Filtration-based synthesis of micelle-derived composite membranes for high-flux ultrafiltration

Ideal membrane configurations for efficient separation at high flux rates consist of thin size-selective layers connected to macroporous supports for mechanical stabilization. We show that micelle-derived (MD) composite membranes combine efficient separation of similarly sized proteins and water flux 5-10 times higher than that of commercial membranes with similar retentions. MD composite membranes were obtained by filtration of solutions of amphiphilic block copolymer (BCP) micelles through commercially available macroporous supports covered by sacrificial nanostrand fabrics followed by annealing and removal of the nanostrand fabrics. Swelling-induced pore generation in the BCP films thus covering the macroporous supports yielded ∼210 nm thin nanoporous size-selective BCP layers with porosities in the 40% range tightly connected to the macroporous supports. Permselectivity and flux rates of the size-selective BCP layers were adjusted by the BCP mass deposited per membrane area and by proper selection of swelling times. The preparation methodology described here may pave the way for a modular assembly system allowing the design of tailored separation membranes.