Recent advances in preparation and morphology control of polymeric membranes formed by nonsolvent induced phase separation

On the Solubility and Stability of Polyvinylidene Fluoride

This literature review covers the solubility and processability of fluoropolymer polyvinylidine fluoride (PVDF). Fluoropolymers consist of a carbon backbone chain with multiple connected C-F bonds; they are typically nonreactive and nontoxic and have good thermal stability. Their processing, recycling and reuse are rapidly becoming more important to the circular economy as fluoropolymers find widespread application in diverse sectors including construction, automotive engineering and electronics. The partially fluorinated polymer PVDF is in strong demand in all of these areas; in addition to its desirable inertness, which is typical of most fluoropolymers, it also has a high dielectric constant and can be ferroelectric in some of its crystal phases. However, processing and reusing PVDF is a challenging task, and this is partly due to its limited solubility. This review begins with a discussion on the useful properties and applications of PVDF, followed by a discussion on the known solvents and diluents of PVDF and how it can be formed into membranes. Finally, we explore the limitations of PVDF's chemical and thermal stability, with a discussion on conditions under which it can degrade. Our aim is to provide a condensed overview that will be of use to both chemists and engineers who need to work with PVDF.

Ultra-strong polymeric hollow fiber membranes for saline dewatering and desalination

Osmotically assisted reverse osmosis (OARO) has become an emerging membrane technology to tackle the limitations of a reverse osmosis (RO) process for water desalination. A strong membrane that can withstand a high hydraulic pressure is crucial for the OARO process. Here, we develop ultra-strong polymeric thin film composite (TFC) hollow fiber membranes with exceptionally high hydraulic burst pressures of up to 110 bar, while maintaining high pure water permeance of around 3 litre/(m² h bar) and a NaCl rejection of about 98%. The ultra-strong TFC hollow fiber membranes are achieved mainly by tuning the concentration of the host polymer in spinning dopes and engineering the fiber dimension and morphology. The optimal TFC membranes display promising water permeance under the OR and OARO operation modes. This work may shed new light on the fabrication of ultra-strong TFC hollow fiber membranes for water treatments and desalination.

Osmotically assisted reverse osmosis can overcome limitations of the reverse osmosis process but a strong membrane which can withstand a high hydraulic pressure is crucial. Here, the authors develop strong polymer thin film composite hollow fiber membranes with exceptionally high hydraulic burst pressures of up to 110 bar, while maintaining high water permeance and salt rejection.

New Preparation Methods for Pore Formation on Polysulfone Membranes

This work described the preparation of membranes based on aromatic polysulfones through the phase-inversion method induced by a nonsolvent, generating the phase separation (NIPS) process. Three new techniques, including the nano iron acid etching method, base hydrolysis method of crosslinked polymers, and base hydrolysis method of a reactive component in a binary polymer blend, were developed for pore creation on membranes. The modified polymers and obtained membranes were carefully characterized. The uniform pores were successfully created by base hydrolysis of the crosslinked polymers and obtained at the size of the crosslinker. Moreover, homogeneous pores were created after base hydrolysis of the membranes prepared from binary polymer blends due to the internal changes in the polymer structure. The separation performance of membranes was tested with different inorganic salt solutions and compared with commercially known membranes. These new membranes exhibited high water flux (up to 3000 L/m^-2·h^-1 at 10 bar and at 25 °C) and reasonable rejections for monovalent (21-44%) and multivalent ions (18-60%), depending on the different etching of the hydrolysis times. The comparison of these membranes with commercial ones confirmed their good separation performance and high potential application for water treatment applications.

