Scalable fabrication of bijel films via continuous flow slit-coating

TL;DR

This paper presents a novel roll-to-roll process for the continuous fabrication of flat-sheet nanocomposite membranes using solvent transfer induced phase separation, enabling scalable production with controlled pore structures.

Contribution

It introduces a continuous, scalable R2R process for flat-sheet nanocomposite membranes via STrIPS, expanding beyond hollow fiber production.

Findings

Successful continuous fabrication of flat-sheet membranes.

Control over pore structure through composition and particle loading.

Understanding of wetting dynamics on the substrate.

Abstract

Nanocomposite membranes are an emerging filtration material in the production of clean water. Recently, the fabrication of porous nanocomposite membranes via solvent transfer induced phase separation (STrIPS) was introduced. During STrIPS, the phase separation of two immiscible liquids is arrested by the attachment of nanoparticles at the liquid-liquid interface, generating a porous particle-stabilized membrane template. STrIPS nanocomposite membranes, however, have so far only been produced as hollow fibers. To overcome this, we designed a roll-to-roll (R2R)-process for the continuous fabrication of flat-sheet nanocomposite membranes via STrIPS. We produce the STrIPS membrane by printing the membrane precursor on a carrier substrate. This allows for the continuous collection of STrIPS membranes with control over the membrane dimensions. Contact angle measurements elucidate the wetting dynamics of the STrIPS membrane on the substrate. Furthermore, we demonstrate control over the membrane pore structure by varying the precusor liquid composition and by changing the particle modification and loading in the membrane. With this, the R2R-approach may stimulate further advancements in the fabrication of flat-sheet nanocomposite membranes via STrIPS.