Title of Invention

POROUS MULTILAYERED HOLLOW-FIBER MEMBRANE AND PROCESS FOR PRODUCING THE SAME

Abstract A porous hollow fiber membrane which has high blocking performance and high water permeability suitable for filtration and the like and exhibits excellent strength, and a process for stably producing the porous hollow fiber membrane are disclosed. The process utilizes a hollow fiber molding nozzle having two or more circular discharge ports which are disposed concentrically. Multilayer melt-extrusion is performed by discharging molten mixtures which include a thermoplastic resin and an organic liquid and differ in composition from the adjacent discharge ports. The resulting product is cooled to solidify to obtain a hollow fiber. The organic liquid is then removed from the hollow fiber by extraction to produce a porous hollow fiber membrane. The molten mixture discharged from at least one circular discharge port includes an inorganic fine powder in addition to the thermoplastic resin and the organic liquid. The inorganic fine powder is removed by extraction after cooling in addition to the organic liquid.
Full Text DESCRIPTION
POROUS MULTILAYERED HOLLOW-FIBER MEMBRANE AND
PROCESS FOR PRODUCING THE SAME
TECHNICAL FIELD
[0001]
The present invention relates to a porous hollow fiber membrane formed of a
thermoplastic resin which has minute pores and high water permeability suitable for
filtration and exhibits excellent strength, and a stable production thereof.
BACKGROUND ART
[0002]
As a method of purifying river water for use as service water and the like, a
filtration method utilizing a porous hollow fiber membrane which improves safety of
treated water and reduces the installation space is being widely used. A porous hollow
fiber membrane is required to exhibit high blocking performance which can reliably
remove bacteria (e.g., cryptosporidium) and components making water turbid, high water
permeability for treating a large quantity of water, and high strength which enables
long-term use under a wide range of operating conditions (e.g., chemical washing and
operation under high operating pressure).
[0003]
A concept of obtaining a porous multilayer hollow fiber membrane which exhibits
high blocking performance and high water permeability by bonding a blocking layer
having a small pore diameter and a strength support layer having a large pore diameter is
disclosed in Patent Document 1, for example. Specifically, Patent Document 1 discloses
a method in which a crystalline thermoplastic resin such as polyethylene is melt-extruded
1
without adding a solvent, and a porous multilayer hollow fiber membrane is produced
from the resulting hollow fiber extruded product using a stretch pore-forming method.
The term "stretch pore-forming method" refers to a method in which a hollow fiber
extruded product is stretched in the longitudinal direction at a high stretch ratio to cleave
the lamellar crystal stack to obtain a porous membrane (see Non-patent Document 1). In
Patent Document 1, crystalline thermoplastic resins which differ in melt index (MI) are
melt-extruded from two circular nozzles disposed concentrically. This is because the
method disclosed in Patent Document 1 utilizes the property that resins which differ in
MI (i.e., differ in molecular weight) have different pore diameters upon stretch
pore-forming. As a result, a porous two-layer hollow fiber membrane in which the outer
layer and the inner layer differ in pore diameter is obtained. However, a porous
multilayer hollow fiber membrane exhibiting high strength cannot be obtained by the
method due to the following problems.
(1) The strength of the porous multilayer hollow fiber membrane in the stretch axis
direction is increased by stretching at a high stretch ratio. However, bursting strength
and compressive strength (i.e., strength in the direction perpendicular to the stretch axis)
important for filtration tend to decrease.
(2) In principle, the outer layer and the inner layer must differ in molecular weight or
polymer type. However, required properties such as chemical resistance and mechanical
strength differ depending on the molecular weight or polymer type. Therefore, when
using a resin having low strength, the strength of the entire membrane decreases.
Therefore, a membrane exhibiting high strength cannot be obtained. Moreover,
since a membrane obtained by this method has a structure in which the pore diameter in
the longitudinal direction of the hollow fiber is larger than the pore diameter in the
thickness direction, the membrane shows low bursting strength and low compressive
strength.
[0004]
2
Therefore, a porous multilayer hollow fiber membrane which exhibits high
blocking performance, high water permeation rate, and high strength and a process for
stably producing such a porous multilayer hollow fiber membrane have not yet been
obtained.
[0005]
A thermally induced phase separation method has been known as a method for
producing a porous membrane. This method utilizes a thermoplastic resin and an
organic liquid. The organic liquid serves as a latent solvent which does not dissolve the
thermoplastic resin at room temperature, but dissolves the thermoplastic resin at a high
temperature. In the thermally induced phase separation method, the thermoplastic resin
and the organic liquid are mixed at a high temperature so that the thermoplastic resin is
dissolved in the organic liquid. The mixture is then cooled to room temperature to
induce phase separation. The organic liquid is then removed from the mixture to obtain
a porous body. This method has the following advantages.
(a) A membrane can be easily produced using a polymer such as polyethylene for
which an appropriate solvent which can dissolve the polymer at room temperature does
not exist.
(b) Since the thermoplastic resin is dissolved at a high temperature and cooled to
solidify and form a membrane. Therefore, particularly when the thermoplastic resin is a
crystalline resin crystallization is promoted so that a high-strength membrane is easily
obtained.
Therefore, the thermally induced phase separation method is widely used as a
porous membrane production method (see Non-patent Documents 1 to 4, for example).
[0006]
[Patent Document 1] JP-A-60-139815
[Patent Document 2] JP-A-3-215535
[Patent Document 3] JP-A-2002-56979
3
[Patent Document 4] JP-A-4-065505
[Non-patent Document 1] "Plastic and Functional Polymer Dictionary", pp. 672 to 679
(Industrial Research Center of Japan, February, 2004)
[Non-patent Document 2] Hideto Matsuyama, "Production of Polymer Porous
Membrane by Thermally Induced Phase Separation (TIPS) method", Chemical
Engineering, pp. 45 to 56 (Kagaku-Kogyo-Sha, June 1998)
[Non-patent Document 3] Akira Takizawa, "Membrane" pp. 404 to 406 (IPC, January
1992)
[Non-patent Document 4] D. R. Lloyd, et. al., Journal of Membrane Science, 64 (1991),
pp. 1 to 11
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0007]
An object of the present invention is to provide a porous hollow fiber membrane
formed of a thermoplastic resin which has minute pores and high water permeability
suitable for filtration and exhibits excellent strength, and a process for stably producing
the porous hollow fiber membrane.
Means for Solving the Problem
[0008]
In order to achieve the above object, the inventors of the present invention
conducted extensive studies aimed at a porous multilayer hollow fiber membrane which
advantageously has both minute pores and high water permeability by the thermally
induced phase separation method (Non-patent Documents 1 to 4) which is considered to
be advantageous for obtaining a high-strength membrane and at stably production of the
porous multilayer hollow fiber membrane. As a result, the inventors found that it is very
important to discharge molten mixtures which differ in composition from adjacent
4
discharge ports and to incorporate an inorganic fine powder in the molten mixture
discharged from at least one discharge port in order to stably spin (produce) a porous
multilayer hollow fiber membrane and further improve the strength of the resulting
porous multilayer hollow fiber membrane. The inventors also found that blocking
performance, water permeability, and strength are effectively well-balanced using a
porous multilayer hollow fiber membrane having at least two layers comprising an inner
layer and an outer layer, the porous multilayer hollow fiber membrane being formed of a
thermoplastic resin, at least one layer (A) of the above two layers having an isotropic
three-dimensional mesh structure and a surface pore diameter 0.6 to 1.4 times a
cross-sectional center pore diameter, and the other layer (B) of the above two
layershaving a surface pore diameter less than half of the cross-sectional center pore
diameter.
[0009]
Specifically, the present invention provides the following process and porous
multilayer hollow fiber membrane.
(1) A process for producing a porous multilayer hollow fiber membrane by a hollow
fiber molding nozzle with a circular discharge port, the process comprising discharging a
molten mixture including a thermoplastic resin and an organic liquid from a circular
discharge port of a hollow fiber molding nozzle to obtain a multilayer hollow fiber, and
removing the organic liquid from the multilayer hollow fiber by extraction to obtain a
porous multilayer hollow fiber membrane, the hollow fiber molding nozzle having two or
more circular discharge ports which are disposed concentrically, molten mixtures which
differ in composition being discharged from the adjacent discharge ports, the molten
mixture discharged from at least one of the circular discharge ports further including an
inorganic fine powder, and the inorganic fine powder being also removed from the
resulting multilayer hollow fiber by extraction.
(2) The process for producing a porous multilayer hollow fiber membrane according
5
to (1), wherein the thermoplastic resin, the organic liquid, and further the inorganic fine
powder are mixed in at least a molten mixture which is discharged in a largest amount
among the molten mixtures discharged from the circular discharge ports.
(3) The process for producing a porous multilayer hollow fiber membrane according
to (1) or (2), wherein the inorganic fine powder is a silica fine powder.
(4) The process for producing a porous multilayer hollow fiber membrane according
to any one of (1) to (3), wherein the molten mixture discharged from a circular discharge
port includes the inorganic fine powder in an amount of 5 mass% or more and 40 mass%
or less.
(5) The process for producing a porous multilayer hollow fiber membrane according
to any one of (1) to (4), wherein a mass ratio D of the organic liquid and a mass ratio S of
the inorganic fine powder with respect to the molten mixture and a maximum mass M of
the organic liquid absorbed by the inorganic fine powder per unit mass satisfy
0.2=(D/S)/M=2.
(6) The process for producing a porous multilayer hollow fiber membrane according
to any one of (1) to (5), wherein the molten mixtures discharged from the adjacent
circular discharge ports include at least one common organic liquid.
(7) The process for producing a porous multilayer hollow fiber membrane according
to any one of (1) to (5), wherein organic liquids contained in the molten mixtures
discharged from the adjacent circular discharge ports are the same in kind but differ in
ratio.
(8) The process for producing a porous multilayer hollow fiber membrane according
to any one of (1) to (7), wherein the molten mixture is discharged so that at least one
spinning nozzle discharge parameter R (1/sec) is 10 or more and 1000 or less, the
spinning nozzle discharge parameter R being a value obtained by dividing a linear
velocity V (m/sec) when discharging the molten mixture by a slit width d (m) of the
discharge port.
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(9) The process for producing a porous multilayer hollow fiber membrane according
to any one of (1) to (8), wherein the multilayer hollow fiber is stretched in a longitudinal
direction of the hollow fiber at a stretch ratio of 1.1 or more and 3 or less before or after
removing the organic liquid and/or the inorganic fine powder by extraction.
