WO2021244117A1 - Procédé de filage par soufflage de solution pour fabriquer une membrane composite à film mince - Google Patents

Procédé de filage par soufflage de solution pour fabriquer une membrane composite à film mince Download PDF

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Publication number
WO2021244117A1
WO2021244117A1 PCT/CN2021/084225 CN2021084225W WO2021244117A1 WO 2021244117 A1 WO2021244117 A1 WO 2021244117A1 CN 2021084225 W CN2021084225 W CN 2021084225W WO 2021244117 A1 WO2021244117 A1 WO 2021244117A1
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WIPO (PCT)
Prior art keywords
approximately
solution
thin film
delivering
film composite
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PCT/CN2021/084225
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English (en)
Inventor
Len Foong KOONG
Siyue Li
Zihao CHEN
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Nano And Advanced Materials Institute Limited
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Publication of WO2021244117A1 publication Critical patent/WO2021244117A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0002—Organic membrane manufacture
    • B01D67/0009—Organic membrane manufacture by phase separation, sol-gel transition, evaporation or solvent quenching
    • B01D67/0013—Casting processes
    • B01D67/00135—Air gap characteristics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0079—Manufacture of membranes comprising organic and inorganic components
    • B01D67/00793—Dispersing a component, e.g. as particles or powder, in another component
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B01D69/107—Organic support material
    • B01D69/1071—Woven, non-woven or net mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/12—Composite membranes; Ultra-thin membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/12—Composite membranes; Ultra-thin membranes
    • B01D69/125—In situ manufacturing by polymerisation, polycondensation, cross-linking or chemical reaction
    • B01D69/1251—In situ manufacturing by polymerisation, polycondensation, cross-linking or chemical reaction by interfacial polymerisation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/56—Polyamides, e.g. polyester-amides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2323/00—Details relating to membrane preparation
    • B01D2323/10—Specific pressure applied
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2323/00—Details relating to membrane preparation
    • B01D2323/26—Spraying processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2323/00—Details relating to membrane preparation
    • B01D2323/42—Details of membrane preparation apparatus

