A review on microporous polyvinylidene fluoride membranes fabricated via thermally induced phase separation for MF/UF application

Progress in the Preparation and Application of Breathable Membranes

Breathable membranes with micropores enable the transfer of gas molecules while blocking liquids and solids, and have a wide range of applications in medical, industrial, environmental, and energy fields. Breathability is highly influenced by the nature of a material, pore size, and pore structure. Preparation methods and the incorporation of functional materials are responsible for the variety of physical properties and applications of breathable membranes. In this review, the preparation methods of breathable membranes, including blown film extrusion, cast film extrusion, phase separation, and electrospinning, are discussed. According to the antibacterial, hydrophobic, thermal insulation, conductive, and adsorption properties, the application of breathable membranes in the fields of electronics, medicine, textiles, packaging, energy, and the environment are summarized. Perspectives on the development trends and challenges of breathable membranes are discussed.

High Modulus, Strut-like poly(ether ether ketone) Aerogels Produced from a Benign Solvent

Poly(ether ether ketone) (PEEK) was found to form gels in the benign solvent 1,3-diphenylacetone (DPA). Gelation of PEEK in DPA was found to form an interconnected, strut-like morphology composed of polymer axialites. To our knowledge, this is the first report of a strut-like morphology for PEEK aerogels. PEEK/DPA gels were prepared by first dissolving PEEK in DPA at 320 °C. Upon cooling to 50 °C, PEEK crystallizes and forms a gel in DPA. The PEEK/DPA phase diagram indicated that phase separation occurs by solid-liquid phase separation, implying that DPA is a good solvent for PEEK. The Flory-Huggins interaction parameter, calculated as χ12 = 0.093 for the PEEK/DPA system, confirmed that DPA is a good solvent for PEEK. PEEK aerogels were prepared by solvent exchanging DPA to water then freeze-drying. PEEK aerogels were found to have densities between 0.09 and 0.25 g/cm3, porosities between 80 and 93%, and surface areas between 200 and 225 m2/g, depending on the initial gel concentration. Using nitrogen adsorption analyses, PEEK aerogels were found to be mesoporous adsorbents, with mesopore sizes of about 8 nm, which formed between stacks of platelike crystalline lamellae. Scanning electron microscopy and X-ray scattering were utilized to elucidate the hierarchical structure of the PEEK aerogels. Morphological analysis found that the PEEK/DPA gels were composed of a highly nucleated network of PEEK axialites (i.e., aggregates of stacked crystalline lamellae). The highly connected axialite network imparted robust mechanical properties on PEEK aerogels, which were found to densify less upon freeze-drying than globular PEEK aerogel counterparts gelled from dichloroacetic acid (DCA) or 4-chlorphenol (4CP). PEEK aerogels formed from DPA were also found to have a modulus-density scaling that was far more efficient in supporting loads than the poorly connected aerogels formed from PEEK/DCA or PEEK/4CP solutions. The strut-like morphology in these new PEEK aerogels also significantly improved the modulus to a degree that is comparable to high-performance crosslinked aerogels based on polyimide and polyurea of comparable densities.

Enhanced management and antifouling performance of a novel NiFe-LDH@MnO2/PVDF hybrid membrane for efficient oily wastewater treatment

Layered double hydroxides (LDHs) have gained significant recognition for their facile synthesis and super-hydrophilic two-dimensional (2D) structure to fabricate antifouling membranes for oily wastewater separation. However, conventional PVDF membranes, due to their hydrophobic nature and inert matrix, often exhibit insufficient permeance and compatibility. In this study, a novel NiFe-LDH@MnO2/PVDF membrane was synthesized using ultrasonic, redox, and microwave-hydrothermal processes. This innovative approach cultivated grass-like NiFe-LDH@MnO2 nanoparticles within an inert PVDF matrix, promoting the growth of highly hydrophilic composites. The presence of NiFe-LDH@MnO2 resulted in pronounced enhancements in surface morphology, interfacial wettability, and oil rejection for the fabricated membrane. The optimal NiFe-LDH@MnO2/PVDF-2 membrane exhibited an extremely high pure water flux (1364 L m-2•h-1), and increased oil rejection (from 81.2% to 93.5%) without sacrificing water permeation compared to the original PVDF membrane. Additionally, the NiFe-LDH@MnO2/PVDF membrane demonstrated remarkable antifouling properties, evident by an exceptional fouling resistance ratio of 96.8% following slight water rinsing. Mechanistic insights into the enhanced antifouling performance were elucidated through a comparative "semi-immersion" investigation. The facile synthesis method, coupled with the improved membrane performance, highlights the potential application prospects of this hybrid membrane in emulsified oily wastewater treatment and environmental remediation.