(10) The process for producing a porous multilayer hollow fiber membrane according
to any one of (1) to (9), wherein the thermoplastic resin is selected from a polyolefin and
polyvinylidene fluoride.
(11) A porous multilayer hollow fiber membrane comprising at least two layers i.e., an
inner layer and an outer layer, the porous multilayer hollow fiber membrane being formed
of a thermoplastic resin, at least one layer (A) among the two layers having an isotropic
three-dimensional mesh structure and a surface pore diameter 0.6 to 1.4 times a
cross-sectional center pore diameter, and the other layer (B) among the two layers having
a surface pore diameter less than half of the cross-sectional center pore diameter.
(12) The porous multilayer hollow fiber membrane according to (11), wherein the
layer (B) has an isotropic three-dimensional mesh structure.
(13) The porous multilayer hollow fiber membrane according to (11) or (12), wherein
the layer (B) has a surface pore diameter of 0.01 µm or more and less than 5 µm.
(14) The porous multilayer hollow fiber membrane according to any one of (11) to (13),
wherein the cross-sectional center pore diameter is 0.1 µm or more and 10 µm or less.
(15) The porous multilayer hollow fiber membrane according to any one of (11) to (14),
wherein the layer (B) has a surface porosity of 20% or more and 80% or less.
(16) The porous multilayer hollow fiber membrane according to any one of (11) to (15),
wherein the layer (B) has a thickness of 1/100 or more and 40/100 or less of the thickness
of the porous multilayer hollow fiber membrane.
(17) The porous multilayer hollow fiber membrane according to any one of (11) to (16),
wherein the layer (A) and the layer (B) both have a degree of isotropy of 80% or more.
(18) The porous multilayer hollow fiber membrane according to any one of (11) to (17),
7
wherein the number of parameters Q which satisfy -0.2=Q=0.2 is 80% or more of the total
number of parameters Q measured values, the parameter Q being a value which indicates
a pore diameter change rate at each position from an outer surface to an inner surface of
the porous multilayer hollow fiber membrane in its thickness direction.
(19) The porous multilayer hollow fiber membrane according to any one of (11) to (18),
wherein the thermoplastic resin is selected from a polyolefin and polyvinylidene fluoride.
(20) The porous multilayer hollow fiber membrane according to any one of (11) to (19),
wherein the porous multilayer hollow fiber membrane has an inner diameter of 0.4 mm or
more and 5 mm or less and a thickness of 0.2 mm or more and 1 mm or less.
(21) A porous multilayer hollow fiber membrane produced by the process according to
any one of (1) to (10).
(22) The porous multilayer hollow fiber membrane according to any one of (11) to (20),
the porous multilayer hollow fiber membrane being produced by the process according to
any one of (1) to (10).
Effect of the Invention
[0010]
According to the present invention, a porous hollow fiber membrane formed of a
thermoplastic resin which has both minute pores and high water permeability suitable for
filtration and exhibits excellent strength can be stably produced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
FIG. 1 is a view showing an example of a two-layer hollow fiber molding nozzle;
FIG. l(a) is a cross-sectional view along a plane horizontal to a discharge direction, FIG.
l(b) is a view opposite to a nozzle discharge port, and FIG. l(c) is a cross-sectional view
showing a two-layer hollow fiber extruded product along a plane perpendicular to an
extrusion direction.
FIG. 2 is a view showing another example of a two-layer hollow fiber molding
8
nozzle.
FIG. 3 is a schematic view showing an isotropic three-dimensional mesh structure.
FIG. 4 is a schematic view showing a spherulite structure.
FIG. 5 is a schematic view showing an example of a change in pore diameter in the
thickness direction of a porous two-layer hollow fiber membrane.
FIG. 6 shows an electron micrograph (magnification: 5000) of the outer surface of
a porous two-layer hollow fiber membrane obtained in Example 1.
FIG. 7 shows an electron micrograph (magnification: 5000) of a cross section
around the outer surface of a porous two-layer hollow fiber membrane obtained in
Example 1.
FIG. 8 shows an electron micrograph (magnification: 1000) of a cross section
around the outer surface of a porous two-layer hollow fiber membrane obtained in
Example 1.
FIG. 9 shows an electron micrograph (magnification: 5000) of the center of a
cross section of a porous two-layer hollow fiber membrane obtained in Example 1.
FIG. 10 shows an electron micrograph (magnification: 5000) of a cross section
around the inner surface of a porous two-layer hollow fiber membrane obtained in
Example 1.
FIG. 11 shows an electron micrograph (magnification: 5000) of the inner surface
of a porous two-layer hollow fiber membrane obtained in Example 1.
FIG. 12 shows a microscope image of the circular cross section of a hollow fiber
extruded product obtained by mixing graphite into a molten mixture (a) (outer layer).
FIG. 13 shows an electron micrograph (magnification: 5000) of the outer surface
of a porous two-layer hollow fiber membrane obtained in Example 1.
FIG. 14 shows an electron micrograph (magnification: 5000) of a cross section
around the outer surface of a porous two-layer hollow fiber membrane obtained in
Example 1.
9
FIG. 15 shows an electron micrograph (magnification: 1000) of a cross section
around the outer surface of a porous two-layer hollow fiber membrane obtained in
Example 2.
FIG. 16 shows an electron micrograph (magnification: 5000) of the center of a
cross section of a porous two-layer hollow fiber membrane obtained in Example 2.
FIG. 17 shows an electron micrograph (magnification: 5000) of a cross section
around the inner surface of a porous two-layer hollow fiber membrane obtained in
Example 2.
FIG. 18 shows an electron micrograph (magnification: 5000) of the inner surface
of a porous two-layer hollow fiber membrane obtained in Example 2.
FIG. 19 shows an electron micrograph (magnification: 60) of the entire circular
cross section of a porous two-layer hollow fiber membrane obtained in Example 2.
FIG. 20 shows an electron micrograph (magnification: 300) of the circular cross
section of a porous two-layer hollow fiber membrane obtained in Example 2.
FIG. 21 is a graph showing a change in cross-sectional pore diameter of a porous
two-layer hollow fiber membrane obtained in Example 2.
FIG. 22 shows an electron micrograph (magnification: 5000) of the outer surface
of a porous two-layer hollow fiber membrane obtained in Comparative Example 2.
FIG. 23 shows an electron micrograph (magnification: 5000) of a cross section
around the outer surface of a porous two-layer hollow fiber membrane obtained in
Comparative Example 2.
FIG. 24 shows an electron micrograph (magnification: 5000) of the center of a
cross section of a porous two-layer hollow fiber membrane obtained in Comparative
Example 2.
FIG. 25 shows an electron micrograph (magnification: 5000) of a cross section
around the inner surface of a porous two-layer hollow fiber membrane obtained in
Comparative Example 2.
10
FIG. 26 shows an electron micrograph (magnification: 5000) of the inner surface
of a porous two-layer hollow fiber membrane obtained in Comparative Example 2.
FIG. 27 shows an electron micrograph (magnification: 5000) of the outer surface
of a porous hollow fiber membrane obtained in Comparative Example 3.
FIG. 28 shows an electron micrograph (magnification: 5000) of a cross section
around the outer surface of a porous hollow fiber membrane obtained in Comparative
Example 3.
FIG. 29 shows an electron micrograph (magnification: 5000) of the center of a
cross section of a porous hollow fiber membrane obtained in Comparative Example 3.
FIG. 30 shows an electron micrograph (magnification: 5000) of a cross section
around the inner surface of a porous hollow fiber membrane obtained in Comparative
Example 3.
FIG. 31 shows an electron micrograph (magnification: 5000) of the inner surface
of a porous hollow fiber membrane obtained in Comparative Example 3.
FIG. 32 shows an electron micrograph (magnification: 1000) of the center of a
cross section of a porous hollow fiber membrane having a spherulite structure obtained in
a reference example.
FIG. 33 shows a change in parameter Q of a porous two-layer hollow fiber
membrane obtained in Example 2 depending on the thickness position. The horizontal
axis a position in the thickness direction when the total thickness is one, and the vertical
axis indicates the parameter Q.
EXPLANATION OF SYMBOLS
[0012]
1: End of extruder A (for outer layer)
2: End of extruder B (for inner layer)
3: Hollow fiber molding nozzle
4: Lower end of partition wall between outer-layer molten mixture discharge port and
11
inner-layer molten mixture discharge port
5: Space in which outer-layer molten mixture flows
6: Space in which inner-layer molten mixture flows
7: Passage for hollow-portion-forming fluid
8: Lower end of partition wall between inner-layer molten mixture discharge port and
hollow-portion-forming fluid discharge port
9: Nozzle lower surface
10: Production device
11: Circular discharge port for outer-layer molten mixture
12: Circular discharge port for inner-layer molten mixture
13: Hollow-portion-forming fluid discharge port
20: Extruded product (cross section)
21: Outer layer
22:Inner layer
23: Hollow portion
30: Production device
31: Lower end of partition wall between outer-layer molten mixture discharge port and
inner-layer molten mixture discharge port
32: Lower end of partition wall between inner-layer molten mixture discharge port and
hollow-portion-forming fluid discharge port
BEST MODE FOR CARRYING OUT THE INVENTION
[0013]
The present invention is described in detail below.
[0014]
A thermoplastic resin exhibits elasticity, but not plasticity at room temperature.
However, it exhibits plasticity when heated to an appropriate temperature to allow
12
molding. The thermoplastic resin again exhibits elasticity when cooled, and does not
undergo a chemical change in molecular structure and the like during this process
(Kagaku Daijiten (Comprehensive Chemical Dictionary), sixth edition (reduced size), pp.
860 and 867 (Kyoritsu Shuppan Co., Ltd., 1963).
[0015]
Examples of the thermoplastic resin include thermoplastic resins described in
"12695 Chemical Products", pp. 829 to 882 (The Chemical Daily Co., Ltd., 1995), resins
described in Kagaku Binran, Ouyou Kagaku, pp. 809 and 810 (edited by The Chemical
Society of Japan, Maruzen, 1980), and the like. Specific examples of the thermoplastic
resin include polyolefins such as polyethylene and polypropylene, polyvinylidene
fluoride, an ethylene-vinyl alcohol copolymer, polyamide, polyetherimide, polystyrene,
polysulfone, polyvinyl alcohol, polyphenylene ether, polyphenylene sulfide, cellulose
acetate, polyacrylonitrile, and the like. In particular, a crystalline thermoplastic resin
such as polyethylene, polypropylene, polyvinylidene fluoride, an ethylene-vinyl alcohol
copolymer, or polyvinyl alcohol may be suitably used from the viewpoint of strength. It
is preferable to use a polyolefin, polyvinylidene fluoride, or the like which exhibits
excellent water resistance due to hydrophobicity and is expected to exhibit durability
when filtering a normal aqueous liquid. It is particularly preferable to use
polyvinylidene fluoride due to excellent chemical durability (e.g., chemical resistance).