Ternary Phase-Field Simulations of the Skin-Sublayer Structures in Poly(vinylidene fluoride) Microporous Membranes Prepared by a Nonsolvent-Induced Phase Separation

In this paper, the existing phase-field model based on the nonsolvent-induced phase separation (NIPS) method was optimized. Two-dimensional simulations using the relevant parameters of a poly(vinylidene fluoride) (PVDF) membrane system were carried out, simulating and analyzing the effects of changes in initial concentrations, concentration fluctuations, and diffusion rates of the solvent on the skin layer and sublayer structures of the membranes. These simulations modeled the process of preparing PVDF microporous membranes by the NIPS method to better understand the structural development of PVDF microporous membranes under different conditions. It was found that dense skin layers were formed at the mass-transfer exchange interface of the PVDF microporous membranes, whose number increased with the decrease of the concentration fluctuation, which has little effect on the structure of the sublayer. The initial concentration of PVDF and the diffusion rate of the solvent had a little impact on the number of skin layers yet played a relatively large role in the formation time of the skin layers and the structure of the sublayers. Also, the validity of the model was verified by corresponding experiments. Hence, the model can be applied to other PVDF ternary membrane systems by modifying specific thermodynamic and kinetic parameters.

Thermodynamic Modeling and Validation of the Temperature Influence in Ternary Phase Polymer Systems

The effect of the temperature, as a process variable in the fabrication of polymeric membranes by the non-solvent induced phase separation (NIPS) technique, has been scarcely studied. In the present work, we studied the influence of temperature, working at 293, 313 and 333 K, on the experimental binodal curves of four ternary systems composed of PVDF and PES as the polymers, DMAc and NMP as the solvents and water as the non-solvent. The increase of the temperature caused an increase on the solubility gap of the ternary system, as expected. The shift of the binodal curve with the temperature was more evident in PVDF systems than in PES systems indicating the influence of the rubbery or glassy state of the polymer on the thermodynamics of phase separation. As a novelty, the present work has introduced the temperature influence on the Flory-Huggins model to fit the experimental cloud points. Binary interaction parameters were calculated as a function of the temperature: (i) non-solvent/solvent (g₁₂) expressions with UNIFAC-Dortmund methodology and (ii) non-solvent/polymer (χ₁₃) and solvent/polymer (χ₂₃) using Hansen solubility parameters. Additionally, the effect of the ternary interaction term was not negligible in the model. Estimated ternary interaction parameters (χ₁₂₃) presented a linear relation with temperature and negative values, indicating that the solubility of the polymers in mixtures of solvent/non-solvent was higher than expected for single binary interaction. Finally, PES ternary systems exhibited higher influence of the ternary interaction parameter than PVDF systems.

Nanofibrous Foams of Poly(3-hydroxybutyrate)/Cellulose Nanocrystal Composite Fabricated Using Nonsolvent-Induced Phase Separation

In this study, we fabricated nanofibrous foams of neat poly(3-hydroxybutyrate) (PHB) and PHB/cellulose nanocrystal (CNC) nanocomposite using nonsolvent-induced phase separation (NIPS) followed by solvent extraction. Two different nonsolvents, tetrahydrofuran (THF) and 1,4-dioxane (Diox), in combination with the solvent, chloroform (CF), were used for NIPS. The parameters of NIPS-derived crystallization kinetics were calculated using Avrami analysis of time-dependent infrared spectral measurements. The lower viscosity and poorer PHB affinity of THF than those of Diox resulted in rapid crystallization and gelation rate, which in turn resulted in higher strength of the foam. The mechanical reinforcement by the incorporation of CNCs was achieved for the composite foam prepared in Diox/CF but not in THF/CF, owing to the relatively better dispersion of the CNCs in Diox than that in THF. A rapid rate of NIPS-derived crystallization and gelation was achieved in THF/CF with the incorporation of CNCs, indicating the effective crystal nucleation of CNCs. However, the presence of CNCs deaccelerated the crystallization in Diox/CF, indicating that the inhibition effect of PHB mobility became more dominant than the nucleation effect of CNCs; this was because the CNC dispersion became more homogeneous in Diox/CF. In vitro cell viability assays exhibited excellent cytocompatibility of the foams, thereby showing potential for use in biomedical applications.