Mechanism of PVDF Membrane Formation by NIPS Revisited: Effect of Precipitation Bath Nature and Polymer-Solvent Affinity

A new interpretation of the mechanism of the polyvinylidene fluoride (PVDF) membrane formation using the nonsolvent-induced phase separation (NIPS) method based on an analysis of the complete experimental phase diagram for the three-component mixture PVDF-dimethyl acetamide (DMAc)-water is proposed. The effects of the precipitation bath's harshness and thermodynamic affinity of the polymer's solvent on the morphology, crystalline structure, transport and physical-mechanical properties of the membranes are investigated. These characteristics were studied via scanning electron microscopy, wide-angle X-ray scattering, liquid-liquid porosimetry and standard methods of physico-mechanical analysis. It is established that an increase in DMAc concentration in the precipitation bath results in the growth of mean pore size from ~60 to ~150 nm and an increase in permeance from ~2.8 to ~8 L m-2 h-1 bar-1. It was observed that pore size transformations are accompanied by changes in the tensile strength of membranes from ~9 to ~11 and to 6 MPa, which were explained by the degeneration of finger-like pores and appearance of spherulitic structures in the samples. The addition of water to the dope solution decreased both the transport (mean pore size changed from ~55 to ~25 nm and permeance reduced from ~2.8 to ~0.5 L m-2 h-1 bar-1) and mechanical properties of the membranes (tensile strength decreased from ~9 to ~6 MPa). It is possible to conclude that the best membrane quality may be reached using pure DMAc as a solvent and a precipitation bath containing 10-30% wt. of DMAc, in addition to water.

Hierarchical 3D Electrode Design with High Mass Loading Enabling High-Energy-Density Flexible Lithium-Ion Batteries

Flexible lithium-ion batteries (LIBs) have attracted significant attention owing to their ever-increasing use in flexible and wearable electronic devices. However, the practical application of flexible LIBs in devices has been plagued by the challenge of simultaneously achieving high energy density and high flexibility. Herein, a hierarchical 3D electrode (H3DE) is introduced with high mass loading that can construct highly flexible LIBs with ultrahigh energy density. The H3DE features a bicontinuous structure and the active materials along with conductive agents are uniformly distributed on the 3D framework regardless of the active material type. The bicontinuous electrode/electrolyte integration enables a rapid ion/electron transport, thereby improving the redox kinetics and lowering the internal cell resistance. Moreover, the H3DE exhibits exceptional structural integrity and flexibility during repeated mechanical deformations. Benefiting from the remarkable physicochemical properties, pouch-type flexible LIBs using H3DE demonstrate stable cycling under various bending states, achieving a record-high energy density (438.6 Wh kg-1 and 20.4 mWh cm-2 ), and areal capacity (5.6 mAh cm-2 ), outperforming all previously reported flexible LIBs. This study provides a feasible solution for the preparation of high-energy-density flexible LIBs for various energy storage devices.

Thermodynamics and kinetic analysis of membrane: Challenges and perspectives

The ultimate structure of the membrane is determined using two important effects: (i) thermodynamic effect and (ii) kinetic effect. Controlling the mechanism of kinetic and thermodynamic processes in phase separation is essential for enhancing membrane performance. However, the relationship between system parameters and the ultimate membrane morphology is still largely empirical. This review focuses on the fundamental ideas behind thermally induced phase separation (TIPS) and nonsolvent-induced phase separation (NIPS) methods, including both kinetic and thermodynamic elements. The thermodynamic approach to understanding phase separation and the effect of different interaction parameters on membrane morphology has been discussed in detail. Furthermore, this review explores the capabilities and limitations of different macroscopic transport models used for the last four decades to explore the phase inversion process. The application of molecular simulations and phase field to understand phase separation has also been briefly examined. Finally, it discusses the thermodynamic approach to understanding phase separation and the consequence of different interaction parameters on membrane morphology, as well as possible directions for artificial intelligence to fill the gaps in the literature. This review aims to provide comprehensive knowledge and motivation for future modeling work for membrane fabrication via new techniques such as nonsolvent-TIPS, complex-TIPS, non-solvent assisted TIPS, combined NIPS-TIPS method, and mixed solvent phase separation.