Examples of polyvinylidene fluoride include a vinylidene fluoride homopolymer and a
vinylidene fluoride copolymer having a vinylidene fluoride content of 50 mol% or more.
Examples of the vinylidene fluoride copolymer include a copolymer of vinylidene
fluoride and one or more monomers selected from tetrafluoroethylene,
hexafluoropropylene, trifluoroethylene chloride, and ethylene. A vinylidene fluoride
homopolymer is most preferable as polyvinylidene fluoride.
[0016]
As the organic liquid, a latent solvent for the thermoplastic resin used in the
13
present application is used. The term "latent solvent" used in the present application
refers to a solvent which rarely dissolves the thermoplastic resin at room temperature
(25°C), but dissolves the thermoplastic resin at a temperature higher than room
temperature. It suffices that the organic liquid be liquid at the melt-mixing temperature
of the thermoplastic resin. The organic liquid need not necessarily be liquid at room
temperature.
[0017]
When the thermoplastic resin is polyethylene, examples of the organic liquid
include phthalates such as dibutyl phthalate, diheptyl phthalate, dioctyl phthalate,
bis(2-ethylhexyl) phthalate, diisodecyl phthalate, and ditridecyl phthalate; sebacates
such as dibutyl sebacate; adipates such as dioctyl adipate; trimellitates such as trioctyl
trimellitate; phosphates such as tributyl phosphate and trioctyl phosphate; glycerol esters
such as propylene glycol dicaprate and propylene glycol dioleate; paraffins such as liquid
paraffins; a mixture of these; and the like.
[0018]
When the thermoplastic resin is polyvinylidene fluoride, examples of the organic
liquid include phthalates such as dimethyl phthalate, diethyl phthalate, dibutyl phthalate,
dicyclohexyl phthalate, diheptyl phthalate, dioctyl phthalate, and bis(2-ethylhexyl)
phthalate; benzoates such as methyl benzoate and ethyl benzoate; phosphates such as
triphenyl phosphate, tributyl phosphate, and tricresyl phosphate; ketones such as
y-butyrolactone, ethylene carbonate, propylene carbonate, cyclohexanone, acetophenone,
and isophorone; a mixture of these; and the like.
[0019]
Examples of the inorganic fine powder include silica, alumina, titanium oxide,
zirconia, calcium carbonate, and the like. It is preferable to use a silica fine powder
having an average primary particle diameter of 3 nm or more and 500 nm or less. The
average primary particle diameter is more preferably 5 nm or more and 100 nm or less.
14
It is more preferable to use a hydrophobic silica fine powder which is hard to aggregate
and exhibits excellent dispersibility. Hydrophobic silica having a methanol wettability
(MW) value of 30 vol% or more is still more preferable. The term "MW value" used
herein refers to the content (vol%) of methanol with which the powder is completely
wetted. The MW value is determined as follows. Specifically, silica is placed in pure
water, and methanol is then added to the mixture below the liquid surface with stirring.
The content (vol%) of methanol in the aqueous solution when 50 mass% of silica has
precipitated is determined to be the MW value.
[0020]
The inorganic fine powder is preferably added so that the content of the inorganic
fine powder in the molten mixture is 5 mass% or more and 40 mass% or less. If the
content of the inorganic fine powder is 5 mass% or more, an effect of mixing the
inorganic fine powder can be sufficiently achieved. If the content of the inorganic fine
powder is 40 mass% or less, a stable spinning operation can be ensured.
[0021]
The mixing ratio during melt-mixing is preferably determined so that the content
of the thermoplastic resin is 15 to 50 vol% and the total content of the organic liquid and
the inorganic fine powder is 50 to 85 vol% from the viewpoint of the balance between the
water permeability and the strength of the resulting hollow fibers and stability of the
spinning operation (i.e., melt-extrusion operation) (the mixing ratio is indicated by a
value obtained by dividing mass by specific gravity). The content of the thermoplastic
resin is preferably 15 vol% or more from the viewpoint of the strength of the resulting
porous multilayer hollow fiber membrane and spinning stability. The content of the
thermoplastic resin is preferably 50 vol% or less from the viewpoint of the water
permeability of the resulting porous multilayer hollow fiber membrane and spinning
stability.
[0022]
15
The thermoplastic resin, the organic liquid, and the inorganic fine powder may be
melt-mixed using a normal melt-mixing means such as a twin-screw extruder. A hollow
fiber molding nozzle having two or more circular discharge ports disposed concentrically
is attached to the end of the extruder. Molten mixtures are respectively supplied to and
extruded from to the circular discharge ports from different extruders. Molten mixtures
supplied from the different extruders are merged through the discharge ports to obtain a
hollow fiber extruded product having a multilayer structure. In this case, a multilayer
membrane in which the adjacent layers differ in pore size can be obtained by extruding
molten mixtures which differ in composition from the adjacent circular discharge ports.
The expression "differ in composition" refers to the case where the molten mixtures differ
in constituent substance or the case where the molten mixtures contain the same
constituent substances but differ in the ratio thereof. When the molten mixtures contain
the same type of thermoplastic resins which differ in molecular weight or molecular
weight distribution, the molten mixtures are considered to differ in constituent substance.
FIGS. 1 and 2 are schematic views showing a multilayer hollow fiber extruded product
production process by multilayer melt-extrusion when the number of layers is two. The
merging point of the molten mixtures which differ in composition may be the lower end
face of the hollow fiber molding nozzle (FIG. 1) or a position differing from the lower end
face of the hollow fiber molding nozzle (FIG. 2). It is preferable to use the nozzle shown
in FIG. 2 which causes the molten mixtures to merge before passing through the lower
end face of the nozzle (i.e., before being cooled and undergoing phase separation) from
the viewpoint of inter-layer adhesion.
[0023]
When using the hollow fiber molding nozzle having two or more circular
discharge ports disposed concentrically, as shown in FIGS. 1 and 2, a molten mixture in
which the thermoplastic resin, the organic liquid, and the inorganic fine powder are mixed
can be extruded from at least one circular discharge port. As a result, a porous multilayer
16
hollow fiber membrane which exhibits blocking performance, water permeability, and
strength in a well-balanced manner can be easily obtained.
[0024]
A porous multilayer hollow fiber membrane exhibiting excellent performance can
be stably obtained by adding the inorganic fine powder due to the following three specific
effects.
(1) The extrusion stability (spinning stability) of the hollow fiber extruded product
having a multilayer structure is significantly improved. This is because the viscosity of
the molten mixture increases to a large extent by adding the inorganic fine powder.
Multilayer extrusion tends to become unstable as compared with single-layer extrusion.
In the present invention, since at least one layer to be bonded has a high viscosity to form
a hard layer, stability is achieved. Specifically, a multilayer hollow fiber extruded
product in which non-uniformity at the layer interface is suppressed can be easily
obtained while maintaining roundness. It is important for multilayer extrusion to
suppress non-uniformity (e.g., waving) at the layer interface.
(2) Since the pore size distribution becomes sharp, a membrane which exhibits
blocking performance, water permeability, and strength in a well-balanced manner can be
obtained. Specifically, since the molten mixture has a high viscosity or the aggregate of
the inorganic fine powder absorbs the organic liquid, a situation in which the organic
liquid enters the adjacent layer is suppressed. When the organic liquid enters from the
adjacent layer, the inorganic fine powder absorbs the organic liquid (i.e., functions as a
buffer). The movement of the organic liquid is suppressed due to high viscosity, or a
change in the membrane structure due to mixing of the organic liquids between the layers
is reduced.
(3) When the inorganic fine powder is added to at least one layer, the mechanical
strength and the chemical strength (chemical resistance) of the membrane tend to increase
before or after extraction/removal of the organic liquid and the inorganic fine powder
17
(although the reason is not known).
[0025]
The above three effects are improved when the molten mixture which is
discharged in the largest amount contains the inorganic fine powder. It is preferable that
all of the molten mixtures to be discharged contain the inorganic fine powder. [0026]
When the molten mixture containing the inorganic fine powder has such a
composition that a value obtained by dividing a mass ratio.D of the organic liquid by a
mass ratio S of the inorganic fine powder and further dividing the resulting value by a
maximum mass M of the organic liquid absorbed by the inorganic fine powder per unit
mass is 0.2 or more and 2 or less, the effect of suppressing the movement of the organic
liquid between the molten mixtures can be further improved. The term "organic liquid"
used herein refers to an organic liquid having the same composition as that of the organic
liquid contained in the molten mixture, i.e., an organic liquid aomprising sole component
or plural components at the same mixing ratio as that of the organic liquid contained in
the molten mixture. If the above value is 0.2 or more, the movement of the organic
liquid from the adjacent layer in the vicinity of the layer interface is suppressed so that a
dense layer is not formed, whereby a high pure water permeation rate is maintained. If
the above value is 2 or less, the amount of the organic liquid which is not absorbed by the
inorganic fine powder is sufficiently small. Therefore, the movement of the organic
liquid in the vicinity of the interface occurs to only a small extent. This reduces a change
in the membrane structure, whereby blocking performance is maintained. The above
value is more preferably 0.3 or more and 1.5 or less, and still more preferably 0.4 or more
and 1.0 or less. This effect is also preferably improved when the molten mixture which
is discharged in the largest amount contains the inorganic fine powder. It is more
preferable that all of the molten mixtures to be discharged contain the inorganic fine
powder. The term "maximum mass M of the organic liquid absorbed by the inorganic
fine powder per unit mass" may be determined by adding the organic liquid dropwise to
18
the inorganic fine powder while mixing the inorganic fine powder, and dividing the mass
of the organic liquid when the mixing torque has reached 70% of the maximum torque by
the mass of the inorganic fine powder.
[0027]
It is preferable that at least one common organic liquid be mixed into the two
adjacent molten mixtures, since an effect of a change in structure when the movement of
the organic liquid occurs between the molten mixtures is reduced. It is more preferable
that the same type of organic liquid be mixed into the adjacent molten mixtures in
different ratios. When the same type of organic liquid is mixed into the adjacent molten
mixtures, the extracted organic liquid can be easily recovered.
