Ultrapermeable Organic Solvent Nanofiltration Membranes with Precisely Tailored Support Layers Fabricated Using Thin-Film Liftoff

Thin-film composite (TFC) membranes are favored for precise molecular sieving in liquid-phase separations; they possess high permeability due to the minimal thickness of the active layer and the high porosity of the support layer. However, current TFC membrane fabrication techniques are limited by the available materials for the selective layer and do not demonstrate the level of structural control needed to substantially advance organic solvent nanofiltration (OSN) membrane technology. In this work, we employ the newly developed thin-film lift-off (T-FLO) technique to fabricate polybenzimidazole (PBI) TFC membranes with porous support layers uniquely tailored to OSN. The drop-cast dense PBI selective layers endow the membranes with an almost complete rejection of common small dye molecules. The polymeric support layer is optimized by a combinatorial approach using four different monomers that alter the cross-linking density and polymer chain flexibility of the final composite. These two properties substantially affect the porogen holding capacity of the reticular polymer network, leading to the formation of different macropore structures. With a 150 nm thick PBI selective layer and fine-tuning of the support layer, the resulting membrane achieves stable and superior permeance of 14.0, 11.7, 16.4, 11.4, 17.1, and 19.7 L m–2 h–1 bar–1 for water, ethanol, methanol, isopropanol, tetrahydrofuran (THF), and acetonitrile, respectively.