Efficiency of Fabricated Adsorptive Polysulfone Mixed Matrix Membrane for Acetic Acid Separation

The ultrafiltration mixed matrix membrane (UF MMMs) process represents an applicable approach for the removal of diluted acetic acid at low concentrations, owing to the low pressures applied. The addition of efficient additives represents an approach to further improve membrane porosity and, subsequently, enhance acetic acid removal. This work demonstrates the incorporation of titanium dioxide (TiO₂) and polyethylene glycol (PEG) as additives into polysulfone (PSf) polymer via the non-solvent-induced phase-inversion (NIPS) method to improve the performance of PSf MMMs performance. Eight PSf MMMs samples designated as M0 to M7, each with independent formulations, were prepared and investigated for their respective density, porosity, and degree of AA retention. Morphology analysis through scanning electron microscopy elucidated sample M7 (PSf/TiO₂/PEG 6000) to have the highest density and porosity among all samples with concomitant highest AA retention at approximately 92.2%. The application of the concentration polarization method further supported this finding by the higher concentration of AA solute present on the surface of the membrane compared to that of AA feed for sample M7. Overall, this study successfully demonstrates the significance of TiO₂ and PEG as high MW additives in improving PSf MMM performance.

Controlled Swelling of Monolithic Films as a Facile Approach to the Synthesis of UHMWPE Membranes

A new method of fabricating porous membranes based on ultra-high molecular weight polyethylene (UHMWPE) by controlled swelling of the dense film was proposed and successfully utilized. The principle of this method is based on the swelling of non-porous UHMWPE film in organic solvent at elevated temperatures, followed by its cooling and further extraction of organic solvent, resulting in the formation of the porous membrane. In this work, we used commercial UHMWPE film (thickness 155 μm) and o-xylene as a solvent. Either homogeneous mixtures of the polymer melt and solvent or thermoreversible gels with crystallites acting as crosslinks of the inter-macromolecular network (swollen semicrystalline polymer) can be obtained at different soaking times. It was shown that the porous structure and filtration performance of the membranes depended on the swelling degree of the polymer, which can be controlled by the time of polymer soaking in organic solvent at elevated temperature (106 °C was found to be the optimal temperature for UHMWPE). In the case of homogeneous mixtures, the resulting membranes possessed both large and small pores. They were characterized by quite high porosity (45-65% vol.), liquid permeance of 46-134 L m^-2 h^-1 bar^-1, a mean flow pore size of 30-75 nm, and a very high crystallinity degree of 86-89% at a decent tensile strength of 3-9 MPa. For these membranes, rejection of blue dextran dye with a molecular weight of 70 kg/mol was 22-76%. In the case of thermoreversible gels, the resulting membranes had only small pores located in the interlamellar spaces. They were characterized by a lower crystallinity degree of 70-74%, a moderate porosity of 12-28%, liquid permeability of up to 12-26 L m^-2 h^-1 bar^-1, a mean flow pore size of up to 12-17 nm, and a higher tensile strength of 11-20 MPa. These membranes demonstrated blue dextran retention of nearly 100%.

Formation of Porous Structures and Crystalline Phases in Poly(vinylidene fluoride) Membranes Prepared with Nonsolvent-Induced Phase Separation-Roles of Solvent Polarity

PVDF membranes were prepared with nonsolvent-induced phase separation, using solvents with various dipole moments, including HMPA, NMP, DMAc and TEP. Both the fraction of the polar crystalline phase and the water permeability of the prepared membrane increased monotonously with an increasing solvent dipole moment. FTIR/ATR analyses were conducted at the surfaces of the cast films during membrane formation to provide information on if the solvents were present as the PVDF crystallized. The results reveal that, with HMPA, NMP or DMAc being used to dissolve PVDF, a solvent with a higher dipole moment resulted in a lower solvent removal rate from the cast film, because the viscosity of the casting solution was higher. The lower solvent removal rate allowed a higher solvent concentration on the surface of the cast film, leading to a more porous surface and longer solvent-governed crystallization. Because of its low polarity, TEP induced non-polar crystals and had a low affinity for water, accounting for the low water permeability and the low fraction of polar crystals with TEP as the solvent. The results provide insight into how the membrane structure on a molecular scale (related to the crystalline phase) and nanoscale (related to water permeability) was related to and influenced by solvent polarity and its removal rate during membrane formation.