Cobweb-like, Ultrathin Porous Polymer Films for Ultrasensitive NO2 Detection

Gas sensors based on polymer field-effect transistors (FETs) have drawn much attention owing to the inherent merits of specific selectivity, low cost, and room temperature operation. Ultrathin (<10 nm) and porous polymer semiconductor films offer a golden opportunity for achieving high-performance gas sensors. However, wafer-scale fabrication of such high-quality polymer films is of great challenge and has rarely been realized before. Herein, the first demonstration of 4 in. wafer-scale, cobweb-like, and ultrathin porous polymer films is reported via a one-step phase-inversion process. This approach is extremely simple and universal for constructing various ultrathin porous polymer semiconductor films. Thanks to the abundant pores, ultrathin size, and high charge-transfer efficiency of the prepared polymer films, our gas sensors exhibit many superior advantages, including ultrahigh response (2.46 × 10⁶%), low limit of detection (LOD) (<1 ppm), and excellent selectivity. Thus, the proposed fabrication strategy is exceptionally promising for mass manufacturing of low-cost high-performance polymer FET-based gas sensors.

Mechanisms of Asymmetric Membrane Formation in Nonsolvent-Induced Phase Separation

We report the first simulations of nonsolvent-induced phase separation (NIPS) that predict membrane microstructures with graded asymmetric pore size distribution. In NIPS, a polymer solution film is immersed in a nonsolvent bath, enriching the film in nonsolvent, and leading to phase separation that forms a solid polymer-rich membrane matrix and polymer-poor membrane pores. We demonstrate how mass-transfer-induced spinodal decomposition, thermal fluctuations, and glass-transition dynamics-implemented with mobility contrast between the polymer-rich and polymer-poor phases-are essential to the formation of asymmetric membrane microstructures. Specifically, we show that the competition between the propagation of the phase-separation and glass-transition fronts determines the degree of pore-size asymmetry. We also explore the sensitivity of these microstructures to the initial film composition, and compare their formation in 2D and 3D.

In Situ Growth of Cationic Covalent Organic Frameworks (COFs) for Mixed Matrix Membranes with Enhanced Performances

Covalent organic frameworks (COFs) are increasingly utilized as doping agents for the design of advanced ultrafiltration mixed matrix membranes, thanks to their prominent nanoporosity and excellent polymer compatibility. However, current strategies are largely limited in the complicated postaddition of neutral COF particulates. Herein, cationic COFs, namely, TpEB, with sizes down to ∼39 nm are in situ synthesized in polyacrylonitrile (PAN) solution as crystalline fillers for the production of highly permeable TpEB-PAN ultrafiltration membranes. After the condensation of monomer pairs, the growth of cationic TpEB crystallites is restrained due to the electrostatic interaction with negatively charged PAN chains, leading to the formation of a homogeneous TpEB-incorporated casting solution. During the subsequent nonsolvent-induced phase separation process, TpEB crystallites facilitate exchange between the solvent and the nonsolvent because of their hydrophilic and nanoporous nature, accelerating the rate of phase inversion to form a highly porous membrane surface. Thus-prepared TpEB-PAN membranes deliver a tight rejection of BSA with water permeance of up to 380 L m^-2 h^-1 bar^-1, which is 35.6% higher than that of the original PAN membranes prepared without TpEB. The TpEB-PAN membranes also exhibit enhanced operation stabilities and fouling resistances. This in situ growth strategy suggests a new avenue for the preparation of advanced mixed matrix membranes.

Phase Inversion-Induced Porous Polybenzimidazole Fuel Cell Membranes: An Efficient Architecture for High-Temperature Water-Free Proton Transport

To cope with the demand for cleaner alternative energy, polymer electrolyte membrane fuel cells (PEMFCs) have received significant research attention owing to their high-power density, high fuel efficiency, and low polluting by-product. However, the water requirement of these cells has necessitated research on systems that do not require water and/or use other mediums with higher boiling points. In this work, a highly porous meta-polybenzimidazole (m-PBI) membrane was fabricated through the non-solvent induced phase inversion technique and thermal cross-linking for high-temperature PEMFC (HT-PEMFC) applications. Standard non-thermally treated porous membranes are susceptible to phosphoric acid (PA) even at low concentrations and are unsuitable as polymer electrolyte membranes (PEMs). With the porous structure of m-PBI membranes, higher PA uptake and minimal swelling, which is controlled via cross-linking, was achieved. In addition, the membranes exhibited partial asymmetrical morphology and are directly applicable to fuel cell systems without any further modifications. Membranes with insufficient cross-linking resulted in an unstable performance in HT-PEMFC environments. By optimizing thermal treatment, a high-performance membrane with limited swelling and improved proton conductivity was achieved. Finally, the m-PBI membrane exhibited enhanced acid retention, proton conductivity, and fuel cell performance.

