EP4150143A1 - Sulfonated polystyrene nonwoven - Google Patents

Sulfonated polystyrene nonwoven

Info

Publication number
EP4150143A1
EP4150143A1 EP21726819.2A EP21726819A EP4150143A1 EP 4150143 A1 EP4150143 A1 EP 4150143A1 EP 21726819 A EP21726819 A EP 21726819A EP 4150143 A1 EP4150143 A1 EP 4150143A1
Authority
EP
European Patent Office
Prior art keywords
meq
fibers
polystyrene
nonwoven
capacity
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21726819.2A
Other languages
German (de)
English (en)
French (fr)
Inventor
Chunxia COSTEUX
Gregory T. Dee
Michael OSTRANDER
John David Finch
Matthew OLSEN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DDP Specialty Electronic Materials US LLC
Original Assignee
DDP Specialty Electronic Materials US LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by DDP Specialty Electronic Materials US LLC filed Critical DDP Specialty Electronic Materials US LLC
Publication of EP4150143A1 publication Critical patent/EP4150143A1/en
Pending legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/728Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by electro-spinning
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D39/00Filtering material for liquid or gaseous fluids
    • B01D39/14Other self-supporting filtering material ; Other filtering material
    • B01D39/16Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/44Treatment of water, waste water, or sewage by dialysis, osmosis or reverse osmosis
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282Addition polymers
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2239/00Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/025Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2239/00Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604Arrangement of the fibres in the filtering material
    • B01D2239/0631Electro-spun
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2239/00Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12Special parameters characterising the filtering material
    • B01D2239/1233Fibre diameter
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/42Treatment of water, waste water, or sewage by ion-exchange
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/20Heavy metals or heavy metal compounds