[0028]
The difference in resin temperature when causing the adjacent molten mixtures to
merge is preferably 20°C or less. If the difference in resin temperature is 20°C or less,
densification or void formation rarely occurs at the interface between the molten mixtures.
As a result, a membrane exhibiting excellent water permeability and strength can be
obtained. The difference in resin temperature when causing the adjacent molten
mixtures to merge is more preferably 10°C or less, and still more preferably 0°C.
[0029]
When extruding the molten mixture from the circular discharge port, it is
preferable to discharge the molten mixture so that a spinning nozzle discharge parameter
R (I/second) is 10 or more and 1000 or less, since a membrane having high strength can
be obtained while achieving high productivity and high spinning stability. The term
"spinning nozzle discharge parameter R" refers to a value obtained by dividing a
discharge linear velocity V (m/sec) by a slit width d (m) of the discharge port. The term
"discharge linear velocity V (m/sec)" refers to a value obtained by dividing the amount
(m3/second) of the molten mixture discharged per unit time by the cross-sectional area
(m2) of the discharge port. If the spinning nozzle discharge parameter R is 10 or more, a
19
problem such as a change (pulsation) in the diameter of the hollow extruded product does
not occur so that the spinning operation can be stably performed with high productivity.
If the spinning nozzle discharge parameter R is 1000 or less, the elongation at break
(important strength) of the resulting porous multilayer hollow fiber membrane can be
maintained at a sufficiently high level. The term "elongation at break" refers to the
elongation with respect to the original length when pulling the membrane in the
longitudinal direction. When the molten mixtures merge before being discharged (see
spinning nozzle shown in FIG. 2), a value obtained by dividing the discharge linear
velocity V of the merged molten mixtures at a lower end face 9 shown in FIG. 2 by the slit
width d of the discharge port is employed as the spinning nozzle discharge parameter R.
When the molten mixtures merge when or after being discharged (see spinning nozzle
shown in FIG. 1), the spinning nozzle discharge parameters R1 and R2 are respectively
calculated for the slit widths d1 and d2 of the circular discharge ports 11 and 12 at the
lower end face 9 shown in FIG. 1. In this case, it is preferable that at least one spinning
nozzle discharge parameter R be 10 or more and 1000 or less. It is more preferable that
the spinning nozzle discharge parameter R of which the amount of discharge is largest be
10 or more and 1000 or less. It is still more preferable that the spinning nozzle discharge
parameters R of all of the circular discharge ports be 10 or more and 1000 or less. The
spinning nozzle discharge parameter R is more preferably 50 or more and 800 or less, and
still more preferably 100 or more and 500 or less.
.[0030]
The number of layers and the ratio of the pore size or the thickness of the layers
may be appropriately set depending on the objective. For example, when forming a
two-layer filter membrane, (i) a combination of a thin outer layer having a small pore
diameter and a thick inner layer having a large pore diameter, or (ii) a combination of a
thick outer layer having a large pore diameter and a thin inner layer having a small pore
diameter is effective for providing minute pores and high water permeability. When
20
forming a three-layer filter membrane, (iii) a combination of a thin outer layer having a
small pore diameter, a thin inner layer having a small pore diameterD, and a thick
intermediate layer having a large pore diameter, or (iv) a combination of a thick outer
layer having a large pore diameter, a thick inner layer having a large pore diameter, and a
thin intermediate layer having a small pore diameter is effective for providing minute
pores and high water permeability.
[0031]
The hollow fiber molten mixtures extruded from the discharge ports to have a
multilayer structure are cooled and solidified through the air or a refrigerant such as water,
and are wound around a reel, as required. Thermally induced phase separation occurs
during cooling. Polymer rich-phases and organic liquid rich-phases are minutely
distributed in the hollow fiber after cooling and solidification. When the inorganic fine
powder is a silica fine powder, the silica fine powder is unevenly distributed in the
organic liquid rich phase. The organic liquid rich-phases form pores by removing the
organic liquid and the inorganic fine powder by extraction from the hollow fiber which
has been cooled and solidified. A porous multilayer hollow fiber membrane can be thus
obtained.
[0032]
The organic liquid and the inorganic fine powder may be removed by extraction at
the same time when the organic liquid and the inorganic fine powder can be extracted
with the same solvent. The organic liquid and the inorganic fine powder are normally
removed separately.
[0033]
The organic liquid is removed by extraction using a liquid appropriate for
extraction which does not dissolve or modify the thermoplastic resin used, but which is
mixed with the organic liquid. Specifically, the organic liquid may be extracted by
contact such as immersion. It is preferable that the liquid used for extraction be volatile
21
so that the liquid can be easily removed from the hollow fiber membrane after extraction.
Examples of such a liquid include an alcohol, methylene chloride, and the like. When
the organic liquid is water-soluble, water may be used as the extraction liquid.
[0034]
The inorganic fine powder is normally removed by extraction using an aqueous
liquid. For example, when the inorganic fine powder is silica, silica may be converted
into a silicate through contact with an alkaline solution, and the silicate is then removed
by extraction through contact with water.
[0035]
The organic liquid and the inorganic fine powder may be removed by extraction in
an arbitrary order. When the organic liquid is immiscible with water, it is preferable to
remove the organic liquid by extraction, and then remove the inorganic fine powder by
extraction. Since the organic liquid and the inorganic fine powder are normally present
in the organic liquid rich-phase in a mixed state, the inorganic fine powder can be
smoothly removed by extraction.
[0036]
A porous multilayer hollow fiber membrane can be obtained by removing the
organic liquid and the inorganic fine powder by extraction from the multilayer hollow
fiber which has been cooled and solidified.
[0037]
The multilayer hollow fiber which has been cooled and solidified may be
stretched in the longitudinal direction at a stretch ratio of 3 or less (i) before removing the
organic liquid and the inorganic fine powder by extraction, (ii) after removing the organic
liquid by extraction, but before removing the inorganic fine powder by extraction, (iii)
after removing the inorganic fine powder by extraction, but before removing the organic
liquid by extraction, or (i) after removing the organic liquid and the inorganic fine powder
by extraction. The water permeability of the multilayer hollow fiber membrane is
22
generally improved by stretching the multilayer hollow fiber membrane in the
longitudinal direction. On the other hand, since the pressure withstand performance
(bursting strength and compressive strength) decreases, the stretched membrane may not
have a practical strength. However, the porous multilayer hollow fiber membrane
obtained by the production process according to the present invention has a high
mechanical strength. Therefore, the multilayer hollow fiber may be stretched at a stretch
ratio of 1.1 or more and 3 or less. The water permeability of the porous multilayer
hollow fiber membrane is improved by stretching the porous multilayer hollow fiber
membrane. The term "stretch ratio" used herein refers to a value obtained by dividing
the length of the hollow fiber after stretching by the length of the hollow fiber before
stretching. For example, when stretching a multilayer hollow fiber having a length of 10
cm to a length of 20 cm, the stretch ratio is two according to the following expression.
20 cm/10 cm = 2
The compressive strength of the membrane may be optionally increased by
subjecting the stretched membrane to a heat treatment. The heat treatment temperature
is normally equal to or less than the melting point of the thermoplastic resin.
[0038]
The porous multilayer hollow fiber membrane according to the present invention
which exhibits blocking performance, water permeability, and strength in a well-balanced
manner is a multilayer membrane which includes at least two layers and is formed of the
thermoplastic resin.
[0039]
The porous multilayer hollow fiber membrane according to the present invention
is described below with reference to a schematic view showing a porous two-layer hollow
fiber membrane (see FIG. 5).
23
[0040]
A layer having a larger pore diameter is referred to as a layer (A), and a layer
having a smaller pore diameter is referred to as a layer (B). The layer (A) is referred to
as an inner layer, and the layer (B) is referred to as an outer layer. Note that the present
invention is not limited thereto. For example, another layer may be provided between
the layer (A) and the layer (B), or another layer may be stacked on the layer (A) or the
layer (B).
[0041]
FIG. 5(1) is a view showing a change in pore diameter in the thickness direction
when the layer (A) and the layer (B) have an isotropic three-dimensional mesh structure.
FIG. 5(2) is a view showing a change in pore diameter when the layer (B) has an
anisotropic three-dimensional mesh structure. FIG. 5(3) is a view showing a change in
pore diameter when a layer (skin layer) having a small pore diameter is formed on the
outer surface in FIG. 5(1). FIGS. 5(1) to 5(3) give graphs showing the relationship
between the thickness and the pore diameter along the cross section of each hollow fiber
membrane. In each graph, the vertical axis indicates the ratio of the pore diameter at
each cross-section to the cross-sectional center pore diameter, and the horizontal axis
indicates the distance from the outer surface to a position in the thickness direction
provided that the total thickness is one. It is preferable that the layer (A) and the layer
(B) have an isotropic three-dimensional mesh structures since the blocking performance
changes to only a small extent even if surface wear occurs.
[0042]
The layer (A) is a support layer. The support layer ensures a high mechanical
strength such as pressure withstand performance, and maintains water permeability as
high as possible.
[0043]
The layer (A) has an isotropic three-dimensional mesh structure. The term
24
"isotropic" used herein means that a change in pore diameter is small (i.e., almost
homogeneous structure) in the thickness direction, the circumferential direction, and the
longitudinal direction of the membrane. The isotropic structure is a structure in which a
portion having a low strength such as a macro-void rarely occurs. Therefore, the
mechanical strength (e.g., pressure withstand performance) of the porous multilayer
hollow fiber membrane can be increased while maintaining the water permeability of the
porous multilayer hollow fiber membrane.
[0044]
The term "three-dimensional mesh structure" used herein refers to a structure
schematically shown in FIG. 3. As shown in FIG. 3, thermoplastic resins a are connected
to form a mesh so that openings b are formed. FIG. 9 shows an example of a microscope
image of the isotropic three-dimensional mesh structure of a porous two-layer hollow
fiber membrane obtained in Example 1. The thickness of the thermoplastic resin which
forms the mesh is almost constant. In this three-dimensional mesh structure, a resin
block having a spherulite structure schematically shown in FIG. 4 is rarely observed.
The opening of the three-dimensional mesh structure is enclosed by the thermoplastic
resin, and each section of the opening communicates. Since most of the thermoplastic
resin used forms a three-dimensional mesh structure which can contribute to the strength
of the hollow fiber membrane, a support layer having a high strength can be formed.
