Formation of Thin, Isoporous Block Copolymer Membranes by an Upscalable Profile Roller Coating Process-A Promising Way to Save Block Copolymer

Amphiphilic Poly(vinyl alcohol) Membranes Leaving Out Chemical Cross-Linkers: Design, Synthesis, and Function of Tailor-Made Poly(vinyl alcohol)-b-poly(styrene) Copolymers

Tailor-made poly(vinyl alcohol)-b-poly(styrene) copolymers (PVA-b-PS) for separation membranes are synthesized by the combination of reversible-deactivation radical polymerization techniques. The special features of these di-block copolymers are the high molecular weight (>70 kDa), the high PVA content (>80 wt%), and the good film-forming property. They are soluble only in hot dimethyl sulfoxide, but by the "solvent-switch" technique, they self-assemble in aqueous media to form micelles. When the self-assembled micelles are cast on a porous substrate, thin-film membranes with higher water permeance than that of PVA homopolymer are obtained. Thus, by using these tailor-made PVA-b-PS copolymers, it is demonstrated that chemical cross-linkers and acid catalysts can no longer be needed to produce PVA membranes, since the PS nanodomains within the PVA matrix act as cross-linking points. Lastly, subsequent thermal annealing of the thin film enhances the membrane selectivity due to the improved microphase separation.

Non-Equilibrium Block Copolymer Self-Assembly Based Porous Membrane Formation Processes Employing Multicomponent Systems

Porous polymer-derived membranes are useful for applications ranging from filtration and separation technologies to energy storage and conversion. Combining block copolymer (BCP) self-assembly with the industrially scalable, non-equilibrium phase inversion technique (SNIPS) yields membranes comprising periodically ordered top surface structures supported by asymmetric, hierarchical substructures that together overcome performance tradeoffs typically faced by materials derived from equilibrium approaches. This review first reports on recent advances in understanding the top surface structural evolution of a model SNIPS-derived system during standard membrane formation. Subsequently, the application of SNIPS to multicomponent systems is described, enabling pore size modulation, chemical modification, and transformation to non-polymeric materials classes without compromising the structural features that define SNIPS membranes. Perspectives on future directions of both single-component and multicomponent membrane materials are provided. This points to a rich and fertile ground for the study of fundamental as well as applied problems using non-equilibrium-derived asymmetric porous materials with tunable chemistry, composition, and structure.

Modeling Microstructure Formation in Block Copolymer Membranes Using Dynamical Self-Consistent Field Theory

Block copolymers have attracted recent interest as candidate materials for ultrafiltration membranes, due to their ability to form isoporous integral-asymmetric membranes by the combined processes of self-assembly and nonsolvent-induced phase separation (SNIPS). However, the dependence of surface layer and substructure morphologies on the processing variables associated with SNIPS is not well understood nor is the interplay between microphase and macrophase separation in block copolymers undergoing such coagulation. Here, we use dynamical self-consistent field theory to simulate the microstructure evolution of block copolymer films during SNIPS and find that such films form the desired sponge-like asymmetric porous substructure only if the solvent and nonsolvent have opposite block selectivities and that otherwise they form a dense nonporous microphase-separated film. Our results could have important implications for the choices of solvent and nonsolvent in the processing of block copolymer membranes.

Solvent-assisted self-assembly of block copolymer thin films

Solvent-assisted block copolymer self-assembly is a compelling method for processing and advancing practical applications of these materials due to the exceptional level of the control of BCP morphology and significant acceleration of ordering kinetics. Despite substantial experimental and theoretical efforts devoted to understanding of solvent-assisted BCP film ordering, the development of a universal BCP patterning protocol remains elusive; possibly due to a multitude of factors which dictate the self-assembly scenario. The aim of this review is to aggregate both seminal reports and the latest progress in solvent-assisted directed self-assembly and to provide the reader with theoretical background, including the outline of BCP ordering thermodynamics and kinetics phenomena. We also indicate significant BCP research areas and emerging high-tech applications where solvent-assisted processing might play a dominant role.

Nonequilibrium Processes in Polymer Membrane Formation: Theory and Experiment

Porous polymer and copolymer membranes are useful for ultrafiltration of functional macromolecules, colloids, and water purification. In particular, block copolymer membranes offer a bottom-up approach to form isoporous membranes. To optimize permeability, selectivity, longevity, and cost, and to rationally design fabrication processes, direct insights into the spatiotemporal structure evolution are necessary. Because of a multitude of nonequilibrium processes in polymer membrane formation, theoretical predictions via continuum models and particle simulations remain a challenge. We compiled experimental observations and theoretical approaches for homo- and block copolymer membranes prepared by nonsolvent-induced phase separation and highlight the interplay of multiple nonequilibrium processes─evaporation, solvent-nonsolvent exchange, diffusion, hydrodynamic flow, viscoelasticity, macro- and microphase separation, and dynamic arrest─that dictates the complex structure of the membrane on different scales.