Definitions

  • the present invention relates to a solution blow spinning method to fabricate the thin film composite membrane through interfacial polymerization, and the thin film prepared thereby.
  • Thin-film composite membrane is a kind of semi-permeable membrane used for water purification, water filtration, water treatment or water desalination systems.
  • Most of these conventional thin-film composite membranes contain three layers: (1) an active surface layer (2) a porous layer (3) a support layer which are configured to exhibit properties of high filtration rate and mechanical strength.
  • the active surface layer is usually made of polyamide which is responsible for the permeability of the water and impermeability of those dissolved impurities, salt ions, and other unfilterable particles.
  • the porous layer which supports the active surface layer is usually made of polyethersulfone and polysulfone.
  • the polyester support layer would provide mechanical stability to the whole membrane structure.
  • the active surface layer of the membrane is further modified such as deposition of the nanoparticles or additives to enhance the hydrophilicity and filtration efficiency.
  • the conventional deposition method such as solution casting method requires excess solution to remove the reactants; otherwise, the remaining residues would form a thicker active surface layer with tiny or closed pores decreasing the filtration efficiency of the membrane.
  • the conventional method has major limitations in mass production and industrialization due to more reactants, higher power consumption and cost. Therefore, there is a need to provide a thin film composite membrane that is not only with high filtration efficiency but also prepared by a scalable and cost-effective method.
  • this disclosure provides a solution blow spinning method to perform interfacial polymerization to fabricate the thin film composite membrane.
  • one aspect of the present invention provides a method for fabricating thin film composite membrane, which includes (1) placing a microporous support on a collector having a rotational speed at approximately 10 rpm to 200 rpm; (2) spraying a first solution onto a surface of the microporous support distal to the collector comprising delivering the first solution through an inner nozzle and simultaneously or prior to said delivering the first solution, delivering a first pressurized gas through an outer nozzle; (3) spraying a second solution onto the surface of the microporous support distal to the collector comprising delivering the second solution through the inner nozzle and simultaneously or prior to said delivering the second solution, delivering a second pressurized gas through the outer nozzle so as to initiate an interfacial polymerization with the first solution to form a thin layer; (4) drying the thin layer at approximately 80°C to 90°C for approximately 0.5 min to 5 mins to form the thin film composite membrane; and the working distance of the collector and the at least one inner or outer nozzle is approximately 10 cm to 100 cm
  • the first solution comprises nanoparticles selected from graphene oxide, zinc oxide, titanium dioxide or any combination thereof.
  • the concentration of the nanoparticles is approximately from 0.01%to 0.1%by weight of the first solution.
  • the first solution further comprises a polyamine monomer selected from metaphenylenediamine (MPD) , triaminobenzene, m-phenylene diamine, p-phenylene diamine, 1, 3, 5-diaminobenzoic acid, 2, 4-diaminotoluene, 2, 4-diaminoanisole, xylylene-diamine, ethylenediamine, propylenediamine, piperazine, diethylenetriamine (DETA) , triethylenetetramine (TETA) , tetraethylenepentamine and tris (2-diaminoethyl) amine.
  • MPD metaphenylenediamine
  • TTA triethylenetetramine
  • the polyamine monomer is in a concentration approximately from 0.1%to 10%by weight of the first solution.
  • the present method further comprises adding additives selected from chitosan, crystalline nanocellulose or any combination thereof into the first or second solution prior to said spraying.
  • the additives are added into the first solution prior to said spraying.
  • the pressure of the first pressurized gas is approximately from 0.2 bar to 2 bar.
  • the second solution comprises a polyfunctional acid halide monomer selected from trimesoyl chloride (TMC) trimellitic acid chloride, isophthaloyl chloride, terephthaloyl chloride, and a hydrolyzed TMC species.
  • TMC trimesoyl chloride
  • the polyfunctional acid halide monomer is in a concentration approximately from 0.05%to 1%by weight of the second solution.
  • the pressure of the second pressurized gas is approximately from 0.5 bar to 2 bar.
  • the resulting thin film composite membrane has a pore size of approximately 5 nm to 50 nm
  • the thin layer has a thickness of approximately 50 nm to 500 nm.
  • the microporous support further comprises one or more nanofiber membranes and one or more reinforcing layers, the nanofiber membranes being positioned on the reinforcing layer.
  • the nanofiber membranes are selected from spinning nanofiber membrane, solution blow spinning nanofiber membrane, or phase inverse membrane, or any combination thereof.
  • the nanofiber membranes have a pore size of approximately 0.1 ⁇ m to 5 ⁇ m
  • the nanofiber membranes have a thickness of approximately 10 ⁇ m to 100 ⁇ m
  • the reinforcing layers are selected from PE membrane, PET membrane or any combination thereof, having a thickness of approximately 100 ⁇ m to 200 ⁇ m.
  • a thin film composite membrane prepared by the method of the present invention having a water contact angle of approximately 15° to 60° is also provided.
  • a thin film composite membrane prepared by the method of the present invention having a flux of approximately 10 LMH to 100 LMH is also provided.
  • a reverse osmosis, nanofiltration or ultrafiltration membrane prepared by the method of the present invention is also provided.
  • FIG. 1 illustrates a thin film composite membrane including a thin layer, nanofiber membrane, and a reinforcing layer.
  • FIG. 2 shows the scanning electron microscope (SEM) image of the thin film composite membrane of one embodiment.
  • FIG. 3 shows the LMH and calcium ion rejection efficiency of the thin film composite membrane of one embodiment.
  • FIG. 4 shows the water contact angle (WCA) of the thin film composite membrane of one embodiment.
  • FIG. 5 illustrates the nanoparticle deposition via interfacial polymerization through solution blow spinning method.
  • step A is carried out first
  • step E is carried out last
  • steps B, C, and D can be carried out in any sequence between steps A and E, and that the sequence still falls within the literal scope of the claimed process.
  • a given step or sub-set of steps can also be repeated.
  • specified steps can be carried out concurrently unless explicit claim language recites that they be carried out separately.
  • a claimed step of doing X and a claimed step of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.
  • the present invention provides a thin film composite membrane and a preparation method thereof.
  • the thin film composite membrane comprises at least one thin layer 10, at least one nanofiber membranes 11, and at least one reinforcing layer 12 as shown in FIG. 1.
  • the thin layer with a thickness approximately 50 nm to 500 nm having a pore size of approximately 5 nm to 50 nm is formed by interfacial polymerization through solution blow spinning method adjacent to the nanofiber membrane (FIG. 2) .
  • the thin layer comprises one or more polyamine monomer and one or more polyfunctional acid halide monomer, wherein the polyamine monomer selected from, for example, but not limited to, metaphenylenediamine (MPD) , triaminobenzene, m-phenylene diamine, p-phenylene diamine, 1, 3, 5-diaminobenzoic acid, 2, 4-diaminotoluene, 2, 4-diaminoanisole, xylylene-diamine, ethylenediamine, propylenediamine, piperazine, diethylenetriamine (DETA) , triethylenetetramine (TETA) , tetraethylenepentamine and tris (2-diaminoethyl) amine and the polyfunctional acid halide monomer selected from, for example, but not limited to trimesoyl chloride (TMC) , trimellitic acid chloride, isophthaloyl chloride, terephthaloyl chloride,