Moreover, chemical resistance increases. The reason that chemical resistance increases
is not clear, but is considered to be as follows. Specifically, since a large amount of
thermoplastic resin forms a mesh which can contribute to strength, the strength of the
entire layer is not affected even if part of the mesh is affected by chemicals. In the
spherulite structure schematically shown in FIG. 4, since the resin gathers in blocks, the
amount of thermoplastic resin which contributes to strength is relatively small.
Therefore, it is considered that the strength of the entire layer is easily affected when part
of the mesh is affected by chemicals. FIG. 4 is a schematic view showing a spherulite
25
structure as a reference. In FIG. 4, spherulites c are partially positioned densely. An
opening d is formed between the spherulites c. FIG. 23 shows an example of a microscope
image of a spherulite structure obtained in Reference Example 1 described later.
[0045]
The surface pore diameter of the layer (A) is 0.6 times to 1.4 times the
cross-sectional center pore diameter. The fact that the surface pore diameter of the layer
(A) is 0.6 times to 1.4 times the cross-sectional center pore diameter is consistent with the
fact that the layer (A) has an isotropic three-dimensional mesh structure. If the surface
pore diameter of the layer (A) is 0.6 times the cross-sectional center pore diameter or
more, filtration resistance at the surface of the support layer does not increase to a large
extent, so that the entire membrane exhibits a high water permeability sufficient for
practical use. If the surface pore diameter of the layer (A) is 1.4 times the cross-sectional
center pore diameter or less, high mechanical strength can be achieved.
[0046]
A hollow fiber membrane must exhibit strength that endures a filtration pressure
differing from a flat membrane which is generally placed on a support such as a
mesh-shaped metal or a plastic. Therefore, a membrane structural design which can
provide strength in the filtration direction (i.e., bursting strength and compressive
strength) is important. It is possible to achieve low filtration resistance and high
compressive strength in combination by suppressing an increase in pore diameter from
the vicinity of the center of the cross section to the inner surface of the hollow fiber.
Blocking performance, water permeability, and mechanical strength can be achieved in a
well-balanced manner by thus controlling the pore diameter of the membrane in the
cross-sectional direction. The surface pore diameter of the layer (A) is preferably 0.7
times to 1.3 times, and more preferably 0.8 times to 1.2 times the cross-sectional center
pore diameter.
[0047]
26
The term "surface pore diameter of the layer (A)" used herein refers to the average
pore diameter of the pores observed in the exposed surface of the layer (A) from the
outside. The average pore diameter is measured as follows. The exposed surface of the
layer (A) of the porous multilayer hollow fiber membrane is photographed using a
scanning electron microscope at a magnification at which the shape of a large number of
pores can be clearly checked as much as possible. Five lines are drawn on the
photograph perpendicularly to each of the horizontal direction and the vertical direction
at almost equal intervals, and the length of the line which crosses the pore on the
photograph is measured. The arithmetic mean value of the measured values is calculated
and taken as the average pore diameter. In order to increase the pore diameter
measurement accuracy, it is preferable that the number of pores over which the ten lines
drawn in horizontal and vertical directions in total pass be 20 or more. When the pore
diameter is about 0.1 to 1 µm, an electron microscope image at a magnification of about
5000 is suitably used.
[0048]
The term "cross-sectional center pore diameter" used herein refers to a value
obtained by photographing the cross section of the porous multilayer hollow fiber
membrane when cut perpendicularly to the longitudinal direction within the range of 10%
of the total thickness from the center position of the thickness using a scanning electron
microscope at an arbitrary magnification, and calculating the arithmetic mean value of the
pore diameter using the resulting photograph in the same manner as the average pore
diameter. The cross-sectional center pore diameter is preferably 0.1 µm or more and 10
µm or less. Water permeability and mechanical strength can be well-balanced when the
cross-sectional center pore diameter is within this range. The cross-sectional center pore
diameter is more preferably 0.3 µm or more and 8 µm or less, still more preferably 0.6 µm
or more and 6 µm or less, and still more preferably 0.8 µm or more and 4 µm or less.
[0049]
27
The porosity of the surface of the layer (B) may be appropriately determined
depending on the objective without specific limitations. The porosity of the surface of
the layer (B) is preferably 20% or more, more preferably 23% or more, and still more
preferably 25% or more from viewpoint of filtration stability of a treatment target liquid
containing a suspended substance or the like. The porosity is preferably 80% or less
from the viewpoint of increasing the mechanical strength of the surface portion. The
porosity is more preferably 60% or less, and still more preferably 50% or less. The
porosity may be determined by placing a transparent sheet on a copy of an electron
microscope image, painting out the pores using a black pen or the like, copying the
transparent sheet onto white paper to clearly distinguish the pores (black) from the
non-pore area (white), and calculating the porosity using commercially available image
analysis software, as disclosed in WO 01/53213 A1, for example.
[0050]
The layer (B) is a blocking layer. The blocking layer prevents a foreign matter
contained in a treatment target liquid from passing through the membrane due to the small
surface pore diameter. The term "surface pore diameter of the layer (B)" used herein
refers to the average pore diameter of the pores observed in the exposed surface of the
layer (B) from the outside. The surface pore diameter of the layer (B) may be measured
using a scanning electron microscope image in the same manner as in the case of
measuring the surface pore diameter of the layer (A). The surface pore diameter of the
layer (B) is preferably 0.01 urn or more and less than 5 µm. If the surface pore diameter
of the layer (B) is 0.01 µm or more, the filtration resistance of the dense surface is low,
whereby water permeability sufficient for practical use is easily obtained. If the surface
pore diameter of the layer (B) is 5 µm or less, cleaning performance important for the
filter membrane can be achieved. The surface pore diameter of the layer (B) is more
preferably 0.05 µm or more and 2 µm or more, still more preferably 0.05 µm or more and
0.5 µm or less, and most preferably 0.1 µm or more and 0.5 µm or less.
28
[0051]
The surface pore diameter of the layer (B) is less than half of the cross-sectional
center pore diameter. This allows the layer (B) to function as a desired blocking layer.
The lower limit of the surface pore diameter may be appropriately selected depending on
the size of the target to be blocked. It is preferable that the surface pore diameter of the
layer (B) be 1/1000 or more of the cross-sectional center pore diameter from the
viewpoint of ensuring water permeability. The surface pore diameter of the layer (B) is
more preferably 1/3 or less and 1/500 or more, and still more preferably 1/4 or less and
1/100 or more of the cross-sectional center pore diameter.
[0052]
It is preferable that the thickness of the layer (B) be 1/100 or more and less than
40/100 of the thickness of the membrane. Even if insoluble matters such as sand and
aggregates are contained in a treatment target liquid, the membrane can.be used by
relatively increasing the thickness of the layer (B) in this manner as described above.
Specifically, the surface pore diameter does not change even if the layer (B) is worn to
some extent. Desirable blocking performance and high water permeability can be
well-balanced when the thickness of the layer (B) is within this range. The thickness of
the layer (B) is more preferably 3/100 or more and 20/100 or less, and still more
preferably 5/100 or more and 15/100 or less of the thickness of the membrane.
[0053]
The layer (B) may have an anisotropic structure in which the diameter of each
pore gradually increases from the surface toward the inside of the membrane, differing
from the layer (A). Alternatively, the layer (B) may have an isotropic structure in which
the diameter of each pore is constant irrespective of the distance from the surface in the
same manner as in the layer (A). The layer (B) preferably has an isotropic
three-dimensional mesh structure similar to that of the layer (A). This enables the
mechanical strength of the entire hollow fiber membrane to be improved while
29
maintaining a desirable blocking performance.
[0054]
The thicknesses of the layer (A) and the layer (B) are determined as follows.
Specifically, the cross-sectional pore diameter of each portion in the thickness direction is
determined by a method described in (7) in the examples. A point at which the pore
diameter is the closest to a value 0.7 times the cross-sectional center pore diameter from
the center of the cross section toward the surface of the layer (B) is determined to lie on a
boundary line between the layers. The distance between the boundary line and the
surface of the layer (A) is taken as the thickness of the layer (A), and the distance between
the boundary line and the surface of the layer (B) is taken as the thickness of the layer (B).
When the pore diameter becomes the closest to a value 0.7 times the cross-sectional
center pore diameter at a plurality of points, the distance between the surface of the layer
(A) and the point closest to the center of the cross section is considered to be the layer (A).
[0055]
The degree of isotropy of the layer (A) is preferably 80% or more. This means
that the layer (A) has an extremely isotropic structure. If the degree of isotropy is 80%
or more, high strength can be achieved while maintaining high water permeability. The
degree of isotropy of the layer (A) is more preferably 90% or more, and still more
preferably 95% or more.
[0056]
The term "degree of isotropy of the layer (A)" refers to a value (ratio) obtained by
dividing the number of portions having a cross-sectional pore diameter 0.8 times to 1.2
times the cross-sectional center pore diameter by the total number of portions included in
the layer (A) measured as described above.
[0057]
The degree of isotropy of the layer (B) is preferably 80% or more. This means
that the layer (B) has an extremely isotropic structure. If the degree of isotropy of the
30
layer (B) is 80% or more, the layer (B) exhibits high blocking performance. Moreover, a
decrease in blocking performance can be suppressed even when the surface of the layer
(B) is worn out due to insoluble matters (e.g., sand or aggregates) contained in a treatment
target liquid. The term "degree of isotropy of the layer (B)" refers to a value (ratio)
obtained by, provided that the cross-sectional pore diameter at a position half the
thickness of the layer (B) is referred to as a cross-sectional center pore diameter (B),
dividing the number of portions having a cross-sectional pore diameter 0.8 times to 1.2
times the cross-sectional center pore diameter (B) by the total number of portions
included in the layer (B) measured as described above. The degree of isotropy of the
layer (B) is more preferably 90% or more, and still more preferably 95% or more. When
the thickness of the layer (B) is very small as compared with the total thickness of the
membrane, the above measurement is conducted while increasing the number of
measurement points of the cross-sectional pore diameter of the layer (B). It is
appropriate to measure the cross-sectional pore diameter at 20 points or more.
[0058]
It is most preferable that the degrees of isotropy of the layer (A) and the layer (B)
be 80% or more. If the degrees of isotropy of the both layers are 80% or more, since
the membrane structure is efficiently formed by the blocking layer and the strength
support layer, a membrane exhibiting blocking performance, water permeability, and
strength in a well-balanced manner can be obtained. The degrees of isotropy of the both
layers are more preferably 90% or more, and still more preferably 95% or more.