Selective Swelling and Functionalization of Integral Asymmetric Isoporous Block Copolymer Membranes

SNIPS stands for a membrane fabrication technique that combines the evaporation induced self-assembly of the block copolymers and the classical nonsolvent induced phase separation. It is a one-step readily scalable technique to fabricate integral asymmetric isoporous membranes. The prominent developments in the last decade have carved out a niche for SNIPS as a potential technique to fabricate next generation isoporous membranes. In the last decade, a rich polymer library and variety of membrane postmodification routes have been successfully implemented to fabricate SNIPS membranes having the desired pore functionality. Some of these membranes form soft nanochannels in hydrated state due to swelling of the pore wall, i.e., the pore forming block of the block copolymer. These membranes having soft nanochannels have demonstrated the potential to perform several challenging separation tasks in ultrafiltration and nanofiltration. This paper highlights the currently accessible pore functionality, the strategies to tune the swelling of the soft nanochannels, the potential applications, and future perspectives of these membranes.

Polymers and Solvents Used in Membrane Fabrication: A Review Focusing on Sustainable Membrane Development

(1) Different methods have been applied to fabricate polymeric membranes with non-solvent induced phase separation (NIPS) being one of the mostly widely used. In NIPS, a solvent or solvent blend is required to dissolve a polymer or polymer blend. N-methyl-2-pyrrolidone (NMP), dimethylacetamide (DMAc), dimethylformamide (DMF) and other petroleum-derived solvents are commonly used to dissolve some petroleum-based polymers. However, these components may have negative impacts on the environment and human health. Therefore, using greener and less toxic components is of great interest for increasing membrane fabrication sustainability. The chemical structure of membranes is not affected by the use of different solvents, polymers, or by the differences in fabrication scale. On the other hand, membrane pore structures and surface roughness can change due to differences in diffusion rates associated with different solvents/co-solvents diffusing into the non-solvent and with differences in evaporation time. (2) Therefore, in this review, solvents and polymers involved in the manufacturing process of membranes are proposed to be replaced by greener/less toxic alternatives. The methods and feasibility of scaling up green polymeric membrane manufacturing are also examined.

Non-Solvent Induced Phase Separation Enables Designer Redox Flow Battery Electrodes

Porous carbonaceous electrodes are performance-defining components in redox flow batteries (RFBs), where their properties impact the efficiency, cost, and durability of the system. The overarching challenge is to simultaneously fulfill multiple seemingly contradictory requirements-i.e., high surface area, low pressure drop, and facile mass transport-without sacrificing scalability or manufacturability. Here, non-solvent induced phase separation (NIPS) is proposed as a versatile method to synthesize tunable porous structures suitable for use as RFB electrodes. The variation of the relative concentration of scaffold-forming polyacrylonitrile to pore-forming poly(vinylpyrrolidone) is demonstrated to result in electrodes with distinct microstructure and porosity. Tomographic microscopy, porosimetry, and spectroscopy are used to characterize the 3D structure and surface chemistry. Flow cell studies with two common redox species (i.e., all-vanadium and Fe^2+/3+ ) reveal that the novel electrodes can outperform traditional carbon fiber electrodes. It is posited that the bimodal porous structure, with interconnected large (>50 µm) macrovoids in the through-plane direction and smaller (<5 µm) pores throughout, provides a favorable balance between offsetting traits. Although nascent, the NIPS synthesis approach has the potential to serve as a technology platform for the development of porous electrodes specifically designed to enable electrochemical flow technologies.

Next-Generation Ultrafiltration Membranes Enabled by Block Polymers

Reliable and equitable access to safe drinking water is a major and growing challenge worldwide. Membrane separations represent one of the most promising strategies for the energy-efficient purification of potential water sources. In particular, porous membranes are used for the ultrafiltration (UF) of water to remove contaminants with nanometric sizes. However, despite exhibiting excellent water permeability and solution processability, existing UF membranes contain a broad distribution of pore sizes that limit their size selectivity. To maximize the potential utility of UF membranes and allow for precise separations, improvements in the size selectivity of these systems must be achieved. Block polymers represent a potentially transformative solution, as these materials self-assemble into well-defined domains of uniform size. Several different strategies have been reported for integrating block polymers into UF membranes, and each strategy has its own set of materials and processing considerations to ensure that uniform and continuous pores are generated. This Review aims to summarize and critically analyze the chemistries, processing techniques, and properties required for the most common methods for producing porous membranes from block polymers, with a particular focus on the fundamental mechanisms underlying block polymer self-assembly and pore formation. Critical structure-property-performance metrics will be analyzed for block polymer UF membranes to understand how these membranes compare to commercial UF membranes and to identify key research areas for continued improvements. This Review is intended to inform readers of the capabilities and current challenges of block polymer UF membranes, while stimulating critical thought on strategies to advance these technologies.