  • MPC
  • the thin layer further comprises one or more additives selected from, for example, but not limited to, chitosan, crystalline nanocellulose so as to manipulate the interfacial polymerization through enhancing the reaction rate by removal of hydrochloric acid or diffusion of monomers to the interfacial layer.
  • the nanoparticles are also deposited in this layer during the process of interfacial polymerization so as to modify and enhance the performance of membrane filtration.
  • Those nanoparticles may include, for example, but not limited to, graphene oxide, zinc oxide, titanium dioxide or any combination thereof.
  • the thin layer serves as a filtration barrier to filter out contaminants of different sizes ranging from 0.5 nm to 2000 nm.
  • the contaminants may include non-oil based.
  • the contaminants may include inorganic salts, for example, but not limited to sulfates, nitrates, phosphates and chromates.
  • the contaminants may include bacteria, for example, but not limited to gram-positive bacterium, gram-negative bacterium.
  • the thin layer offers a high salt rejection rate of approximately 75%to 95%, and high flux with approximately 10 LMH (L/ (m 2 hour) ) to 100 LMH (FIG. 3) .
  • the present invention also provides a thin layer with high hydrophilicity with the water contact angle of approximately 15° to 60° (FIG. 4) .
  • the nanofiber membrane is positioned adjacent to the thin layer.
  • the nanofiber membrane with a thickness of approximately 10 ⁇ m to 100 ⁇ m and a pore size of approximately 0.1 ⁇ m to 5 ⁇ m are selected from spinning nanofiber membrane, solution blow spinning nanofiber membrane, or phase inverse membrane, or any combination thereof.
  • the nanofiber membrane, a porous interlayer not only offers mechanical strength to withstand high pressure compression during the filtration process but also provides a support to perform interfacial polymerization.
  • the nanofiber membrane comprises one or more polymers selected from, for example, not limited to polysulfone (PSU) , polyethersulfone (PES) , poly (ether sulfone) (PSF) , polyacrylonitrile (PAN) , polypropylene (PP) , polyvinylidene fluoride (PVDF) , polytetrafluoroethylene (PTFE) , polyimide (PI) , and poly (arylene ether nitrile ketone) (PPENK) .
  • PSU polysulfone
  • PES polyethersulfone
  • PSF poly (ether sulfone)
  • PAN polyacrylonitrile
  • PP polypropylene
  • PVDF polyvinylidene fluoride
  • PTFE polytetrafluoroethylene
  • PI polyimide
  • PPENK poly (arylene ether nitrile ketone)
  • the reinforcing layer is positioned adjacent to the nanofiber membrane.
  • the reinforcing layer having a thickness of approximately 100 ⁇ m to 200 ⁇ m are selected from, for example, but not limited to PE membrane, PET membrane or any combination thereof.
  • a method for fabricating thin film composite membrane which includes (1) placing a microporous support on a collector having a rotational speed at approximately 10 rpm to 200 rpm; (2) spraying a first solution onto a surface of the microporous support distal to the collector comprising delivering the first solution through an inner nozzle and simultaneously or prior to said delivering the first solution, delivering a first pressurized gas through an outer nozzle; (3) spraying a second solution onto the surface of the microporous support distal to the collector comprising delivering the second solution through the inner nozzle and simultaneously or prior to said delivering the second solution, delivering a second pressurized gas through the outer nozzle so as to initiate an interfacial polymerization with the first solution to form a thin layer; (4) drying the thin layer at approximately 80°C to 90°C for approximately 0.5 min to 5 mins to form the thin film composite membrane; and the working distance of the collector and the at least one inner or outer nozzle is approximately 10 cm to 100 cm
  • the first solution described hereinabove comprises one or more polyamide monomer, one or more nanoparticles, and one or more solvents.
  • the solvents include, for example, but not limited to water.
  • Table 1 shows the major components of the first solution described herein along with their corresponding weight percentage and exemplary materials for each of the components.
  • the first solution is delivered through a syringe pump to the inner nozzle and a pressurized gas with approximately from 0.2 bar to 2 bar is passed through the outer nozzle simultaneously to from a spray with a spray speed approximately from 1 to 5 mL/min on the collector having a rotational speed at approximately 10 rpm to 200 rpm, and the working distance of the collector and the inner or outer nozzle is approximately 10 cm to 100 cm.
  • it is also provided an air suction to assist the deposition.
  • the second solution described hereinabove comprises one or more polyfunctional acid halide monomer, one or more additives, and one or more solvent.
  • the solvents include, for example, but not limited to hexane, cyclohexane. benzene, toluene, hexadecane, diethyl ether, pentane or ethyl acetate.
  • Table 2 shows the major components of the second solution described herein along with their corresponding weight percentage and exemplary materials for each of the components.
  • the second solution is also delivered through a syringe pump to the inner nozzle and a pressurized gas with approximately from 0.5 bar to 2 bar is passed through the outer nozzle simultaneously to from a spray with a spray speed approximately from 1 to 5 mL/min on the collector having a rotational speed at approximately 10 rpm to 200 rpm, and the working distance of the collector and the inner or outer nozzle is approximately 10 cm to 100 cm.
  • the second solution would initiate the interfacial polymerization with the first solution to form the thin layer having a thickness of approximately 50 nm to 500 nm adjacent to the nanofiber membrane.
  • a thin film composite membrane contains a polyamide semi permeable layer synthesized on top of a microporous support via interfacial polymerization reaction.
  • the interfacial polymerization takes place where monomers from the immiscible aqueous and organic solvents meet and react at the interface.
  • the aqueous layer is introduced onto the microporous layer before the organic layer for the reaction to take place.
  • the amine group from the diamine monomers in the aqueous phase reacts with acyl chloride group from the acyl chloride in the organic phase at the interface forming crosslinks into an ultra-thin polyamide layer.
  • Examples of the combination of diamine and acyl chloride monomers are piperazine dissolved in water and trimesoyl chloride dissolved in hexane or m-phenylenediamine dissolved in water and trimesoyl chloride dissolved in hexane.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Dispersion Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'une membrane composite à film mince comprenant les étapes consistant à : placer un support microporeux sur un collecteur; pulvériser une première solution sur une surface du support microporeux distale par rapport au collecteur comprenant la distribution de la première solution à travers une buse interne et simultanément ou avant ladite distribution de la première solution, distribuer un premier gaz sous pression à travers une buse externe; pulvériser une seconde solution sur la surface du support microporeux distale par rapport au collecteur comprenant la distribution de la seconde solution à travers la buse interne et simultanément ou avant ladite distribution de la seconde solution, distribuer un second gaz sous pression à travers la buse externe de façon à initier une polymérisation interfaciale avec la première solution pour former une couche mince; sécher la couche mince à environ 80 °C à 90 °C pendant environ 0,5 min à 5 min pour former la membrane composite à film mince. L'invention concerne également la membrane obtenue.
PCT/CN2021/084225 2020-06-01 2021-03-31 Procédé de filage par soufflage de solution pour fabriquer une membrane composite à film mince WO2021244117A1 (fr)