[0059]
The term "isotropy" used herein may be expressed by a parameter Q described
below.
[0060]
The term "parameter Q" refers to a value which indicates the pore diameter
change rate at each position from the outer surface to the inner surface in the thickness
31
direction. The parameter Q is calculated as follows.
[0061]
The cross-sectional pore diameters at each position in the thickness direction are
arranged in order from the outer surface to the inner surface.
The outer surface pore diameter is referred to as Do, the cross-sectional pore
diameters are referred to as D1, D2, and Dn in order from the outer surface, and the inner
surface pore diameter is referred to as Dj.
[0062]
The parameter Q is given by the following general expression.
Q=(Dn-Dn-1)/Dn
The parameter Q for the outer surface pore diameter is calculated as follows.
Q=(D1-D0)/D1
The parameter Q for the inner surface pore diameter is calculated as follows.
Q=(D1-Dn)/Di
[0063]
In the porous multilayer hollow fiber membrane according to the present
invention, it is preferable that the number of parameters Q which satisfy -0.2=Q=0.2 be
80% or more of the total number of parameters Q measured. The number of parameters
Q which satisfy -0.2=Q=0.2 is more preferably 85% or more, and still more preferably
90% or more of the total number of parameters Q measured. Since most of the
membrane has a uniform pore diameter when the number of parameters Q which satisfy
32
-0.2=Q=0.2 is within the above range, a membrane exhibiting blocking performance,
water permeability, and strength in a well-balanced manner can be obtained.
[0064]
It is preferable that the number of parameters Q which satisfy -0. 1=Q=0.1 be 50%
or more of the total number of parameters Q measured. The number of parameters Q
which satisfy -0. 1=Q=0.1 is more preferably 60% or more, and still more preferably 70%
or more of the total number of parameters Q measured.
[0065]
A portion for which the parameters Q is smaller than -0.2 or larger than 0.2 shows
a large change in pore diameter depending on the position in the thickness direction.
[0066]
The outer surface pore diameter and the inner surface pore diameter are measured
by the above-described method. The cross-sectional pore diameter is measured by the
measuring method described in (7) in the examples.
[0067]
The layer (A) or the layer (B) may be positioned on the outer side of the hollow
fiber membrane depending on the objective. When using the hollow fiber membrane for
service water filtration, it is preferable to dispose the blocking layer on the outer side of
the hollow fiber membrane from the viewpoint of long-term stable operation.
[0068]
The inner diameter of the hollow fiber membrane is preferably 0.4 mm or more
and 5 mm or less. If the inner diameter of the hollow fiber membrane is 0.4 mm or more,
the pressure loss of a liquid which flows through the hollow fiber membrane does not
increase to a large extent. If the inner diameter of the hollow fiber membrane is 5 mm or
less, sufficient compressive strength and bursting strength are easily achieved by a hollow
fiber membrane having a relatively small thickness. The inner diameter of the hollow
fiber membrane is more preferably 0.5 mm or more and 3 mm or less, and still more
33
preferably 0.6 mm or more and 1 mm or less.
The thickness of the hollow fiber membrane is preferably 0.1 mm or more and 1
mm or less. If the thickness of the hollow fiber membrane is 0.1 mm or more, sufficient
compressive strength and bursting strength are easily achieved. If the thickness of the
hollow fiber membrane is 1 mm or less, sufficient water permeability is easily achieved.
The thickness of the hollow fiber membrane is more preferably 0.15 mm or more and 0.8
mm or less, and still more preferably 0.2 mm or more and 0.6 mm or less.
[0069]
A hollow fiber membrane having such a preferable structure exhibits blocking
performance, water permeability, and mechanical strength in a well-balanced manner,
and exhibits a high performance under a wide range of operating conditions. Moreover,
the hollow fiber membrane does not change relating to the blocking performance (i.e., it
exhibits high abrasion resistance) even if insoluble matters such as sand or aggregates are
contained in a treatment target liquid.
[0070]
A membrane having a uniform latex sphere (0.2 (xm) blocking rate of 95% or
more, a pure water permeability of 5000 1/m2/hr/0.1 MPa or more, and a compressive
strength of 0.3 MPa or more is particularly preferable for the objective of the present
invention.
EXAMPLES
[0071]
The present invention is described in detail below by way of examples. Property
measurement methods are as follows. The measurement was conducted at 25°C unless
otherwise indicated.
(1) Fiber diameter (mm) and aspect ratio
The hollow fiber membrane was cut to a small thickness using a razor or the like
34
perpendicularly to the longitudinal direction of the membrane. The cross section of the
membrane was observed using a microscope. The major axis diameter and the minor
axis diameter of the inner diameter and the major axis diameter and the minor axis
diameter of the outer diameter of the hollow fiber were measured, and the inner diameter
and the outer diameter were determined according to the following expressions.
[0072]
Inner diameter (mm) = (inner major axis diameter (mm) + inner minor axis diameter
(mm)) / 2
[0073]
Outer diameter (mm) = (outer major axis diameter (mm) + outer minor axis diameter
(mm)) / 2
[0074]
The aspect ratio was determined by dividing the major axis of the inner diameter
by the minor axis of the inner diameter.
(2) Pure water permeation rate (L/m2/hr/0.1 MPa)
The hollow fiber membrane was immersed in a 50 mass% ethanol aqueous
solution for 30 minutes, and then immersed in water for 30 minutes to wet the hollow
fiber membrane. One end of the wet hollow fiber membrane having a length of 10 cm
was sealed, and a syringe needle was inserted into the other end. Pure water was injected
into the hollow portion through the syringe needle at a pressure of 0.1 MPa. The amount
of pure water which passed through the membrane was measured. The pure water
permeation rate was determined by the following expression.
[0075]
Pure water permeation rate (1/m2/hr) = (60 (min/hr) x amount of water permeated (1)) / (p
x inner diameter (m) x effective length (m) x measurement time (min))
[0076]
The effective membrane length used herein refers to the net membrane length
35
excluding a portion in which the syringe needle is inserted.
[0077]
(3) Breaking strength (MPa) and elongation at break (%)
Load and displacement upon tension and breakage were measured under the
following conditions.
Sample: wet hollow fiber membrane produced by the method (2) .
Measuring instrument: Instron tensile tester (AGS-5D manufactured by Shimadzu
Corporation), chuck distance: 5 cm
Tensile rate: 20 cm/minute
The breaking strength and the elongation at break were determined by the
following expressions.
[0078]
Breaking strength (kgf/cm2) = load at break (kgf) / cross-sectional area (cm2)
[0079]
Elongation at break (%) = (displacement at break (cm) / 5 (cm)) x 100
[0080]
The cross-sectional area of the membrane is determined by the following
expression.
[0081]
Cross-sectional area (cm2) = p x ((outer diameter (cm) / 2)2 - ((inner diameter (cm) / 2)2)
[0082]
(4) Latex blocking rate (%)
A monodisperse latex having a particle diameter of 0.208 µm (STADEX
manufactured by JSR Corporation, solid content: 1 mass%) was diluted with a 0.5 mass%
sodium dodecyl sulfonate (SDS) aqueous solution to prepare a suspension with a latex
concentration of 0.01 mass%. 100 ml of the latex suspension was placed in a beaker, and
supplied to a wet hollow fiber membrane having an effective length of about 12 cm from
36
the outer surface using a tube pump at a pressure of 0.03 MPa at a linear velocity of 0.1
m/sec so that the liquid which permeated the membrane was let off from the ends (open to
the atmosphere) of the hollow fiber membrane to filter the latex suspension. The filtered
liquid was returned to the beaker, and filtered with a liquid in a closed system. After 10
minutes of filtration, the liquid which permeated the membrane from the ends of the
hollow fiber membrane and the liquid supplied from the beaker were sampled, and
measured for an absorbance at 600 nm using an absorbance detector. The latex blocking
rate was determined by the following expression.
[0083]
Latex blocking rate (%) = (1 - (absorbance of liquid permeated / absorbance of liquid
supplied)) x 100
[0084]
(5) Compressive strength (MPa)
One end of a wet hollow fiber membrane having a length of about 5 cm was sealed
with the other end open to the atmosphere. Pure water at 40°C was caused to permeate
the hollow fiber membrane from the outer surface under pressure, and water which
permeated the membrane was removed from the open end. In this case, the total amount
of water supplied to the membrane was filtered, without circulation (i.e., total amount
filtration method). The pressure was increased from 0.1 MPa stepwise by 0.01 MPa.
The pressure was maintained for 15 seconds, and water removed from the open end
within 15 seconds was sampled. When the hollow portion of the hollow fiber membrane
is not crushed, the absolute value of the amount (mass) of water which permeates the
membrane increases as the pressure increases. When the pressure exceeds the
compressive strength of the hollow fiber membrane, the hollow portion of the hollow
fiber membrane is crushed so that clogging occurs. As a result, the absolute value of the
amount of water which permeates the membrane decreases even if the pressure increases.
Therefore, the pressure at which the absolute value of the amount of water which
37
permeated the membrane becomes a maximum was taken as the compressive strength of
the hollow fiber membrane.
(6) Inner surface pore diameter, outer surface pore diameter, and pore diameter at the
center of cross section (µm)
The inner surface pore diameter, the outer surface pore diameter, and the
cross-sectional center pore diameter of the porous hollow fiber membrane were measured
using a scanning electron micrograph in which the shape of 20 or more pores could be
verified. Five lines were drawn on the photograph (A4) perpendicularly to each of the
horizontal direction and the vertical direction at almost equal intervals so that the
photograph was divided into six sections in the horizontal direction and the vertical
direction. The length of the line crossing the pore on the photograph was measured.
The arithmetic mean length was calculated to determine the inner surface pore diameter,
the outer surface pore diameter, and the cross-sectional center pore diameter of the porous
hollow fiber membrane. When the pore diameter is about 0.1 to 1 µm, an electron
microscope image at a magnification of about 5000 is suitably used. The cross-sectional
center pore diameter was measured in the range of 10% of the total thickness around the
center in the thickness direction.
