Process for preparing microporous polyvinylidene fluoride membranes

Claim 2

In a process for preparing an assymetric, microporous polymeric membrane, which process comprises preparing a membrane-casting solution, casting a thin film of the casting solution on a support base and contacting the cast film with a leaching liquid to provide the microporous membrane, the improvement which comprises: providing a casting solution comprising a vinylidene fluoride polymer, a polar solvent capable of dissolving said polymer and a pore forming agent of an ammonium salt which is a nonsolvent for the casting solution and which does not precipitate out in said casting solution.

Claim 3

The process of claim 1 wherein the pore forming agent is selected from the group consisting of ammonium hydroxide, ammonium acetate, ammonium bifluoride, ammonium carbonate, ammonium chloride and ammonium thiocyanate.

Claim 4

The process of claim 1 wherein said casting solution is comprised of between about 14-21 wt. % of vinylidene fluoride polymer, between about 0.05 to 500 parts per million (ppm) of the pore forming agent with the remainder being substantially said polar solvent.

Claim 5

The process of claim 1 wherein the polar solvent is selected from the group consisting of dimethyl acetamide, dimethyl formamide, N-methyl-2-pyrrolidone, dimethyl sulfoxide, diethyl acetamide, triethyl phosphate, hexamethyl phosphoramide, propylene carbonate, tetramethylurea, and acetone.

Claim 6

The process of claim 1 wherein the temperature of the leaching liquid is between 20° C. to 80° C. and the leaching liquid is methanol.

Claim 7

The process of claim 1 wherein the leaching liquid comprises a mixture of methanol and water and the leaching temperature is from about 20° to 80° C.

Claim 8

The process of claim 1 wherein the casting solution is cast in a thin film onto a porous or fibrous support base.

Claim 9

The process of claim 7 wherein the support base is selected from the group consisting of polypropylene, polyethylene and epoxy coated cloth.

Claim 10

The process of claim 7 wherein the film is cast in a thickness of about 0.5 to 125 mills on a porous support base.

Claim 11

In a process for preparing an assymetric, microporous polymeric membrane, which process comprises preparing a membrane-casting solution, casting a thin film of the casting solution on a support base and contacting the cast film with a leaching liquid to provide the microporous membrane, the improvement which comprises: providing a casting solution comprised of between about 14-21 weight percent of a polyvinylidene fluoride polymer, 79-86 weight percent of N-methyl-2-pyrrolidone and 0.5-500 ppm of a pore forming agent selected from the group consisting of ammonium hydroxide, ammonium acetate, ammonium bifluoride, ammonium carbonate, ammonium chloride and ammonium thiocyanate, casting a film of a thickness of about 0.5-125 mils on a porous support base and thereafter coagulating said film by contacting the same with a methanol or methanol-water mixture leach bath at a temperature between 20°-80° C. to provide a membrane having a high permeation rate with controlled and distinct particle size cut-off properties.

Claim 12

In a process for preparing an assymetric, microporous polymeric membrane, which process comprises preparing a membrane-casting solution, casting a thin film of the casting solution on a support base and contacting the cast film with a leaching liquid to provide the microporous membrane, the improvement which comprises: providing a casting solution comprised of between about 14-21 weight percent of a polyvinylidene fluoride polymer, 79-86 weight percent of N-methyl-2-pyrrolidone and 0.5-500 ppm of a pore forming agent selected from the group consisting of ammonium hydroxide, ammonium acetate, ammonium bifluoride, ammonium carbonate, ammonium chloride and ammonium thiocyanate, casting a film of a thickness of about 0.5-125 mils on a porous support base and thereafter coagulating said film by contacting the same with a methanol or methanol-water mixture leach bath at a temperature between 20°-80° C. to provide a membrane having a high permeation rate with controlled and distinct particle size cut-off properties.

Claim 13

The process of claim 10 wherein the film is immediately coagulated by contacting with said leach bath with substantially no prior exposure to air.