Wastewater Treatment of Real Effluents by Microfiltration Using Poly(vinylidene fluoride-hexafluoropropylene) Membranes

Over the last decades, the growing contamination of wastewater, mainly caused by industrial processes, improper sewage, natural calamities, and a variety of anthropogenic activities, has caused an increase in water-borne diseases. Notably, industrial applications require careful consideration as they pose significant threats to human health and ecosystem biodiversity due to the production of persistent and complex contaminants. The present work reports on the development, characterization, and application of a poly (vinylidene fluoride-hexafluoropropylene) (PVDF-HFP) porous membrane for the remediation of a wide range of contaminants from wastewater withdrawn from industrial applications. The PVDF-HFP membrane showed a micrometric porous structure with thermal, chemical, and mechanical stability and a hydrophobic nature, leading to high permeability. The prepared membranes exhibited simultaneous activity on the removal of organic matter (total suspended and dissolved solids, TSS, and TDS, respectively), the mitigation of salinity in 50%, and the effective removal of some inorganic anions and heavy metals, achieving efficiencies around 60% for nickel, cadmium, and lead. The membrane proved to be a suitable approach for wastewater treatment, as it showed potential for the simultaneous remediation of a wide range of contaminants. Thus, the as-prepared PVDF-HFP membrane and the designed membrane reactor represent an efficient, straightforward, and low-cost alternative as a pretreatment step for continuous treatment processes for simultaneous organic and inorganic contaminants' remediation in real industrial effluent sources.

Recent Advances on the Fabrication of Antifouling Phase-Inversion Membranes by Physical Blending Modification Method

Membrane technology is an essential tool for water treatment and biomedical applications. Despite their extensive use in these fields, polymeric-based membranes still face several challenges, including instability, low mechanical strength, and propensity to fouling. The latter point has attracted the attention of numerous teams worldwide developing antifouling materials for membranes and interfaces. A convenient method to prepare antifouling membranes is via physical blending (or simply blending), which is a one-step method that consists of mixing the main matrix polymer and the antifouling material prior to casting and film formation by a phase inversion process. This review focuses on the recent development (past 10 years) of antifouling membranes via this method and uses different phase-inversion processes including liquid-induced phase separation, vapor induced phase separation, and thermally induced phase separation. Antifouling materials used in these recent studies including polymers, metals, ceramics, and carbon-based and porous nanomaterials are also surveyed. Furthermore, the assessment of antifouling properties and performances are extensively summarized. Finally, we conclude this review with a list of technical and scientific challenges that still need to be overcome to improve the functional properties and widen the range of applications of antifouling membranes prepared by blending modification.

Aging of polyvinylidene fluoride (PVDF) ultrafiltration membrane due to ozone exposure in water treatment: Evolution of membrane properties and performance

Pre-ozonation is an effective pretreatment tactic for mitigating fouling of ultrafiltration (UF) membrane in water and wastewater treatment, but the compatibility of polymeric UF membranes with residual ozone remains unclear. In this study, effects of long-term ozone exposure on properties and performance of polyvinylidene fluoride (PVDF) UF membrane reinforced by polyethylene terephthalate (PET) layer were systematically investigated. The exposure intensities were designed to simulate ozone exposure at 0.1 mg/L for 0.5-5 years. Chemical composition analysis suggested that the hydrophilic additives, such as possibly polyvinyl pyrrolidone (PVP), was gradually degraded and released from the membrane, whereas the PVDF matrix exhibited fairly good ozone resistance. Ozonation resulted in increase of pore size and decrease of surface hydrophilicity, which can be attributed to oxidation and dislodgement of hydrophilic additives. Accordingly, long-term ozonation led to moderate changes in performance factors, including increase of membrane permeability by 34%, decrease of retention ability by 21.8%, increase of organic fouling propensity. It is worth noting that membrane tensile strength suffered substantial decrease after ozonation, probably due to ozonation of the PET support layer. Overall, it seems that the PVDF functional layer exhibited good ozone resistance, but the PET support layer was the Achilles' heel of the reinforced PVDF membrane for integrating with pre-ozonation.

