Thin membrane fabrication

Figure 7. Apparatus for Ultra-thin Membrane Fabrication...

In heterogeneous solid membranes, the active (selective) material is mixed in the form of a powder with a suitable binder (e.g., silicone rubber) and cast in the form of thin membranes. In this case, the difficulties associated with single-crystal fabrication are avoided, and better stability is obtained than in membranes compressed from polycrystalline powder. 

These incorporate membranes fabricated from insoluble crystalline materials. They can be in the form of a single crystal, a compressed disc of micro-crystalline material or an agglomerate of micro-crystals embedded in a silicone rubber or paraffin matrix which is moulded in the form of a thin disc. The materials used are highly insoluble salts such as lanthanum fluoride, barium sulphate, silver halides and metal sulphides. These types of membrane show a selective and Nemstian response to solutions containing either the cation or the anion of the salt used. Factors to be considered in the fabrication of a suitable membrane include solubility, mechanical strength, conductivity and resistance to abrasion or corrosion. 

Circular Bragg nanolasers (CBNLs) of several geometries and Bragg reflector orders were fabricated within a thin membrane of InGaAsP semiconductor material21. A cross-section of the semiconductor epitaxial structure used is illustrated... 

Electron Transfer Type of Dehydrogenase Sensors To fabricate an enzyme sensor for fructose, we found that a molecular interface of polypyrrole was not sufficient to realize high sensitivity and stability. We thus incorporated mediators (ferricyanide and ferrocene) in the enzyme-interface for the effective and the most sensitive detection of fructose in two different ways (l) two step method first, a monolayer FDH was electrochemically adsorbed on the electrode surface by electrostatic interaction, then entrapment of mediator and electro-polymerization of pyrrole in thin membrane was simultaneously performed in a separate solution containing mediator and pyrrole, (2) one-step method co-immobilization of mediator and enzyme and polymerization of pyrrole was simultaneously done in a solution containing enzyme enzyme, mediator and pyrrole as illustrated in Fig.22. 

Dr. Hui has worked on various projects, including chemical sensors, solid oxide fuel cells, magnetic materials, gas separation membranes, nanostruc-tured materials, thin film fabrication, and protective coatings for metals. He has more than 80 research publications, one worldwide patent, and one U.S. patent (pending). He is currently leading and involved in several projects for the development of metal-supported solid oxide fuel cells (SOFCs), ceramic nanomaterials as catalyst supports for high-temperature PEM fuel cells, protective ceramic coatings on metallic substrates, ceramic electrode materials for batteries, and ceramic proton conductors. Dr. Hui is also an active member of the Electrochemical Society and the American Ceramic Society. 

Nondegradable polymers are also useful as matrices for ocular implants. This application requires the polymer to be hydrophilic, to minimize local tissue irritation. Need for ocular implants stems from the challenges posed to conventional ocular medicines (i.e., eye drops) such as rapid dilution, tear washout, poor patient compliance, and limited bioavailability. Ocular implants from hydrophilic polymer matrices that provide localized sustained release may overcome the above limitations. The first polymeric sustained release product to reach the market was Ocusert , a pilocarpin sustained release ocular implant developed by Alza. Ocusert has the drug reservoir as a thin disc of pilocarpine-alginate complex sandwiched between two transparent discs of microporous membrane fabricated from ethylene-vinyl acetate copolymer. The microporous membranes permit the tear fluid to penetrate into the drug reservoir compartment to dissolve pilocarpine from the complex. Pilocarpine molecules are then released at a constant rate of 20 or 40 pg/hr for a four- to seven-day management of glaucoma. 

The enzyme-containing FET, called ENFET, is fabricated from an ISFET by casting a thin membrane containing the enzyme over an ion-selective membrane... 

In SOFCs, the difference in chemical potential or activity of oxygen across the electrolyte surfaces provides the electromotive force, and thus the electrical potential. Extensive research over the past decades has resulted in the development of cost-effective processes for the fabrication of thin and dense electrolyte layers. YSZ has been considered one of the best choices for high-temperature applications (>650°C) because of its feasibility of fabrication of a thin membrane, reasonable ionic conductivity, large ionic domain, and, most importantly, chemical and mechanical stability... 

In this controlled-release ocular insert, the drug reservoir is a thin disc of pilocarpine-alginate complex sandwiched between two transparent discs of micro-porous membrane fabricated from ethylene-vinyl acetate copolymer (Fig. 5). The microporous membranes permit the tear fluid to penetrate into the drug... 

PTFE has a remarkable range of properties. It possesses the simple monomer unit, -(CFj-CE )-, with a molecular weight of 100, an SG of 2.1-2.3 and a degree of polymerisation of 10 000. PTFE is extremely stable and inert, is not soluble in any known liquid solvent and is unaffected by concentrated acids and alkalis. It will not bum in air, is flexible down to -80 °C and dimensionally stable up to 4-250 °C. It has a low coefficient of friction, good abrasion resistance and has excellent liquid repellency properties. It is predominantly available as a thin membrane that is laminated to one or more textile fabrics. PTFE is thus well suited for use against chemicals and liquids in harsh environments. One of the special uses of the membrane is in a shock-expanded microporous form, which confers high liquid barrier properties with high water vapour permeability. In this form laminates are... 

The diffusivity of most molecules through liquids is much higher than through polymer membranes, which are so low that exceedingly thin membranes must be constructed to produce industrially acceptable fluxes, which may lead to fabrication and mechanical integrity problems. 

Membrane Fabrication, Lamination and Reinforcement. The thermoplastic copolymer of TFE and PVEX monomer can be extruded or molded into a thin film by conventional methods. Extrusion is most appropriate for continuous production of large membranes because it facilitates control of film thickness. Lamination can be performed with a roll press to obtain multilayer membrane. To improve their mechanical properties, membranes are generally reinforced with an inert material such as fabric made of PTFE (67, 68), fibriled PTFE (69), or wire netting (70). 

The high value of the water flux parameter DiCi, along with adequately low NaCl transport, motivated the fabrication of p-2221 into asymmetric membranes. The preparation of asymmetric membranes is a multistep process involving solution casting, partial solvent evaporation, and gelation as the most critical operations. The resulting asymmetric structure (a thin dense "skin" supported by a porous substructure 50-100 urn in thickness) combines the high flux of a thin membrane with the mechanical properties of a much thicker film. 

When furfuryl alcohol was added as a comonomer to the THEIC, water fluxes were increased tenfold. In addition, the extremely high salt rejections characteristic of NS-200 were obtained, while the high organic rejections characteristic of the isocyanurate moiety were retained. A typical patent example of membrane fabrication uses a water solution of 1 2 2 1 weight percent THEIC fur-furyl alcohol sulfuric acid dodecyl sodium sulfate, deposited on microporous polysulfone and cured at 150°C for 15 minutes. This membrane, possessing a thin active layer 100 to 300 angstroms thick, showed 99.9% rejection and 12 gfd flux under seawater test conditions at 1,000 psi. 

Although oxygen flux increases inversely with membrane thickness, if membrane thickness becomes smaller than a few hundred microns, it must be supported on a porous substrate. This requires novel methods to fabricate thin membranes mounted on porous supports, membrane sealing materials and techniques, and optimal membrane geometry. 

Dense, composite membranes that are 35 p,m in thickness were successfully fabricated. A cross section of a supported, thin membrane structure is shown in Fig. 4.6. 

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