Porous Polyvinyl Alcohol Membranes: Preparation Methods and Applications

Polymeric membrane technology is a constantly developing field in both the research and industrial sector, with many applications considered nowadays as mature such as desalination, wastewater treatment, and hemodialysis. A variety of polymers have been used for the development of porous membranes by implementing numerous approaches such as phase inversion, electrospinning, sintering, melt-spinning and cold-stretching, 3D printing, and others. Depending on the application, certain polymer characteristics such as solubility to non-toxic solvents, mechanical and thermal stability, non-toxicity, resistance to solvents, and separation capabilities are highly desired. Poly (vinyl alcohol) (PVA) is a polymer that combines the above-mentioned properties with great film forming capabilities, good chemical and mechanical stability, and tuned hydrophilicity, rendering it a prominent candidate for membrane preparation since the 1970s. Since then, great progress has been made both in preparation methods and possible unique applications. In this review, the main preparation methods and applications of porous PVA based membranes, along with introductory material are presented.

Porous Poly(3-hydroxybutyrate) Scaffolds Prepared by Non-Solvent-Induced Phase Separation for Tissue Engineering

Highly porous poly(3-hydroxybutyrate) (PHB) scaffolds were fabricated using non-solvent-induced phase separation with chloroform as the solvent and tetrahydrofuran as the non-solvent. The microporosity, nanofiber morphology, and mechanical strength of the scaffolds were adjusted by varying the fabrication parameters, such as the polymer concentration and solvent composition. The influence of these parameters on the structure and morphology of PHB organogels and scaffolds was elucidated using small-angle neutron scattering and scanning electron microscopy. The organogels and scaffolds in this study have a complex hierarchical structure, extending over a wide range of length scales. In vitro viability assays were performed using the human keratinocyte cell line (HaCaT), and all PHB scaffolds demonstrated the excellent cell viability. Microporosity had the greatest impact on HaCaT cell proliferation on PHB scaffolds, which was determined after a 3-day incubation period with scaffolds of different morphologies and mechanical properties. The superior cell viability and the controlled scaffold properties and morphologies suggested PHB scaffolds fabricated by non-solvent-induced phase separation using chloroform and tetrahydrofuran as promising biomaterials for the applications of tissue engineering, particularly of epidermal engineering.

Highlighting Thermodynamic Coupling Effects in the Immersion Precipitation Process for Formation of Polymeric Membranes

In the immersion precipitation process for membrane formation, a polymer casting film is placed in contact with a nonsolvent in a coagulation bath; an essential feature of the membrane formation process is the foray into the metastable region of the ternary phase diagram for the nonsolvent/solvent/polymer system. The primary objective of this article is to trace the origins of such forays. The Maxwell-Stefan diffusion formulation is combined with the Flory-Huggins description of phase equilibrium thermodynamics to set up a model for describing the transient equilibration trajectory that is followed in the polymer casting film. Four different systems are analyzed: water/acetone/CA, water/DMF/PVDF, water/NMP/PSF, and water/NMP/PEI (CA = cellulose acetate; PVDF = poly(vinylidene fluoride); PSF = polysulfone; PEI = polyetherimide, DMF = dimethyl formamide; NMP = N-methyl-2-pyrrolidone). The analysis shows that diffusional forays are mainly engendered due to thermodynamic coupling effects; such effects are quantified by the set of thermodynamic factors , where a _i , the activity of species i, is dependent on the volume fractions, ϕ _i and ϕ _j , of both nonsolvent (i) and solvent (j). In regions close to phase transitions, the off-diagonal elements Γ _ij (i ≠ j) are often negative and may attain large magnitudes in relation to the diagonal elements Γ _ii . Strong thermodynamic coupling effects cause the transient equilibration trajectories to be strongly curvilinear, causing ingress into the metastable region. If thermodynamic coupling effects are ignored, no such ingress occurs. It is also shown that analogous diffusional forays may lead to emulsion formation in partially miscible liquid mixtures.