Spraying of Ultrathin Isoporous Block Copolymer Membranes-A Story about Challenges and Limitations

Isoporous membranes can be prepared by a combination of self-assembly of amphiphilic block copolymers and the non-solvent induced phase separation process. As the general doctor-blade technique suffers from high consumption of expensive block copolymer, other methods to reduce its concentration in the casting solution are sought after. Decreasing the block copolymer concentration during membrane casting and applying the block copolymer solution on a support membrane to obtain ultrathin isoporous membrane layers with e.g., spraying techniques, can be an answer. In this work we focused on the question if upscaling of thin block copolymer membranes produced by spraying techniques is feasible. To upscale the spray coating process, three different approaches were pursued, namely air-brush, 1-fluid nozzles and 2-fluid nozzles as generally used in the coating industry. The different spraying systems were implemented successfully in a membrane casting machine. Thinking about future development of isoporous block copolymer membranes in application it was significant that a continuous preparation process can be realised combining spraying of thin layers and immersion of the thin block copolymer layers in water to ensure phase-separation. The system was tested using a solution of polystyrene-block-poly(4-vinylpyridine) diblock copolymer. A detailed examination of the spray pattern and its homogeneity was carried out. The limitations of this method are discussed.

Flux model development and synthesis optimization for an enhanced GO embedded nanocomposite membrane through FFD and RSM approach

A two-level full factorial design was used to analyze several factors involved in PSF–GO–Pebax thin film nanocomposite membranes development. Permeate flux was chosen as a single response for four possible factors: Pebax selective layer concentration, amount of GO load to Pebax selective layer, Pebax–GO selective layer thickness, and amount of GO load to PSF substrate. The study is aimed at factors interaction and contribution towards the highest permeation flux via FFD and RSM approach. R² obtained from the ANOVA is 0.9937 with Pebax concentration as the highest contributing factor. Pebax concentration–amount of GO load to PSF substrate is the only interaction contributing to the highest flux. A regression analysis concluded the study with model development and an optimized condition for the membrane design.

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.

Isoporous Membranes from Novel Polystyrene-b-poly(4-vinylpyridine)-b-poly(solketal methacrylate) (PS-b-P4VP-b-PSMA) Triblock Terpolymers and Their Post-Modification

In this paper, the formation of nanostructured triblock terpolymer polystyrene-b-poly(4-vinylpyridine)-b-poly(solketal methacrylate) (PS-b-P4VP-b-PSMA), polystyrene-b-poly(4-vinylpyridine)-b-poly(glyceryl methacrylate) (PS-b-P4VP-b-PGMA) membranes via block copolymer self-assembly followed by non-solvent-induced phase separation (SNIPS) is demonstrated. An increase in the hydrophilicity was observed after treatment of non-charged isoporous membranes from PS-b-P4VP-b-PSMA, through acidic hydrolysis of the hydrophobic poly(solketal methacrylate) PSMA block into a hydrophilic poly(glyceryl methacrylate) PGMA block, which contains two neighbored hydroxyl (-OH) groups per repeating unit. For the first time, PS-b-P4VP-b-PSMA triblock terpolymers with varying compositions were successfully synthesized by sequential living anionic polymerization. Composite membranes of PS-b-P4VP-b-PSMA and PS-b-P4VP-b-PGMA triblock terpolymers with ordered hexagonally packed cylindrical pores were developed. The morphology of the membranes was studied with scanning electron microscopy (SEM) and atomic force microscopy (AFM). PS-b-P4VP-b-PSMA triblock terpolymer membranes were further treated with acid (1 M HCl) to get polystyrene-b-poly(4-vinylpyridine)-b-poly(glyceryl methacrylate) (PS-b-P4VP-b-PGMA). Notably, the pristine porous membrane structure could be maintained even after acidic hydrolysis. It was found that membranes containing hydroxyl groups (PS-b-P4VP-b-PGMA) show a stable and higher water permeance than membranes without hydroxyl groups (PS-b-P4VP-b-PSMA), what is due to the increase in hydrophilicity. The membrane properties were analyzed further by contact angle, protein retention, and adsorption measurements.

Size Fractionation of Fluorescent Graphene Quantum Dots Using a Cross-Flow Membrane Filtration System

Graphene quantum dots (GQDs) have received great attention as optical agents because of their low toxicity, stable photoluminescence (PL) in moderate pH solutions, and size-dependent optical properties. Although many synthetic routes have been proposed for producing GQD solutions, the broad size distribution in GQD solutions limits its use as an efficient optical agent. Here, we present a straightforward method for size fractionation of GQDs dispersed in water using a cross-flow filtration system and a track-etched membrane with cylindrical uniform nanopores. The GQD aqueous suspension, which primarily contained blue-emitting GQDs (B-GQDs) and green-emitting GQDs (G-GQDs), was introduced to the membrane in tangential flow and was fractionated with a constant permeate flow of about 800 L m-2 h-1 bar-1. After filtration, we observed a clear blue PL spectrum from the permeate side, which can be attributed to selective permeation of relatively small B-GQDs. The process provided a separation factor (B-GQDs/G-GQDs) of 0.74. In the cross-flow filtration system, size-dependent permeation through cylindrical nanochannels was confirmed by simulation. Our results demonstrate a feasible method facilitating size fractionation of two-dimensional nanostructures using a cross-flow membrane filtration system. Since membrane filtration is simple, cost-effective, and scalable, our approach can be applied to prepare a large amount of size-controlled GQDs required for high performance opto-electronics and bio-imaging applications.