Open-Celled Foams of Polyethersulfone/Poly(N-vinylpyrrolidone) Blends for Ultrafiltration Applications.

Since membranes made of open porous polymer foams can eliminate the use of organic solvents during their manufacturing, a series of previous studies have explored the foaming process of various polymers including polyethersulfone (PESU) using physical blowing agents but failed to produce ultrafiltration membranes. In this study, blends containing different ratios of PESU and poly(N-vinylpyrrolidone) (PVP) were used for preparation of open-celled polymer foams. In batch foaming experiments involving a combination of supercritical CO2 and superheated water as blowing agents, blends with low concentration of PVP delivered uniform open-celled foams that consisted of cells with average cell size less than 20 µm and cell walls containing open pores with average pore size less than 100 nm. A novel sample preparation method was developed to eliminate the non-foamed skin layer and to achieve a high porosity. Flat sheet membranes with an average cell size of 50 nm in the selective layer and average internal pore size of 200 nm were manufactured by batch foaming a PESU blend with higher concentration of PVP and post-treatment with an aqueous solution of sodium hypochlorite. These foams are associated with a water-flux up to 45 L/(h m2 bar). Retention tests confirmed their applicability as ultrafiltration membranes.

Open-Celled Foams from Polyethersulfone/Poly(Ethylene Glycol) Blends Using Foam Extrusion.

Polyethersulfone (PESU), as both a pristine polymer and a component of a blend, can be used to obtain highly porous foams through batch foaming. However, batch foaming is limited to a small scale and is a slow process. In our study, we used foam extrusion due to its capacity for large-scale continuous production and deployed carbon dioxide (CO2) and water as physical foaming agents. PESU is a high-temperature thermoplastic polymer that requires processing temperatures of at least 320 °C. To lower the processing temperature and obtain foams with higher porosity, we produced PESU/poly(ethylene glycol) (PEG) blends using material penetration. In this way, without the use of organic solvents or a compounding extruder, a partially miscible PESU/PEG blend was prepared. The thermal and rheological properties of homopolymers and blends were characterized and the CO2 sorption performance of selected blends was evaluated. By using these blends, we were able to significantly reduce the processing temperature required for the extrusion foaming process by approximately 100 °C without changing the duration of processing. This is a significant advancement that makes this process more energy-efficient and sustainable. Additionally, the effects of blend composition, nozzle temperature and foaming agent type were investigated, and we found that higher concentrations of PEG, lower nozzle temperatures, and a combination of CO2 and water as the foaming agent delivered high porosity. The optimum blend process settings provided foams with a porosity of approximately 51% and an average foam cell diameter of 5 µm, which is the lowest yet reported for extruded polymer foams according to the literature.

Hydrophilic Dual Layer Hollow Fiber Membranes for Ultrafiltration.

In this study, a triblock copolymer was used as additive to fabricate new dual layer hollow fiber membranes with a hydrophilic active inner surface in order to improve their fouling resistance. The polymeric components of the solutions for membrane fabrication were poly(ether sulfone), poly(N-vinyl pyrrolidone), and the triblock copolymer. The additive consists of three blocks: a middle hydrophobic poly(ether sulfone) block and two outer hydrophilic alkyl poly(ethylene glycol) blocks. By varying the additive concentration in the solutions, it was possible to fabricate dual layer hollow fiber membranes that are characterized by a hydrophilic inner layer, a pure water permeance of over 1800 L/(m2 bar h) and a molecular weight cut-off of 100 kDa similar to commercial membranes. Contact angle and composition determination by XPS measurements revealed the hydrophilic character of the membranes, which improved with increasing additive concentration. Rheological, dynamic light scattering, transmission, and cloud point experiments elucidated the molecular interaction, precipitation, and spinning behavior of the solutions. The low-molecular weight additive reduces the solution viscosity and thus the average relaxation time. On the contrary, slow processes appear with increasing additive concentration in the scattering data. Furthermore, phase separation occurred at a lower non-solvent concentration and the precipitation time increased with increasing additive content. These effects revealed a coupling mechanism of the triblock copolymer with poly(N-vinyl pyrrolidone) in solution. The chosen process parameters as well as the additive solutions provide an easy and inexpensive way to create an antifouling protection layer in situ with established recipes of poly(ether sulfone) hollow fiber membranes. Therefore, the membranes are promising candidates for fast integration in the membrane industry.

