Dry process for forming polycarbonate membranes

Claim 2

The dry process for preparing high void volume, integral, microporous membranes consisting essentially of the steps of: preparing a casting solution containing from about 3 to about 10 grams of polycarbonate homopolymers or copolymers having a molecular weight of between about 46,000 ([η] = 75) and 145,000 ([η] = 190) in about 100 ml of solution consisting essentially of from about 30 to about 90 ml of solvent for said polymer and from about 5 to about 50 grams of nonsolvent swelling agent for said polymer, casting the solution upon a substrate, and allowing the casting solution to evaporate to completion thereby forming an integral, high void volume, microporous membrane.

Claim 3

The dry process as defined in claim 1 wherein the solvent is selected from the group consisting of methylene chloride, methyl ethyl ketone and mixtures of same, and wherein the swelling agent is selected from the group consisting of trifluoroethanol, hexafluoroisopropanol and mixtures of isopropanol with trifluoroethanol, hexafluoroisopropanol or both.

Claim 4

The dry process as defined in claim 2 wherein the molecular weight of the polycarbonate resin is between about 70,000 ([η] = 100) and about 145,000 ([η] = 190).

Claim 5

The dry process as defined in claim 3 wherein the void volume is above about 65%.

Claim 6

The dry process as defined in claim 3 wherein the molecular weight of the polycarbonate resin is between about 110,000 ([η] = 150) and about 130,000 ([η] = 175).

Claim 7

The dry process as defined in claim 5 wherein the void volume is between about 70% and about 85%.

Claim 8

The dry process as defined in claim 2 wherein the polycarbonate resin has the structure ##STR9## or the structure ##STR10## wherein: n is an integer greater than about 180, x is an integer from about 180 to about 600, y is an integer from about 1 to about 6, z is an integer from about 13 to about 450, R is a radical selected from the group consisting of H--, (CH 3 ) 2 CH--, and ##STR11## R' is a radical selected from the group consisting of ##STR12## and substituted derivatives thereof, and wherein R" is a radical selected from the group consisting of ##STR13## wherein a and b are integers ranging from about 3 to about 10 and c is an integer ranging from about 20 to about 50.

Claim 9

The dry process as defined in claim 7 wherein the molecular weight of the polycarbonate resin is between about 70,000 ([η] = 100) and about 145,000 ([η] = 190).

Claim 10

The dry process as defined in claim 7 wherein the solvent consists essentially of methylene chloride.

Claim 11

The dry process as defined in claim 8 wherein the void volume is above about 65%.

Claim 12

The dry process as defined in claim 8 wherein the molecular weight of the polycarbonate resin is between about 110,000 ([η] = 150) and about 130,000 ([η] = 175).

Claim 13

The dry process as defined in claim 11 wherein the void volume is between about 70% and about 85%.

Claim 14

The dry process as defined in claim 1 wherein the solvent is selected from the group consisting of methyl ethyl ketone, dioxane, tetrahydrofuran, and methylene chloride, bis-dichloroethylene, chloroform, and other 1 to 4 carbon-chlorinated hydrocarbons, and mixtures thereof.

Claim 15

The dry process as defined in claim 1 wherein the swelling agent is selected from the group consisting of resorcinol, trifluoroethanol, cyclohexanol, the hemiacetal formed by the reaction of hexafluoroacetone and methyl alcohol, hexafluoro-isopropanol, and mixtures of at least one of the foregoing compounds with isopropanol.

Claim 16

The dry process as defined in claim 14 wherein the polycarbonate resin has the structure ##STR14## or the structure ##STR15## wherein: n is an integer greater than about 180, x is an integer from about 180 to about 600, y is an integer from about 1 to about 6, z is an integer from about 13 to about 450, R is a radical selected from the group consisting of H--, (CH 3 ) 2 CH--, and ##STR16## R' is a radical selected from the group consisting of ##STR17## and substituted derivatives thereof, and wherein R" is a radical selected from the group consisting of ##STR18## wherein a and b are integers ranging from about 3 to about 10 and c is an integer ranging from about 20 to about 50.

Claim 17

The dry process as defined in claim 15 wherein the solution includes as a wetting agent a nonionic surfactant composition.

Claim 18

The dry process as defined in claim 16 wherein the surfactant composition is a polyalkylene oxide surfactant.