Composite porous materials and methods of making and using the same
View Patent ↗The invention provides composite porous materials in which a second material is fused to and/or is in the pores and/or is fused directly to some of the pore walls of a porous first material. The invention also provides methods of filtering a fluid using these composite porous materials and methods of manufacturing the composite porous materials.
1. A composite porous material comprising:
a substrate comprising a sintered porous first polymeric material having a first average pore size;
a membrane comprising a precipitated porous second polymeric material having a second average pore size smaller than the first average pore size;
wherein at least a portion of the membrane is fused to the substrate by at least one direct physical bond, the second polymeric material is in at least some of the pores of the first polymeric material, and the first polymeric material and the second polymeric material are soluble in a common solvent.
2. The composite porous material of claim 1 , wherein
the first polymeric material comprises polyvinylidene fluoride, polysulfone, polyethersulfone, polyamide, polyether imide, polyacrylonitrile, polyester, polyvinyl chloride, or polyetheretherketone, and the second polymeric material comprises polyvinylidene fluoride, polysulfone, polyethersulfone, polyamide, polyether imide, polyacrylonitrile, polyester, polyvinyl chloride, or polyetheretherketone.
3. The composite material of claim 2 , wherein the first polymeric material comprises polysulfone and the second polymeric material comprises polyethersulfone.
4. The composite material of claim 2 , wherein the first polymeric material comprises polyethersulfone and the second polymeric material comprises polyethersulfone.
5. The composite material of claim 2 , wherein the first polymeric material comprises polyethersulfone and the second polymeric material comprises polysulfone.
6. The composite material of claim 2 , wherein the first polymeric material comprises polyvinylidene fluoride and the second polymeric material comprises polyethersulfone.
7. The composite material of claim 2 , wherein the first polymeric material comprises polyamide and the second polymeric material comprises polyamide.
8. The composite material of claim 2 , wherein the first polymeric material comprises polyamide and the second polymeric material comprises polyvinylidene fluoride.
9. The composite material of claim 2 , wherein the first polymeric material comprises polyvinylidene fluoride and the second polymeric material comprises polyamide.
10. The composite material of claim 2 , wherein the first polymeric material comprises polyvinylidene fluoride and the second polymeric material comprises polysulfone.
11. The composite material of claim 2 , wherein the first polymeric material comprises polysulfone and the second polymeric material comprises polyvinylidene fluoride.
12. The composite material of claim 2 , wherein the first polymeric material comprises polysulfone and the second polymeric material comprises polyamide.
13. The composite material of claim 2 , wherein the first polymeric material comprises polyether imide and the second polymeric material comprises polyether imide.
14. The composite material of claim 2 , wherein the first polymeric material comprises polyether imide and the second polymeric material comprises polyvinylidene fluoride.
15. The composite material of claim 2 , wherein the first polymeric material comprises polyether imide and the second polymeric material comprises polyethersulfone.
16. The composite material of claim 2 , wherein the first polymeric material comprises polyether imide and the second polymeric material comprises polysulfone.
17. The composite material of claim 2 , wherein the first polymeric material comprises polyether imide and the second polymeric material comprises polyamide.
18. The composite material of claim 2 , wherein the first polymeric material comprises polyvinylidene fluoride and the second polymeric material comprises polyether imide.
19. The composite material of claim 2 , wherein the first polymeric material comprises polysulfone and the second polymeric material comprises polyether imide.
20. The composite material of claim 2 , wherein the first polymeric material comprises polyethersulfone and the second polymeric material comprises polyether imide.
21. The composite material of claim 2 , wherein the first polymeric material comprises polyamide and the second polymeric material comprises polyether imide.
22. The composite material of claim 2 , wherein the first polymeric material comprises polyvinylidene fluoride and the second polymeric material comprises polyvinylidene fluoride.
23. The composite porous material of claim 1 , wherein the first polymeric material is a sheet, tube, or other molded shape.
24. The composite porous material of claim 1 , wherein the first polymeric material has a thickness greater than about 250 μm.
25. The composite porous material of claim 1 , wherein the second polymeric material has a thickness less than about 125 μm.
26. The composite porous material of claim 1 , wherein the first polymeric material comprises sintered underwater pelletized particles.
27. The composite porous material of claim 1 , wherein the first polymeric material comprises sintered cryogenically ground particles.
28. The composite material of claim 1 , wherein the second polymeric material is in greater than about 1% of the pores of the first polymeric material.
29. The composite porous material of claim 1 , wherein the first average pore size ranges from about 1 μm to about 200 μm.
30. The composite porous material of claim 1 , wherein the second average pore size ranges from about 0.2 nm to about 10 μm.
31. The composite material of claim 1 , wherein the second polymeric material has a thickness less than or equal to the first polymeric material.
32. The composite material of claim 1 , wherein at least a portion of the membrane is fused to the first polymeric material by a plurality of direct physical bonds.
33. A composite porous material comprising:
a substrate comprising a sintered porous first polymeric material having a first average pore size;
a membrane comprising a precipitated porous second polymeric material having a second average pore size smaller than the first average pore size;
wherein at least a portion of the membrane is fused to the substrate by at least one direct physical bond, the second polymeric material is in at least some of the pores of the first polymeric material, and the first polymeric material comprises polyvinylidene fluoride, polysulfone, polyethersulfone, polyamide, polyether imide, polyacrylonitrile, polyester, polyvinyl chloride, or polyetheretherketone, and the second polymeric material comprises polyvinylidene fluoride, polysulfone, polyethersulfone, polyamide, polyether imide, polyacrylonitrile, polyester, polyvinyl chloride, or polyetheretherketone.
34. A composite porous material comprising:
a substrate comprising a sintered porous first polymeric material having a first average pore size;
a membrane comprising a precipitated porous second polymeric material having a second average pore size smaller than the first average pore size;
wherein at least a portion of the membrane is fused to the substrate by at least one direct physical bond, the second polymeric material is in at least some of the pores of the first polymeric material, and the first polymeric material comprises polyvinylidene fluoride, polysulfone, polyethersulfone, polyamide, polyether imide, polyacrylonitrile, polyester, polyvinyl chloride, or polyetheretherketone, the second polymeric material comprises polyvinylidene fluoride, polysulfone, polyethersulfone, polyamide, polyether imide, polyacrylonitrile, polyester, polyvinyl chloride, or polyetheretherketone, and the first polymeric material and the second polymeric material are soluble in a common solvent.