Facilitated Structure Formation in Isoporous Block Copolymer Membranes upon Controlled Evaporation by Gas Flow.

The conventional fabrication of isoporous membranes via the evaporation-induced self-assembly of block copolymers in combination with non-solvent induced phase separation (SNIPS) is achieved under certain environmental conditions. In this study, we report a modification in the conventional fabrication process of (isoporous) flat sheet membranes in which the self-assembly of block copolymers is achieved by providing controlled evaporation conditions using gas flow and the process is introduced as gSNIPS. This fabrication approach can not only trigger and control the microphase separation but also provides isoporous structure formation in a much broader range of solution concentrations and casting parameters, as compared to fabrication under ambient, uncontrolled conditions. We systematically investigated the structure formation of the fabrication of integral asymmetric isoporous membranes by gSNIPS. A quantitative correlation between the evaporation conditions (causing solvent evaporation and temperature drop) and the self-assembly of block copolymers beginning from the top layer up to a certain depth, orientation of pores in the top layer and the substructure morphology has been discussed empirically.

Self-assembly of block copolymers during hollow fiber spinning: an in situ small-angle X-ray scattering study.

We investigated the self-assembly of block copolymers during hollow fiber membrane (HFM) fabrication by conducting in situ small angle X-ray scattering (SAXS) and ex situ scanning electron microscopy (SEM) studies. SAXS enables us to follow the structural rearrangements after extrusion at different distances from the spinning nozzle. The kinetics of the spinning process is examined as a function of the composition of block copolymer solutions and the spinning parameters. We studied the influence of the extrusion rate on the block copolymer microdomains and their self-assembly in weakly segregated and ordered solutions. The addition of magnesium acetate (MgAc2) leads to the ordering of micelles in the block copolymer solution already at lower polymer concentrations and shows an increased number of micelles with larger domain spacing as compared to the pristine solution. The SAXS data show the effect of shear within the spinneret on the self-assembly of block copolymers and the kinetics of phase separation after extrusion. It is observed that the ordering of micelles in solutions is decreased as indicated by the loss of crystallinity while high extrusion rates orient the structures perpendicular to the fiber direction. The structural features obtained from in situ SAXS experiments are correlated to the structure in the block copolymer solutions in the absence of shear and the morphologies in flat sheet and HF membranes obtained by ex situ SEM. This allows a systematic and comparative study of the effects varying the microdomain ordering within different block copolymer solutions and the formed membrane structures.

Adsorption of Proteins on Degradable Magnesium-Which Factors are Relevant?

Although the adsorption of proteins on the Mg surface was ascribed to be the main reason for the effect of proteins on magnesium (Mg) degradation, few studies about the adsorption of proteins on the Mg surface were performed due to the labile circumstances during immersion. In the present study, the adsorption of bovine serum albumin (BSA) and fibrinogen (Fib) on the Mg surface during and after immersion was extensively investigated in different media for the first time. The results revealed that BSA and Fib showed a similar adsorption trend on the Mg surface during and after immersion, and they adsorbed more on the Mg surface in Hank's balanced salt solution (HBSS) than in Dulbecco's modified Eagle medium Glutamax-I (DMEM). The possible influence factors for protein adsorption, such as pH, surface roughness, and wettability, were considered to elucidate different adsorption in HBSS and DMEM. It was found that the participation of Ca2+ in the formation of degradation products largely affected the degradation rate of Mg, changed surface roughness, compactness, and surface charge during immersion, which largely suppressed the adsorption of proteins on the Mg surface.