Definitions

  • This invention relates generally to sulfonated polystyrene nonwovens and a method for their preparation.
  • the present invention is directed to a sulfonated polystyrene nonwoven having an average diameter from 450 nm to 2000 nm and a capacity from 0.05 meq/g to 2.0 meq/g.
  • the polystyrene used to make the fibers is a high heat crystalline polystyrene, preferably one that is acceptable in pharmaceutical processing.
  • the average diameter of the fibers is at least 480 nm, preferably at least 500 nm, preferably at least 520 nm; preferably no greater than 1750 nm, preferably no greater than 1500 nm, preferably no greater than 1200 nm, preferably no greater than 1000 nm, preferably no greater than 800 nm, preferably no greater than 750 nm, preferably no greater than 700 nm.
  • the fibers are produced by Hybrid Membrane Technology (HMT). This technology is described, e.g., in US7618579.
  • HMT Hybrid Membrane Technology
  • fibers are made from a solution of polystyrene in an aprotic solvent.
  • Preferred solvents are those capable of dissolving polystyrene at room temperature, and include, e.g., N,N-dimethylformamide (DMF), dimethylacetamide, methyl ethyl ketone, dichloromethane and toluene.
  • the solution is processed via electroblowing under conditions which may be adjusted by known techniques to vary fiber properties, producing a nonwoven fiber mat.
  • the concentration of polystyrene in the solvent is from 15 to 30 wt%, preferably 18 to 27 wt%.
  • the solution is processed on a single hole or multi-hole electro-blowing unit.
  • the fiber is spun onto a rotating drum.
  • the fibers are treated with a crosslinking agent capable of crosslinking polystyrene prior to sulfonation.
  • crosslinking agents are aldehydes and dialdehydes, preferably formaldehyde/sulfuric acid or glutaraldehyde/sulfuric acid, preferably formaldehyde/sulfuric acid.
  • at least 90 wt% of the polystyrene molecules contain crosslinks, preferably at least 94 wt%, preferably at least 96 wt%, preferably at least 98 wt%.
  • the wt% of polystyrene molecules that are crosslinked may be determined by immersing the fibers in dichloroethane and weighing the insoluble material, which is the polystyrene molecules containing crosslinks.
  • fibers are treated with crosslinking agent at a temperature from 20 to 110°C, preferably at least 45°C, preferably at least 55°C; preferably no more than 100°C, preferably no more than 95°C. Both time and temperature may be adjusted to produce the desired degree of crosslinking, however typical times preferably are in the range from 30 minutes to 6 hours, preferably 1 to 4 hours.
  • treatment with a crosslinking agent is done without a catalyst under the conditions given above. If a catalyst is used (e.g., Ag2SC>4), times will be much shorter at a given temperature and can be adjusted to provide desired properties.
  • the fibers resulting from treatment with a crosslinking agent are sulfonated by contacting them with a sulfonating agent, preferably at least 80 wt% (remainder at least 95 wt% water), preferably at least 90 wt%, preferably at least 94 wt%.
  • Sulfonating agents are reagents capable of sulfonating aromatic rings.
  • Preferred sulfonating agents include sulfuric acid, chlorosulfonic acid and oleum; preferably sulfuric acid.
  • sulfonation is performed at a temperature from 30 to 160°C, preferably at least 50°C, preferably at least 70°C; preferably no more than 120°C, preferably no more than 110°C. Both time and temperature may be adjusted to produce the desired capacity, however typical times preferably are in the range from 30 minutes to 6 hours, preferably 1 to 4 hours.
  • fibers are contacted with concentrated sulfuric acid for a time sufficient to produce sulfonated polystyrene fibers having a capacity from 0.4 meq/g to 2.0 meq/g or in any desired range therein contained.
  • sulfonation is done without a catalyst under the conditions given above. If a catalyst is used (e.g., Ag2SC>4, acetic anhydride, trifluoroacetic anhydride), time will be much shorter at a given temperature and can be adjusted to provide desired properties
  • capacity of the sulfonated nonwoven is at least 0.2 meq/g, preferably at least 0.4 meq/g, preferably at least 0.45 meq/g, preferably at least 0.50 meq/g, preferably at least 0.55 meq/g, preferably at least 0.60 meq/g, preferably at least 0.65 meq/g; preferably no greater than 1.8 meq/g, preferably no greater than 1.6 meq/g, preferably no greater than 1.5 meq/g, preferably no greater than 1.4 meq/g, preferably no greater than 1.3 meq/g, preferably no greater than 1.2 meq/g, preferably no greater than 1.1 meq/g.
  • C e.g., 30 C
  • PS solutions were prepared using PS 685 D grade polystyrene obtained from Aldrich.
  • the solvent was dimethylformamide (DMF). Solutions with concentrations in the range of 21 to 25 wt% were scouted. Sample solutions were spun on a single hole electro-blowing unit. The fiber was spun onto a rotating drum and the sample non-woven was collected from the drum after the run. Typical samples were prepared from a 21 wt% solution with 0.1 wt% salt added based on solution.
  • the typical basis weight varied from 60 to 100 gsm. Typical distance between the spin pack and the drum collector was 33 cm.
  • the typical applied voltage was 100 kV.
  • the typical spin cell temperature was 30 C.
  • the typical sample mean flow pour was 1 micron.
  • the nanofiber membrane (1700 nm average fiber diameter) is immersed into a bath containing a mixture of reagent grade concentrated sulfuric acid and formalin (37 wt% formaldehyde), typically 90: 10 sulfuric acid : formalin (V/V).
  • the bath is typically heated to 70 C for 3h and gently shaken on an orbital shaker at 60 -120 rpm.
  • the bath is cooled to ⁇ 50 C, the reaction fluid is decanted, and membrane is slowly hydrated with 50% sulfuric acid, and the membrane is gradually diluted down to pure DI water.
  • the nanofiber membrane after treatment with sulfuric acid/formalin is immersed in concentrated sulfuric acid (typically 96%), and then heated to 90 C for 0 to 8 h while shaking on an orbital. Next, the bath is cooled to ⁇ 50C, the reaction fluid is decanted, and the membrane is slowly hydrated with 50% sulfuric acid, and then gradually diluted down to pure DI water.
  • concentrated sulfuric acid typically 96%
  • volumetric Flow rate 6.9 ml/min for membrane, 5 ml/min for ion exchange resin.
  • Metal content of the nonwoven PS membrane is reduced to 9.76 ppb in 210 minutes, at which time the resin still had a metal content of 20.26ppb. .
  • the media is further rinsed with DI water to at least pH>5.
  • Total metal content in the initial resin bed effluent was 512.7 ppb and total metal in the membrane disk effluent was 823.4 ppb.
  • the membrane disk removes 96% of the initial metals at the first residence time of 3.5 seconds while ion exchange resin removes 94% of the initial metals at the first residence time of 15 min.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Hydrology & Water Resources (AREA)
  • Environmental & Geological Engineering (AREA)
  • Water Supply & Treatment (AREA)
  • Organic Chemistry (AREA)
  • Nonwoven Fabrics (AREA)
  • Artificial Filaments (AREA)
EP21726819.2A 2020-05-11 2021-05-03 Sulfonated polystyrene nonwoven Pending EP4150143A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202063022718P 2020-05-11 2020-05-11
PCT/US2021/030406 WO2021231114A1 (en) 2020-05-11 2021-05-03 Sulfonated polystyrene nonwoven