Facile construction of gas diode membrane towards in situ gas consumption via coupling two chemical reactions

Controlling the bubbles' behavior on a solid surface is significant for exploring more related applications and thus recently has attracted increased investigations. Based on this, a Janus poly (l-lactic acid) (PLLA) membrane with definitely opposite water wettability in air and opposite bubble wettability underwater was successfully fabricated in this work. The obtained Janus membrane exhibited unidirectional transport for air bubble underwater from the superaerophilic side to superaerophobic side, meanwhile prevented the permeation of water medium from both sides under low pressure. This special membrane was designed to couple two chemical reactions. During the designed chemical reaction process, the feature of bubble unidirectional transport allowed the carbon dioxide (CO₂) produced in one reaction system to transport through the resultant membrane into another reaction system, wherein it could be consumed. Meanwhile, the anti-water-permeation function of the membrane guaranteed that the two chemical reactions could be performed independently. We believe that the present research could broaden the potential applications of membranes with super-wetting character for gas bubbles.

Membrane Surface Patterning as a Fouling Mitigation Strategy in Liquid Filtration: A Review

Membrane fouling is seen as the main culprit that hinders the widespread of membrane application in liquid-based filtration. Therefore, fouling management is key for the successful implementation of membrane processes, and it is done across all magnitudes. For optimum operation, membrane developments and surface modifications have largely been reported, including membrane surface patterning. Membrane surface patterning involves structural modification of the membrane surface to induce secondary flow due to eddies, which mitigate foulant agglomeration and increase the effective surface area for improved permeance and antifouling properties. This paper reviews surface patterning approaches used for fouling mitigation in water and wastewater treatments. The focus is given on the pattern formation methods and their effect on overall process performances.

A Review on Porous Polymeric Membrane Preparation. Part I: Production Techniques with Polysulfone and Poly (Vinylidene Fluoride)

Porous polymeric membranes have emerged as the core technology in the field of separation. But some challenges remain for several methods used for membrane fabrication, suggesting the need for a critical review of the literature. We present here an overview on porous polymeric membrane preparation and characterization for two commonly used polymers: polysulfone and poly (vinylidene fluoride). Five different methods for membrane fabrication are introduced: non-solvent induced phase separation, vapor-induced phase separation, electrospinning, track etching and sintering. The key factors of each method are discussed, including the solvent and non-solvent system type and composition, the polymer solution composition and concentration, the processing parameters, and the ambient conditions. To evaluate these methods, a brief description on membrane characterization is given related to morphology and performance. One objective of this review is to present the basics for selecting an appropriate method and membrane fabrication systems with appropriate processing conditions to produce membranes with the desired morphology, performance and stability, as well as to select the best methods to determine these properties.

A New Hollow-Fiber Adsorbent Material for Removing Arsenic from Groundwater

To optimize the arsenic-adsorption efficiency and the mechanical strength of a hollow-fiber-type adsorbent, the optimal condition of polymeric solution was determined as 32 wt.% TiO2 and 17 wt.% polymer. A micropore-sponge form was developed at the slurry-extrusion speed of 2.500 ml/min and the internal coagulant-solution-extrusion speed of 1.250 ml/min, and the arsenic-adsorption efficiency improved. Given the result under conditions in natural groundwater containing various ions, the hollow-fiber-type adsorbent can be applied to real groundwater purification processes.

