IP Library Granted Patent US 8,602,223
Granted Patent B2
US 8,602,223 · App. 12/743,089 · Granted Dec 10, 2013

High performance membrane

Inventors: Jun Qiu (Weert, NL); Rudy Rulkens (Margraten, NL); Johannes L. M. OP Den Kamp (Beek, NL); Jens C Thies (Eijsden, NL)
Assignee: DSM IP Assets B.V.
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Quick Facts
Patent No.
US 8,602,223
App. No.
12/743,089
Granted
Dec 10, 2013
Kind
B2
Abstract

The invention relates to a micro-porous membrane comprising a porous membrane carrier made of a first polymeric material (A) and comprising a second polymeric material (B) intimately divided throughout the porous membrane carrier, wherein the porous membrane carrier comprises a plurality of interconnected polymeric fibers, fibrils, filaments and/or lamellae having a thickness of less than 1 μm, the porous membrane carrier has an interconnected open porous structure formed by the plurality of interconnected polymeric fibers, fibrils, filaments and/or lamellae and a porosity of at least 50%; and the polymeric material (B) comprises a thermoplastic polycondensation polymer and is present in an amount of at most 30 wt. %, relative to the total weight of (A) and (B). The invention also relates to a process for preparing such a micro-porous membrane comprising steps wherein (i) a porous membrane carrier made of a first polymeric material (A) is impregnated with a polymer solution comprising a second polymeric material (B) in a solvent system (X), and (ii) the resulting impregnated membrane carrier is quenched in a non-solvent system (Y), thereby precipitating at least part of the second polymeric material (B).

Claims (26)

1. A micro-porous membrane comprising a porous membrane carrier made of a first polymeric material (A) and comprising a second polymeric material (B) intimately divided throughout the porous membrane carrier, wherein

(a) the porous membrane carrier (i) comprises a plurality of interconnected polymeric fibers, fibrils, filaments and/or lamellae having a thickness of less than 1 μm, (ii) has an interconnected open porous structure formed by the plurality of interconnected polymeric fibers, fibrils, filaments and/or lamellae and (iii) has a porosity of at least 50%;

(b) the first polymeric material (A) comprises a polyolefin; and

(c) the second polymeric material (B) comprises a polyamide and is present in an amount of at most 30 wt. %, relative to the total weight of (A) and (B).

2. The micro-porous membrane according to claim 1 , wherein the porous membrane carrier is a stretched polymeric layer or a spun-bound polymeric layer.

3. The micro-porous membrane according to claim 1 or 2 , wherein the first polymeric material (A) has a softening point T A and the second polymeric material (B) has a softening point T B , and T B is higher than T A .

4. The micro-porous membrane according to claim 1 or 2 , wherein the polyamide is a semi-crystalline aliphatic polyamide.

5. The micro-porous membrane according to claim 1 or 2 , wherein the amount of polymeric material (B) is in the range of 1-15 wt. %, relative to the total weight of (A) and (B).

6. The micro-porous membrane according to claim 1 or 2 , wherein the polymeric material (B) comprises at least one additive.

7. The micro-porous membrane according to claim 1 or 2 , wherein the porous membrane carrier has a thickness of less than 200 μm.

8. The micro-porous membrane according to claim 1 or 2 , wherein the porosity is at least 65%.

9. The micro-porous membrane according to claim 1 or 2 , wherein the porous membrane carrier (A) has pores with an average pore size of 0.01-10 μm and a porosity of at least 80 volume %, relative to the total volume of the membrane carrier, and the micro-porous membrane has an average pore size of 1 nm-1 μm and a porosity of at least 60 volume %, relative to the total volume of the micro-porous membrane, and wherein the average pore size is obtained from a calculation wherein 1.77 is divided by a Gurley number measured according to ISO 5636-5 and expressed in s/50 ml.

10. A micro-porous membrane according to claim 1 or 2 for use in molecular separations, filtration, reverse osmosis, waste water purification, electrochemical applications, pharmaceutical or nutraceutical controlled release applications, pertraction, pervaporation and contactor applications, enzyme immobilization, and humidifiers.

11. A separation process which comprises passing a liquid and/or gas containing a component to be separated through a microporous membrane according to claim 1 or 2 to thereby separate the component from the liquid and/or gas.

12. A membrane construction comprising a microporous membrane according to claim 1 or 2 , and a support layer.

13. The membrane construction according to claim 12 , wherein the micro-porous membrane is folded.

14. The membrane construction according to claim 12 , wherein the micro-porous membrane is wound.

15. The membrane construction according to claim 12 , which is an article for use in molecular separations, filtration, reverse osmosis, waste water purification, electrochemical applications, pharmaceutical or nutraceutical controlled release application, pertraction, pervaporation and contactor applications; enzyme immobilization, and humidifiers.

16. A process for preparing a micro-porous membrane according to claim 1 or 2 , comprising the steps of (i) impregnating a porous membrane carrier made of a first polymeric material (A) with a polymer solution comprising a second polymeric material (B) in a solvent system (X), and (ii) quenching the resulting impregnated membrane carrier in a non-solvent system (Y), thereby precipitating at least part of the second polymeric material (B).

17. The process according to claim 16 , wherein the solvent comprises a polar organic solvent and optionally a salt, and the non-solvent comprises water or mixtures of water and alcohol.

18. The process according to claim 17 , wherein the polymer solution comprises an alcohol, 0.1-30 wt. % water, 1-50 wt. % of a salt, and 0.1-10 wt. % of a polyamide with a weight average molar mass of 2-100 kg/mol, wherein the weight percentages (wt. %) are relative to the total weight of the polymer solution.

19. The process according to claim 17 , wherein the solvent system (X) comprises a polar organic solvent and the non-solvent system (Y) comprises water or mixtures of water and alcohol.

20. The process according to claim 19 , wherein the solvent system (X) further comprises a salt.

21. The process according to claim 16 , wherein the polymer solution comprises an alcohol, 0.1-30 wt. % water, 1-50 wt. % of a salt, and 0.1-10 wt. % of a polyamide with a weight average molar mass of 2-100 kg/mol, wherein the weight percentages (wt. %) are relative to the total weight of the polymer solution.

22. The process according to claim 16 , wherein the solvent system (X) comprises a polar organic solvent and the non-solvent system (Y) comprises water or mixtures of water and alcohol.

23. The process according to claim 22 , wherein the solvent system (X) further comprises a salt.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 13, 2010
From: QIU, JUN; RULKENS, RUDY; OP DEN KAMP, JOHANNES LEONARDUS MARIA; THIES, JENS CHRISTOPH
To: DSM IP ASSETS B.V.
Reel/Frame 024837/0304 →
Priority Claims (1)
EP 07022189 · Nov 15, 2007 · regional
Continuity (1)
Related Publication 20100305217A1 · Dec 2, 2010