(7) Cross-sectional pore diameter in each portion in the thickness direction and
thicknesses of layer (A) and layer (B)
The cross section of the hollow fiber membrane was photographed using a
scanning electron microscope. A photograph in which the shape of 20 or more pores
could be verified was used. One hundred lines of which the distance from the outer
surface was equal (i.e., lines connecting points at an equal thickness) were drawn on an
A4 photograph so that the total thickness was divided into 101 sections. The length of
the line crossing the pore on the photograph was measured. The arithmetic mean length
was calculated to determine the cross-sectional pore diameter in each portion in the
thickness direction. When the scanning electron micrograph is taken at a sufficiently
38
high magnification, a line whereof the points lie at an equal distance from the outer
surface may be approximated by a straight line. A point at which the pore diameter was
closest to a value 0.7 times the cross-sectional center pore diameter from the center of the
cross section toward the surface of the layer (B) was determined to lie on a boundary line
between the layers. The distance between the boundary line and the surface of the layer
(A) was taken as the thickness of the layer (A), and the distance between the boundary
line and the surface of the layer (B) was taken as the thickness of the layer (B). When the
pore diameter is about 0.1 to 1 µm, an electron microscope image at a magnification of
about 5000 is suitably used. In the present invention, the total thickness was divided into
14 sections. Specifically, the above measurement was conducted using fourteen electron
micrographs (magnification: 5000) of the cross section of the hollow fiber membrane.
When the electron micrograph was taken at a sufficiently high magnification, a line
whereof the points lie at an equal distance from the outer surface was approximated by a
straight line.
(8) Degree of isotropy (%) of layer (A)
A value (ratio) obtained by dividing the number of portions having a
cross-sectional pore diameter 0.8 times to 1.2 times the cross-sectional center pore
diameter in the layer (A) by the total number of portions included in the layer (A)
measured in (7) was taken as the degree of isotropy of the layer (A).
(9) Degree of isotropy (%) of layer (B)
Lines were drawn concentrically with circles indicated by the cross section of the
hollow fiber at intervals at which the thickness of the layer (B) measured in (7) was
equally divided into 20 sections. The length of the line crossing the pore on the
photograph was measured. The arithmetic mean length was calculated to determine the
cross-sectional pore diameter in each portion of the layer (B) in the thickness direction.
[0085]
The cross-sectional pore diameter at a position half the thickness of the layer (B)
39
is referred to as the cross-sectional center pore diameter (B). A value (ratio) obtained by
dividing the number of portions having a cross-sectional pore diameter 0.8 times to 1.2
times the cross-sectional center pore diameter (B) by the total number (20) of portions
included in the layer (B) was taken as the degree of isotropy of the layer (B).
[0086]
(10) Maximum mass M absorbed by inorganic fine powder
The oil absorption was measured using an oil absorption measuring device (S410
manufactured by FRONTEX) in accordance with JIS K6217-4. 5 g of the silica fine
powder was placed in a sample chamber. The organic liquid was added dropwise to the
silica fine powder at 4 ml/min while rotating a rotor blade at 125 rpm. The torque
increases as the silica fine powder absorbs the organic liquid. After the torque reaches
the maximum value, the torque then decreases. The maximum oil absorption mass M
per unit mass of the inorganic fine powder was calculated by the following expression
from the total mass of the organic liquid when the torque initially reached 70% of the
maximum value.
[0087]
Maximum mass absorbed by inorganic fine powder per unit mass = total mass of organic
liquid when torque reaches 70% of maximum value(g) / 5 (g)
[0088]
(11) Maximum pore diameter (µm) (bubble point method)
The maximum pore diameter of the membrane was measured in accordance with
ASTMF316-03.
(12) Average pore diameter (µm) (half-dry method)
The average pore diameter of the minimum pore diameter layer of the membrane
was measured in accordance with ASTM F316-03.
(13) Spinning stability
A hollow fiber membrane was continuously spun for eight hours. A process in
40
which the molten mixture was extruded and cooled to form a multilayer hollow fiber was
observed with the naked eye. A case where the diameter of the hollow fiber did not
change and the hollow fiber did not show interface non-uniformity and had roundness
was evaluated as "Excellent". A case (a) where interface non-uniformity did not occur,
but the hollow fiber had a poor roundness to some extent, or a case (b) where interface
non-uniformity did not occur, but the fiber diameter changed to some extent with not
impairing production was evaluated as "Good". A case where the hollow fiber showed
interface non-uniformity and had a poor roundness was evaluated as "Bad".
[0089]
Raw materials used in the examples are given below.

Thermoplastic resin
(R-1) Vinylidcne fluoride homopolymer (KF#1000 manufactured by Kureha
Corporation)
(R-2) High-density polyethylene resin (SH800 manufactured by Asahi Kasei Chemicals
Corporation)
Organic liquid
(L-l) Bis(2-ethylhexyl) phthalate (manufactured by CG Ester Corporation)
(L-2) Dibutyl phthalate (manufactured by CG Ester Corporation)
(L-3) y-Butyrolactone (special grade, manufactured by Wako Pure Chemical Industries,
Ltd.)
Inorganic fine powder
(P-l) Silica fine powder (AEROSIL-R972 manufactured by Nippon Aerosil Co., Ltd.
Ltd., primary particle diameter: about 16 nm)
The mixing ratio and the production conditions in each example are shown in
Table 1.
Example 1
41
A vinylidene fluoride homopolymer was used as the thermoplastic resin, a
mixture of di(2-ethylhexyl) phthalate and dibutyl phthalate was used as the organic liquid,
and a silica fine powder was used as the inorganic fine powder. A two-layer hollow fiber
membrane was melt-extruded using two extruders utilizing a hollow fiber molding nozzle
shown in FIG. 2. An outer-layer molten mixture (a) had a composition in which
vinylidene fluoride homopolymer: bis(2-ethylhexyl) phthalate: dibutyl phthalate: silica
fine powder - 40.0:30.8:6.2:23.0 (mass ratio) (volume ratio: 32.2:44.4:8.4:15). An
inner-layer molten mixture (b) had a composition in which vinylidene fluoride
homopolymer:bis(2-ethylhexyl) phthalate:dibutyl phthalate:silica fine powder =
40.0:35.1:1.9:23.0 (mass ratio) (volume ratio: 32.0:50.0:2.6:14.9). Air was used as a
hollow-portion-forming fluid. The molten mixture was extruded from a hollow fiber
molding nozzle (outer diameter: 2.00 mm, inner diameter: 0.92 mm) at a resin
temperature of 240°C and a discharge linear velocity of 14.2 m/min (i.e., spinning nozzle
discharge parameter R was 440/sec) so that the thickness ratio (outer layeninner layer)
was 10:90. The outer diameter of the nozzle refers to the outermost diameter of the
discharge port in FIG. 2. The inner diameter of the nozzle refers to the maximum
diameter of the lower end of the partition wall between the inner-layer molten mixture
discharge port and the hollow-portion-forming fluid discharge port.
[0090]
The extruded hollow fiber extruded product traveled over 60 cm in the air, and
was introduced into a water bath at 40°C to solidify the product. The product was wound
around a reel at 40 m/min. The resulting two-layer hollow fiber was immersed in
methylene chloride to remove bis(2-ethylhexyl) phthalate and dibutyl phthalate by
extraction, and was then dried. The dried product was immersed in a 50 mass% ethanol
aqueous solution for 30 minutes, immersed in water for 30 minutes, immersed in a 20
mass% sodium hydroxide aqueous solution at 70°C for one hour, and then washed with
water to remove the silica fine powder by extraction.
42
[0091]
The resulting porous two-layer hollow fiber membrane did not show interface
non-uniformity and had a high roundness. As a result of cross-sectional observation
using an electron microscope, it was confirmed that the blocking layer and the support
layer had an isotropic three-dimensional mesh structure without macro-voids. Table 2
shows the outer diameter, the inner diameter, the aspect ratio, the pure water permeation
rate, the uniform latex sphere blocking rate, the breaking strength, the elongation at break,
the compressive strength, the outer surface pore diameter (corresponding to the surface
pore diameter of the layer (B)), the inner surface pore diameter (corresponding to the
surface pore diameter of the layer (A)), the cross-sectional center pore diameter, the ratio
of the outer surface pore diameter and the cross-sectional center pore diameter, the ratio
of the inner surface pore diameter and the cross-sectional center pore diameter, and the
degrees of isotropy of the layer (A) and the layer (B) of the resulting membrane. The
porous two-layer hollow fiber membrane had a high pure water permeation rate, latex
blocking rate, and mechanical strength.
[0092]
The porous two-layer hollow fiber membrane was wetted by the method (2), and
immersed in a 4 mass% sodium hydroxide aqueous solution containing sodium
hypochlorite (free chlorine concentration: 0.5 mass%) at room temperature for 10 days.
The elongation at break of the porous two-layer hollow fiber membrane was measured
before and after immersion. The elongation at break after immersion was 90% of the
elongation at break before immersion. It was confirmed that the porous two-layer
hollow fiber membrane had excellent chemical resistance.
[0093]
FIG. 6 shows an electron microscope image of the outer surface of the porous
two-layer hollow fiber membrane at a magnification of 5000. FIG. 7 shows an electron
microscope image of a portion around the outer surface of the cross section at a
43
magnification of 5000. FIG. 8 shows an electron microscope image of a portion around
the outer surface of the cross section at a magnification of 1000. FIG. 9 shows an
electron microscope image of the center of the cross section at a magnification of 5000.
FIG. 10 shows an electron microscope image of a portion around the inner surface of the
cross section at a magnification of 5000. FIG. 11 shows an electron microscope image of
the inner surface at a magnification of 5000. As is clear from the electron microscope
images shown in FIGS. 6 to 11, the outer layer having a small pore diameter and the inner
layer having a large pore diameter were formed in the porous two-layer hollow fiber
membrane. The surface porosity of the layer (B) was 25%.
[0094]
A small amount of graphite was mixed into the molten mixture (a) (outer layer) to
obtain a two-layer hollow fiber (organic liquid was not removed). The entire outer
surface of the two-layer hollow fiber was black. This indicates that the entire outer
surface was covered with the molten mixture (a). A white area which indicates that the
molten mixture (b) was exposed on the outer surface was not observed on the two-layer
hollow fiber over 100 meters or more. FIG. 12 shows a microscope image of the circular
cross section of the two-layer hollow fiber. As shown in FIG. 12, the black layer (layer
of the molten mixture (a)) covered the outer surface in the cross-sectional direction to a
uniform thickness without defects.
Example 2
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except for using an outer-layer molten mixture (a) having a composition in
which vinylidene fluoride homopolymer: bis(2-ethylhexyl) phthalate: dibutyl phthalate:
silica fine powder = 34:33.8:6.8:25.4 (mass ratio) and an inner-layer molten mixture (b)
having a composition in which vinylidene fluoride homopolymer:bis(2-ethylhexyl)
phthalaterdibutyl phthalate:silica fine powder = 36:35.3:5.0:23.7 (mass ratio).