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US63/032,754 2020-06-01

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115487686A (zh) * 2022-09-01 2022-12-20 成都博睿兴材科技有限公司 一种多功能电纺纤维复合膜及其制备方法与应用

Citations (6)

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Publication number Priority date Publication date Assignee Title
US20140199483A1 (en) * 2013-01-14 2014-07-17 Dow Global Technologies Llc Composite polyamide membrane including tri-hydrocarbyl phosphate
CN107519769A (zh) * 2017-10-13 2017-12-29 北京工业大学 一种微相扩散控制界面聚合制备超薄膜的方法
WO2018205251A1 (fr) * 2017-05-12 2018-11-15 Honeywell International Inc. Membrane d'osmose inverse perméable à flux élevé et son procédé de fabrication
US20190282967A1 (en) * 2018-02-07 2019-09-19 Zhejiang University Semipermeable membrane and preparation method thereof
CN110359298A (zh) * 2019-07-10 2019-10-22 浙江海印数码科技有限公司 一种低盐化的活性染料的制备方法及其在喷墨印花用墨水中的应用
CN110960987A (zh) * 2019-12-11 2020-04-07 恩泰环保科技（常州）有限公司 一种高性能纳米杂化反渗透膜及其制备方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140199483A1 (en) * 2013-01-14 2014-07-17 Dow Global Technologies Llc Composite polyamide membrane including tri-hydrocarbyl phosphate
WO2018205251A1 (fr) * 2017-05-12 2018-11-15 Honeywell International Inc. Membrane d'osmose inverse perméable à flux élevé et son procédé de fabrication
CN107519769A (zh) * 2017-10-13 2017-12-29 北京工业大学 一种微相扩散控制界面聚合制备超薄膜的方法
US20190282967A1 (en) * 2018-02-07 2019-09-19 Zhejiang University Semipermeable membrane and preparation method thereof
CN110359298A (zh) * 2019-07-10 2019-10-22 浙江海印数码科技有限公司 一种低盐化的活性染料的制备方法及其在喷墨印花用墨水中的应用
CN110960987A (zh) * 2019-12-11 2020-04-07 恩泰环保科技（常州）有限公司 一种高性能纳米杂化反渗透膜及其制备方法

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115487686A (zh) * 2022-09-01 2022-12-20 成都博睿兴材科技有限公司 一种多功能电纺纤维复合膜及其制备方法与应用
CN115487686B (zh) * 2022-09-01 2023-08-29 成都博睿兴材科技有限公司 一种多功能电纺纤维复合膜及其制备方法与应用

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