A New Look at the Structure and Thermal Behavior of Polyvinylidene Fluoride-Camphor Mixtures

An experimental quasi-equilibrium phase diagram of the polyvinylidene fluoride (PVDF)-camphor mixture is constructed using an original optical method. For the first time, it contains a boundary curve that describes the dependence of camphor solubility in the amorphous regions of PVDF on temperature. It is argued that this diagram cannot be considered a full analogue of the eutectic phase diagrams of two low-molar-mass crystalline substances. The phase diagram is used to interpret the polarized light hot-stage microscopy data on cooling the above mixtures from a homogeneous state to room temperature and scanning electron microscopy data on the morphology of capillary-porous bodies formed upon camphor removal. Based on our calorimetry and X-ray studies, we put in doubt the possibility of incongruent crystalline complex formation between PVDF and camphor previously suggested by Dasgupta et al. (Macromolecules 2005, 38, 5602-5608). We also describe and discuss the high-temperature crystalline structure of racemic camphor, which is not available in the modern literature.

Current State-of-the-Art in Membrane Formation from Ultra-High Molecular Weight Polyethylene

One of the materials that attracts attention as a potential material for membrane formation is ultrahigh molecular weight polyethylene (UHMWPE). One potential material for membrane formation is ultrahigh molecular weight polyethylene (UHMWPE). The present review summarizes the results of studies carried out over the last 30 years in the field of preparation, modification and structure and property control of membranes made from ultrahigh molecular weight polyethylene. The review also presents a classification of the methods of membrane formation from this polymer and analyzes the conventional (based on the analysis of incomplete phase diagrams) and alternative (based on the analysis of phase diagrams supplemented by a boundary line reflecting the polymer swelling degree dependence on temperature) physicochemical concepts of the thermally induced phase separation (TIPS) method used to prepare UHMWPE membranes. It also considers the main ways to control the structure and properties of UHMWPE membranes obtained by TIPS and the original variations of this method. This review discusses the current challenges in UHMWPE membrane formation, such as the preparation of a homogeneous solution and membrane shrinkage. Finally, the article speculates about the modification and application of UHMWPE membranes and further development prospects. Thus, this paper summarizes the achievements in all aspects of UHMWPE membrane studies.

Preparation of polyamide 12 powder for additive manufacturing applications via thermally induced phase separation

Spherical polyamide 12 (PA12) powder for selective laser sintering (SLS) was prepared by thermally induced phase separation (TIPS) method. It was authenticated that the mixed solvent can regulate the liquid–liquid phase separation (LLPS) process by changing the ratio of diluent to non-diluent. The polymer droplets mainly coalesced in the solution, and then the crystal nucleus of PA12 was formed in the droplets. Finally, high crystallinity PA12 powder was precipitated. The morphology, particle size distribution, thermal properties, the change of crystal structure, and powder spreading performances of the obtained powder were characterized. The powder had a narrow particle size distribution, an average particle size of 55.2 μm, and a broad sintering window of 29°C. The results exhibited that the powders prepared by TIPS had excellent sintering properties, and TIPS method provided more choices for SLS technology.

Isoporous Polyvinylidene Fluoride Membranes with Selective Skin Layers via a Thermal-Vapor Assisted Phase Separation Method for Industrial Purification Applications

The membrane filtration process is the most widely used purification process in various industries due to its high separation efficiency, process simplicity, and low cost. Although there is a wide range of membrane products with diverse materials and pore sizes on the market, there is a technological gap between microfiltration and ultrafiltration membranes. Here we developed highly porous polyvinylidene fluoride (PVDF) membranes with a selective skin layer with a pore size range of 20 to 80 nm by using a thermal-vapor assisted phase separation method. Porous and bi-continuous sublayers were generated from spinodal decomposition induced by cooling. The overall membrane structure and pore size changed with the dope composition, while the pore size and thickness of the selective skin layer were effectively controlled by water vapor exposure. The excellent nanoparticle removal efficiencies of the prepared PVDF membranes were confirmed, indicating their potential application in high-level purification processes to remove small trace organic or inorganic impurities from various industrial fluids.