Zwitterionic Membrane via Nonsolvent Induced Phase Separation: A Computer Simulation Study

Dissipative particle dynamics (DPD) was adopted to study the nonsolvent induced phase separation (NIPS) process during a pH-responsive poly(ether sulfone) membrane preparation with a zwitterionic copolymer poly(ether sulfone)- block-polycarboxybetaine methacrylate (PES-b-PCBMA) as the blending additive. The membrane formation process and final morphology were analyzed. Simulation results show that the hydrophilic PCBMA segments enrich on the membrane surface by surface segregation and exhibit pH-responsive behavior, which is attributed to the deprotonation of the carboxylic acid group. With the polymer concentration increasing, both the shrinkage of the membrane and the flexibility of the system decrease, which also reduce the effect of surface segregation. By adjusting the blend ratio of PES-b-PCBMA with PES from 5% to 15%, the surface coverage of PCBMA segments on the membrane can be regulated. This work contributes to a better understanding on the mechanism of NIPS and can serve as a guide for the design of the polymer blend membrane.

Preparation of Highly Porous Polymer Membranes with Hierarchical Porous Structures via Spinodal Decomposition of Mixed Solvents with UCST Phase Behavior

The predominant method to prepare polymer membranes is based on phase inversion. However, this method always leads to a dense skin with low porosity when normal polymers are used. Using the self-assembly of certain block copolymers, it is possible to prepare uniform pores with high porosity, but the prices of these polymers are too high to be afforded in practical applications. Here, we report a novel strategy to prepare highly porous and asymmetric polymer membranes using the widely used poly(vinylidene fluoride) (PVDF) as a prototype. The method combines spinodal decomposition with phase inversion utilizing mixed solvents that have the unique upper critical solution temperature phase behavior. The spinodal decomposition generates a thin surface layer containing a high density of relatively uniform pores in the mesoporous range, and the phase inversion generates a thick bulk layer composed of macrovoids; the two types of structures are interconnected, yielding a highly permeable, selective, and mechanically strong porous membrane. The membranes show an order of magnitude higher water permeance than commercial membranes and efficient molecular sieving of macromolecules. Notably, our strategy provides a general toolbox to prepare highly porous membranes from normal polymers. By blending PVDF with cellulose acetate (CA), a highly porous PVDF/CA membrane was prepared and showed similarly high separation performance, but the higher hydrophilicity of CA improved the membrane flux in the presence of proteins.

Biodegradable Poly(l-lactic acid) (PLLA) Coatings Fabricated from Nonsolvent Induced Phase Separation for Improving Corrosion Resistance of Magnesium Rods in Biological Fluids

Magnesium (Mg)-based biometals are increasingly becoming a promising candidate of the next-generation implantable materials due to their unique properties, such as high biocompatibility, favorable mechanical strength, and good biodegradability in physiological conditions. However, the swift corrosion of Mg, resulting in early loss of structural support, has posed an enormous challenge in clinical application of Mg-based implants. To overcome these limitations, herein we developed a novel method, which combines the traditional dip-coating with nonsolvent induced phase separation (NIPS), to fabricate biodegradable PLLA coatings with controlled membrane morphology on pure Mg rods. Unlike the conventional dip-coating, where the polymer solution on the Mg substrates is left to evaporate directly under proper atmosphere, in NIPS, the polymer solution on the substrates is not left to dry but immersed in a nonsolvent of the PLLA, leading to the precipitation of polymer networks. Our results demonstrated that various polymer coatings with different morphologies and inner structures could be easily fabricated by a careful selection of nonsolvents. In comparison to dense PLLA coatings obtained from conventional solvent evaporation, PLLA coatings with a dense surface and porous inner structure were obtained when hexane and petroleum ether were used as the nonsolvents, while PLLA coatings with a completely porous structure were obtained when polar acetone and ethanol were chosen. The electrochemical corrosion tests and immersion tests further showed that all polymer coatings could significantly improve the corrosion resistance and suppress the corrosion rates of the substrates. However, PLLA films obtained via NIPS had much lower pH changes and slower Mg²⁺ release, implying better protective effects of the fabricated coatings. Based on results of all experiments, a new process for the corrosion mechanism of Mg implants during immersion has also been proposed in this work.