Virus-Removal Composite Membrane With Porous Bonding Region
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Solution Overview
Problem
Existing virus-removal filter membranes with double-layer structures face challenges such as complex processes, reduced membrane flux due to dense layer formation at interfaces, and compromised service life, making them less adaptable to diverse applications.
Innovation Solution
A virus-removal composite membrane with a bonding region formed by a second polymer permeating into the porous substrate layer, ensuring connectivity and avoiding dense layer formation, using polymers with different solubility parameters and controlled thickness and pore sizes to enhance flux and bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double-layer structure is used with an ultrafiltration cortex on a polyethersulfone filter membrane, then virus retention is improved, but membrane flux is reduced due to dense layer formation at the interface
Solution Approach 1:
The patent employs a microporous polyvinylidene fluoride substrate layer with controlled pore structure to maintain porosity while providing mechanical support. The bonding region incorporates porous structures that prevent dense layer formation, ensuring both virus retention through the ultrafiltration cortex and adequate flux through the microporous substrate.
Solution Approach 2:
The patent creates a composite membrane structure combining polyvinylidene fluoride microporous substrate with polyethersulfone ultrafiltration cortex. The bonding region uses a gradient pore structure that transitions from the microporous substrate to the dense ultrafiltration layer, maintaining material compatibility while preventing harmful dense layer formation at the interface.
2Reliability
If a double-layer structure is used to improve virus removal, then separation efficiency is improved, but the preparation process becomes more complex
Solution Approach 1:
The patent prepares the microporous polyvinylidene fluoride substrate layer in advance with controlled pore parameters before forming the ultrafiltration cortex. This preliminary preparation of the substrate with optimized pore structure simplifies the subsequent coating process and ensures consistent bonding without requiring complex multi-step procedures.
Solution Approach 2:
The patent optimizes specific parameters including the pore size (0.03-0.1 μm), porosity (30-60%), and thickness (10-50 μm) of the microporous substrate layer to achieve the desired balance between mechanical strength, flux, and bonding efficiency, thereby simplifying the overall preparation process while maintaining high separation efficiency.
3Stability of the object's composition
If the ultrafiltration cortex is cast on a prefabricated microporous membrane, then a transition region with continuous pores is formed, but a dense layer structure forms at the interface reducing flux
Solution Approach 1:
The patent applies different pore structure characteristics to different regions: the microporous substrate layer has larger pores (0.03-0.1 μm) for mechanical support and flux, while the ultrafiltration cortex has a finer pore structure for virus retention. The bonding region transitions locally from microporous to ultrafiltration structure, maintaining continuous porosity while preventing harmful dense layer formation through controlled local composition gradients.
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 membrane achieves improved flux, mechanical strength, and virus retention efficiency while maintaining high protein yield, simplifying the preparation process and enhancing adaptability to various filtration scenarios.
Implementation Method 1
the second polymer permeates from a surface of the porous substrate layer into a pore structure of the porous substrate layer to form a bonding region
Implementation Method 2
a bonding region is formed in a porous substrate layer... ensuring connectivity and avoiding dense layer formation
Data Source
AI summary
Disclosed are a virus-removal composite membrane and a preparation method thereof. A virus-removal composite membrane comprises a main body, wherein the main body comprises: a porous substrate layer including a liquid inlet surface and a separation layer including a liquid outlet surface, the porous substrate layer is a microporous membrane layer formed by a first polymer, the separation layer is formed by a second polymer, and the first polymer and the second polymer are different polymer materials; in a region of the porous substrate layer close to one side of the separation layer, the second polymer permeates from a surface of the porous substrate layer into a pore structure of the porous substrate layer to form a bonding region, and pores formed by the second polymer in the bonding region are connected to pores of the separation layer.