and chemical resistance, while the pore surfaces are functionalized with hydrophilic block copolymer segments. This local quality differentiation enables the membrane to simultaneously achieve structural integrity, controlled porosity, and enhanced water resistance.
2Ease of manufacture
If conventional membrane manufacturing is used, then production is simplified, but solvent consumption increases
Solution Approach 1:
The invention changes the physical parameters of the starting materials by using pre-synthesized PVDF particle latex and block copolymer. This allows the membrane formation process to proceed with reduced solvent requirements compared to conventional approaches that require dissolving bulk polymers and then controlling phase separation.
3Manufacturing precision
If membrane material is designed for specific applications, then filtration performance is improved, but adaptability to various supports deteriorates
Solution Approach 1:
The block copolymer serves multiple functions: it functionalizes pore surfaces for hydrophilicity, provides adhesion between PVDF particles, and can interact with various support substrates. This multi-functionality allows the same membrane material to be adapted to different supports (microfiltration membranes, woven fabrics, non-wovens) while maintaining consistent filtration performance.
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 approach enables the production of membranes with precise and uniform pore sizes, reduced solvent usage, and the ability to be applied on diverse substrates, resulting in mechanically and chemically stable active layers with tailored water permeability and selectivity for filtration applications.
Implementation Method 1
the block copolymer comprising at least one block constituted by a polymer sequence immiscible with the polymer P, and at least two blocks constituted by polymer sequences miscible with the polymer P
Implementation Method 2
The solvent used to suspend the mixture (polymer P + block copolymer) (according to the first embodiment described), or to precipitate the mixture (polymer P + block copolymer) (according to the second embodiment described) must to be able to: dissolve the block copolymer, for the first case, to produce the swelling of the polymer P and/or its dissolution
Implementation Method 3
precipitating the mixture of a solution of polymer P and the block copolymer in water, in the presence of a solvent, leading to obtaining a latex
Implementation Method 4
mixing the suspension of polymer particles P and the block copolymer, in the presence of a solvent; drying of this mixture
Data Source
AI summary
The invention relates to a porous material comprising particles of polymer P assembled by a block copolymer, said block copolymer comprising at least one block consisting of a polymer sequence immiscible with polymer P, and at least two blocks consisting of polymer sequences which are miscible with polymer P. The invention also relates to films produced with this material.