Publications (1)

Publication Number Publication Date
EP4150143A1 true EP4150143A1 (en) 2023-03-22

Family

ID=76012067

Family Applications (1)

Application Number Title Priority Date Filing Date
EP21726819.2A Pending EP4150143A1 (en) 2020-05-11 2021-05-03 Sulfonated polystyrene nonwoven

Country Status (5)

Country Link
EP (1) EP4150143A1 (ja)
JP (1) JP2023526197A (ja)
KR (1) KR20230041959A (ja)
CN (1) CN115702268A (ja)
WO (1) WO2021231114A1 (ja)

Family Cites Families (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5213722A (en) * 1987-11-17 1993-05-25 Matsushita Electric Industrial Co., Ltd. Method of making a separator material for a storage battery
TW288051B (ja) * 1994-11-22 1996-10-11 Ebara Corp
KR100549140B1 (ko) 2002-03-26 2006-02-03 이 아이 듀폰 디 네모아 앤드 캄파니 일렉트로-브로운 방사법에 의한 초극세 나노섬유 웹제조방법
WO2007135689A2 (en) * 2006-05-24 2007-11-29 Ben Gurion University Of The Negev R&D Authority Membranes, coatings and films and methods for their preparation
JP5172859B2 (ja) * 2007-01-19 2013-03-27 ザ・ピュロライト・カンパニー 逆浸透膜の汚染減少
KR20080090079A (ko) * 2007-04-04 2008-10-08 성균관대학교산학협력단 다공성 이온교환 촉매 멤브레인 및 그 제조방법
JP5062630B2 (ja) * 2008-05-14 2012-10-31 栗田工業株式会社 複合繊維体、その製造方法、フィルタ及び流体濾過方法
KR100992557B1 (ko) * 2008-08-30 2010-11-08 충남대학교산학협력단 고분기 폴리스틸렌과 반응형 아크릴산 수지를 이용한 이온선택성 나노섬유 구조체 제조방법
JP5867828B2 (ja) * 2011-04-28 2016-02-24 日本バイリーン株式会社 複合膜およびその製造方法
US9096959B2 (en) * 2012-02-22 2015-08-04 Ut-Battelle, Llc Method for production of carbon nanofiber mat or carbon paper
CN105103654B (zh) * 2013-02-14 2017-06-23 纳米帕雷尔股份有限公司 纳米纤维混合毛毡
KR101628899B1 (ko) * 2013-05-22 2016-06-21 주식회사 아모그린텍 술폰화된 나노 섬유 웹을 이용한 액체처리 케미컬 필터 및 그의 제조방법
JP6256443B2 (ja) * 2015-09-30 2018-01-10 栗田工業株式会社 製品洗浄方法
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CN109898322A (zh) * 2019-03-15 2019-06-18 天津工业大学 一种磺化非织造布及制备方法

Also Published As

Publication number Publication date
KR20230041959A (ko) 2023-03-27
CN115702268A (zh) 2023-02-14
WO2021231114A1 (en) 2021-11-18
JP2023526197A (ja) 2023-06-21

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