Ultra-thin polymer film and porous ultra-thin polymer film

Patent metadata

Field	Value
Publication number	US-10858490-B2
Application number	US-201815902501-A
Country	US
Kind code	B2
Filing date	Feb 22, 2018
Priority date	Mar 12, 2012
Publication date	Dec 8, 2020
Grant date	Dec 8, 2020

Abstract

A porous ultra-thin polymer film has a film thickness of 10 nm-1000 nm. A method of producing the porous ultra-thin polymer film includes dissolving two types of mutually-immiscible polymers in a first solvent in an arbitrary proportion to obtain a solution; applying the solution onto a substrate and then removing the first solvent from the solution applied onto the substrate to obtain a phase-separated ultra-thin polymer film that has been phase-separated into a sea-island structure; and immersing the ultra-thin polymer film in a second solvent which is a good solvent for the polymer of the island parts but a poor solvent for a polymer other than the island parts to remove the island parts, thereby obtaining a porous ultra-thin polymer film.

First claim

What is claimed is:

1. A complex of a substrate, a water-soluble sacrificial film and a porous ultra-thin polymer film, comprising the water-soluble sacrificial film on the substrate, and the porous ultra-thin polymer film having a film thickness of 10 nm-1000 nm thereon, wherein the porous ultra-thin polymer film comprises non-penetrating pores.

2. The complex according to claim 1 , wherein the pores with a size of 30 nm-50 μm are present on the surface of the porous ultra-thin polymer film at a density of 5×10 −3 pores/μm 2 -50 pores/μm 2 .

3. The complex according to claim 1 , wherein the pore diameter distribution in the porous ultra-thin polymer film is at least ±20%.

4. The complex according to claim 1 , wherein the ratio of the pore diameter in microns to the film thickness in microns of the porous ultra-thin polymer film is 0.1-50.

5. The complex according to claim 1 , wherein the polymer is at least one selected from the group consisting of polyhydroxyalkanoic acid, a copolymer of polyhydroxyalkanoic acid, poly(ester-ether), a polyester of aliphatic dicarboxylic acid and aliphatic diol, polyamide, polyurethane, polysaccharide ester, poly(acrylate), poly(methacrylate), polystyrene, polyvinyl acetate and polysiloxane.

6. A complex of a substrate, a porous ultra-thin polymer film and a water-soluble support membrane, comprising, in order, the porous ultra-thin polymer film having a film thickness of 10 nm-1000 nm on the substrate, and further the water-soluble support membrane on the porous ultra-thin polymer film, the water-soluble support membrane being selected from the group consisting of a polyvinyl alcohol film, a polyacrylate film, a polymethacrylate film, a sodium alginate film, a polyethylene oxide film, a polyacrylic amide film, a polyvinylpyrrolidone film, a starch film, a carboxymethyl cellulose film, a collagen film, a pullulan film, an agar film, and a silicon film.

7. The complex according to claim 6 , wherein the pores with a size of 30 nm-50 μm are present on the surface of the porous ultra-thin polymer film at a density of 5×10 −3 pores/μm 2 -50 pores/μm 2 .

8. The complex according to claim 7 , wherein the size of the pores in the porous ultra-thin polymer film is greater than 1 μm and less than or equal to 25 μm.

9. The complex according to claim 8 , wherein the size of the pores in the porous ultra-thin polymer film is greater than 1 μm and less than or equal to 15 μm.

10. The complex according to claim 6 , wherein the pore diameter distribution in the porous ultra-thin polymer film is at least ±20%.

11. The complex according to claim 6 , wherein the ratio of the pore diameter in microns to the film thickness in microns of the porous ultra-thin polymer film is 0.1-50.

12. The complex according to claim 6 , wherein the polymer is at least one selected from the group consisting of polyhydroxyalkanoic acid, a copolymer of polyhydroxyalkanoic acid, poly(ester-ether), a polyester of aliphatic dicarboxylic acid and aliphatic diol, polyamide, polyurethane, polysaccharide ester, poly(acrylate), poly(methacrylate), polystyrene, polyvinyl acetate and polysiloxane.

13. The complex according to claim 6 , wherein the water-soluble support membrane is a polyvinyl alcohol film.

14. A complex of a porous ultra-thin polymer film and a water-soluble support membrane, comprising the water-soluble support membrane on the porous ultra-thin polymer film having a film thickness of 10 nm-1000 nm, wherein the porous ultra-thin polymer film comprises non-penetrating pores.

15. The complex according to claim 14 , wherein the pores with a size of 30 nm-50 μm are present on the surface of the porous ultra-thin polymer film at a density of 5×10 −3 pores/μm 2 -50 pores/μm 2 .

16. The complex according to claim 14 , wherein the pore diameter distribution in the porous ultra-thin polymer film is at least ±20%.

17. The complex according to claim 14 , wherein the ratio of the pore diameter in microns to the film thickness in microns of the porous ultra-thin polymer film is 0.1-50.

18. The complex according to claim 14 , wherein the polymer is at least one selected from the group consisting of polyhydroxyalkanoic acid, a copolymer of polyhydroxyalkanoic acid, poly(ester-ether), a polyester of aliphatic dicarboxylic acid and aliphatic diol, polyamide, polyurethane, polysaccharide ester, poly(acrylate), poly(methacrylate), polystyrene, polyvinyl acetate and polysiloxane.

19. A method of producing a free-standing porous ultra-thin polymer film comprising removing the water-soluble sacrificial film of the complex according to claim 1 with water to obtain a porous ultra-thin polymer film in water.

20. The method according to claim 19 , further comprising:
picking up and placing the porous ultra-thin polymer film on another substrate; and
removing the water from the picked up porous ultra-thin polymer film to obtain a porous ultra-thin polymer film in a dry state.

21. A method of producing a complex of a mesh and a porous ultra-thin polymer film, comprising picking up a free-standing porous ultra-thin polymer film produced by the method according to claim 19 with the mesh to produce a complex of the porous ultra-thin polymer film and the mesh.

Assignees

• Nanotheta Co Ltd
• Takeoka Shinji
• Toray Industries
• Shinji Takeoka

Inventors

• Takeoka Shinji
• Saito Akihiro
• Zhang Hong
• TAKAMIZAWA Natsuki

Classifications

• B01D2323/64

  Use of a temporary support · CPC title

• B29C41/12 Primary

  Spreading-out the material on a substrate {, e.g. on the surface of a liquid} · CPC title

• B01D2325/0283

  Pore size · CPC title

• B01D69/1411

  containing dispersed material in a continuous matrix · CPC title

• B01D71/48

  Polyesters · CPC title