Hollow Fiber Membranes of Blends of Polyethersulfone and Sulfonated Polymers.

Hollow fiber membranes (HFM) are fabricated from blend solutions of a polyethersulfone (PESU) with a sulfonated PESU (sPESU) or a sulfonated polyphenylenesulfone (sPPSU). The influence of different additives in the dope solution and different bore fluids on the HFM are studied. The addition of poly(sodium 4-styrene sulfonate) (PSSNa)/ethylene glycol (EG) to the dope solution results in an increased water flux of the HFM compared to its counterparts without this additive system. The morphology of the hollow fibers is examined by scanning electron microscopy (SEM). The inner surface of the hollow fibers is studied by X-ray photoelectron spectroscopy (XPS), and it is found that water permeation through the hollow fiber membranes is facilitated due to the change in morphology upon the addition of the PSSNa/EG additive system, but not by the presence of hydrophilic sulfonic acid groups on the membrane surface.

Setting the Stage for Fabrication of Self-Assembled Structures in Compact Geometries: Inside-Out Isoporous Hollow Fiber Membranes.

Fabrication of evaporation-induced self-assembled structures on easily accessible surfaces is an established strategy, while achieving such microphase-separated structures in compact geometries has been a long-standing goal. The requirement of comparatively less concentrated block copolymer (BCP) solution to pass through the compact geometries significantly reduces the stimulations required for self-assembly. The high polymer relaxation rates and decreased thermodynamic driving forces, as well as high capillary suction of dilute solutions in the porous substrates, complicates the BCP self-assembly and fabrication of the uniform coated layer, respectively. In this study, highly permeable robust poly(ether sulfone) hollow fiber membranes (PES HFM) with an inner diameter of approximately 1 mm are selected as compact geometries, and the isoporous structures are developed on top of ≤10 µm thin coated layer. This fabrication process introduces a technologically favored inside-out configuration for isoporous composite HFM with large bore diameters.

Continuous Production of Macroporous Films: an Alternative to Breath Figure Assembly.

Despite the need for sophisticated instrumentation, breath figure assembly (BFA) methods are restricted to produce macroporous films on a tiny scale so far. The current study narrates the fabrication of macroporous films in hollow fiber geometry which extends to adopt the method for continuous production of isoporous surfaces from commercially available low-priced polymer materials. The fabrication of the films in the hollow fiber geometry is carried out by a co-centric quadruple orifice spinneret through which four different liquids are co-extruded simultaneously: bore fluid (to fill the lumen of the fiber), support layer solution, glycerol, and an isoporous film forming solution through the outer most orifice. The extruded entities plunge into a coagulation bath after passing a definite air gap. The implementation of the concept of diffuse-in, droplet formation, and then condense-out behavior of glycerol in a co-extrusion method of hollow fiber spinning makes macroporous film formation possible in an interminable way sidestepping the use of breath figure assembly method. Moreover, the continuous film formation by the proposed mechanism is also authenticated in flat sheet geometry by employing two casting blades in a casting machine. The structure of the films is analyzed by scanning electron microscopy (SEM).

A Facile Method to Prepare Double-Layer Isoporous Hollow Fiber Membrane by In Situ Hydrogen Bond Formation in the Spinning Line.

A double-layer hollow fiber is fabricated where an isoporous surface of polystyrene-block-poly(4-vinylpyridine) is fixed on a support layer by co-extrusion. Due to the sulfonation of the support layer material, delamination of the two layers is suppressed without increasing the number of subsequent processing steps for isoporous composite membrane formation. Electron microscope-energy-dispersive X-ray spectroscopy images unveil the existence of a high sulfur concentration in the interfacial region by which in-process H-bond formation between the layers is evidenced. For the very first time, our study reports a facile method to fabricate a sturdy isoporous double-layer hollow fiber.