[0095]
44
FIG. 13 shows an electron microscope image of the outer surface of the porous
two-layer hollow fiber membrane at a magnification of 5000. FIG. 14 shows an electron
microscope image of a portion around the outer surface of the cross section at a
magnification of 5000. FIG. 15 shows an electron microscope image of a portion around
the outer surface of the cross section at a magnification of 1000. FIG. 16 shows an
electron microscope image of the center of the cross section at a magnification of 5000.
FIG. 17 shows an electron microscope image of a portion around the inner surface of the
cross section at a magnification of 5000. FIG. 18 shows an electron microscope image of
the inner surface at a magnification of 5000. FIG. 19 shows an electron microscope
image of the cross section at a magnification of 60. FIG. 20 shows an electron
microscope image of the cross section at a magnification of 300. As is clear from the
electron microscope images shown in FIGS. 13 to 20, the outer layer having a small pore
diameter and the inner layer having a large pore diameter were formed in the porous
two-layer hollow fiber membrane. The surface porosity of the layer (B) was 30%.
[0096]
The resulting porous two-layer hollow fiber membrane did not show interface
non-uniformity and had a high roundness. As a result of cross-sectional observation
using an electron microscope, it was confirmed that the blocking layer and the support
layer had an isotropic three-dimensional mesh structure without macro-voids. The
property evaluation results of the resulting membrane are shown in Table 2. The porous
two-layer hollow fiber membrane had a high pure water permeation rate, latex blocking
rate, and mechanical strength. FIG. 21 shows the measurement results for the
cross-sectional pore diameter when equally dividing the cross section of the porous
two-layer hollow fiber membrane into 100 sections. The porous two-layer hollow fiber
membrane had a structure very similar to that shown in FIG. 5(3). FIG. 33 shows the
measurement results for the parameter Q.
Example 3
45
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except for using an outer-layer molten mixture (a) having a composition in
which vinylidene fluoride homopolymer:(2-ethylhexyl) phthalate:dibutyl phthalate =
40.0:36.0:24.0 (mass ratio).
[0097]
The resulting porous two-layer hollow fiber membrane did not show interface
non-uniformity and had a high roundness. As a result of cross-sectional observation
using an electron microscope, it was confirmed that the blocking layer and the support
layer had an isotropic three-dimensional mesh structure without macro-voids. The
property evaluation results of the resulting membrane are shown in Table 2. The porous
two-layer hollow fiber membrane had a high pure water permeation rate, latex blocking
rate, and mechanical strength.
Example 4
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except that the compositions of inner-layer and outer-layer are exchanged,
thus, an inner-layer molten mixture having a composition in which vinylidene fluoride
homopolymcr:bis(2-ethylhexyl) phthalate:dibutyl phthalate:silica fine powder =
40.0:30.8:6.2:23.0 (mass ratio) and an outer-layer molten mixture having a composition
in which vinylidene fluoride homopolymer: bis(2-ethylhexyl) phthalate: dibutyl
phthalate: silica fine powder = 40.0:35.1:1.9:23.0 (mass ratio) were extruded so that the
thickness ratio (outer layeninner layer) was 90:10. As a result of cross-sectional
observation of the resulting porous two-layer hollow fiber membrane using an electron
microscope, it was confirmed that the blocking layer and the support layer had an
isotropic three-dimensional mesh structure without macro-voids. The property
evaluation results of the resulting membrane are shown in Table 2. The porous two-layer
hollow fiber membrane had a high pure water permeation rate, latex blocking rate, and
mechanical strength in the same manner as in Example 1.
46
Example 5
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except for using an outer-layer molten mixture (a) having a composition in
which high-density polyethylene resin (thermoplastic resin):bis(2-ethylhexyl) phthalate
(organic liquid):silica fine powder (inorganic fine powder) = 20.0:56.0:24.0 (mass ratio)
(volume ratio: 23.5:64.2:12.3). As a result of cross-sectional observation of the resulting
porous two-layer hollow fiber membrane using an electron microscope, it was confirmed
that the blocking layer and the support layer had an isotropic three-dimensional mesh
structure without macro-voids. The property evaluation results of the resulting
membrane are shown in Table 2.
[0098]
The porous two-layer hollow fiber membrane was wetted by the method (2), and
immersed in a 4 mass% sodium hydroxide aqueous solution containing sodium
hypochlorite (free chlorine concentration: 0.5 mass%) at room temperature for 10 days.
The elongation at break of the porous two-layer hollow fiber membrane was measured
before and after immersion. The elongation at break after immersion was 60% of the
elongation at break before immersion. It was confirmed that the porous two-layer
hollow fiber membrane had excellent chemical resistance.
Example 6
The ends of the porous two-layer hollow fiber membrane (effective length: 10 cm)
from which the organic liquid and the inorganic fine powder were removed by extraction
obtained in Example 2 were held withboth hands and stretched to a fiber length of 20 cm,
and the hands were then removed. The fiber length decreased to 13 cm. The property
evaluation results of the resulting membrane are shown in Table 2.
Example 7
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except for setting the resin temperatures of the outer-layer molten mixture (a)
47
at 270°C and the inner-layer molten mixture (b) during merging at 250°C. The
property evaluation results of the resulting membrane are shown in Table 2.
Example 8
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except for using an inner-layer molten mixture (b) having a composition in
which vinylidcne fluoride homopolymer:bis(2-ethylhexyl) phthalate:dibutyl
phthalate:silica fine powder = 40:19.1:1.0:39.9 (mass ratio). The property evaluation
results of the resulting membrane are shown in Table 2.
Example 9
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except for using an inner-layer molten mixture (b) having a composition in
which vinylidene fluoride homopolymer:bis(2-ethylhexyl) phthalaterdibutyl
phthalatc:silica fine powder = 40:49.9:2.6:7.5 (mass ratio). The resulting hollow fiber
membrane was fiat to some extent and did not maintain roundness within a practical
range. The property evaluation results of the resulting membrane are shown in Table 2.
Example 10
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except that the molten mixture was extruded from a hollow fiber molding
nozzle (outer diameter: 1.75 mm, inner diameter: 0.92 mm) at a discharge linear velocity
of 20.2 m/min (i.e., spinning nozzle discharge parameter R was 814/sec). The property
evaluation results of the resulting membrane are shown in Table 2.
Example 11
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except that the molten mixture was extruded from a hollow fiber molding
nozzle (outer diameter: 1.75 mm, inner diameter: 0.92 mm) at a discharge linear velocity
of 10.1 m/min (i.e., spinning nozzle discharge parameter R was 407/sec), the extruded
hollow fiber extruded product traveled over 30 cm in the air and was introduced into a
48
water bath at 40°C to solidify the product, and the product was wound around a reel at 20
m/min. The property evaluation results of the resulting membrane are shown in Table 2.
Example 12
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except that the molten mixture was extruded from a hollow fiber molding
nozzle (outer diameter: 1.75 mm, inner diameter: 0.92 mm) at a discharge linear velocity
of 0.20 m/min (i.e., spinning nozzle discharge parameter R was 8/sec), the extruded
hollow fiber extruded product traveled over 0.6 cm in the air and was introduced into a
water bath at 40°C to solidify the product, and the product was wound around a reel at 0.4
m/min. A change in fiber diameter was observed during travel in the air, but was within
a practical range. The property evaluation results of the resulting membrane are shown
in Table 2.
Example 13
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except that the molten mixture was extruded from a hollow fiber molding
nozzle (outer diameter: 1.75 mm, inner diameter: 0.92 mm) at a discharge linear velocity
of 25.3 m/min (i.e., spinning nozzle discharge parameter R was 1017/sec), the extruded
hollow fiber extruded product traveled over 75 cm in the air and was introduced into a
water bath at 40°C to solidify the product, and the product was wound around a reel at 50
m/min. The property evaluation results of the resulting membrane are shown in Table 2.
Example 14
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 1 except that the molten mixtures were extruded so that the thickness ratio
(outer layer:inner layer) was 5:95, the extruded hollow fiber extruded product traveled
over 30 cm in the air and was introduced into a water bath at 40°C to solidify the product,
and the .product was wound around a reel at 20 m/min. The property evaluation results
of the resulting membrane are shown in Table 2.
49
Comparative Example 1
A porous two-layer hollow fiber membrane was obtained in the same manner as in
Example 3 except for using an inner-layer molten mixture (b) having a composition in
which vinylidene fluoride homopolymer:bis(2-ethylhexyl) phthalate:dibutyl phthalate =
40.0:42.0:18.0 (mass ratio). The resulting porous two-layer hollow fiber membrane did
not become stably round (i.e., the membrane became oval or surface waving occurred),
differing from the porous two-layer hollow fiber membranes obtained in the examples.
The property evaluation results of the resulting membrane are shown in Table 2.
[0099]
The porous two-layer hollow fiber membrane was wetted by the method (2), and
immersed in a 4 mass% sodium hydroxide aqueous solution containing sodium
hypochlorite (free chlorine concentration: 0.5 mass%) at room temperature for 10 days.
The elongation at break of the porous two-layer hollow fiber membrane was measured
before and after immersion. The elongation at break after immersion decreased to 20%
of the elongation at break before immersion.
[0100]
A small amount of graphite was mixed into the molten mixture (a) (outer layer) to
obtain a two-layer hollow fiber (organic liquid was not removed) in the same manner as in
Example 1. The outer surface of the two-layer hollow fiber was not entirely black (i.e., a
number of white streaks and spots were observed). This indicates that the outer surface
was not entirely covered with the molten mixture (a) so that the molten mixture (b) (inner
layer) was exposed on the outer surface at a number of points. As a result of
cross-sectional observation of the hollow fiber, the black layer (layer of the molten
mixture (a)) did not thinly covered the outer surface to a uniform thickness without
defects (see FIG. 12). The interface between the layer of the molten mixture (a) (black
layer; outer layer) and the layer of the molten mixture (b) (white layer; inner layer) was
wavy. This indicates that the outer layer partially broke so that the inner layer was
50
exposed on the outer surface.
Comparative Example 2
A porous hollow fiber membrane was obtained in the same manner as in Example
1 having the same thickness as that of Example 1 except that the outer-layer molten
mixture (a) was not extruded, and only an inner-layer molten mixture (b) having a
composition in which vinylidene fluoride homopolymer:bis(2-ethylhexyl)
phthalate:dibutyl phthalate:silicafine powder = 40.0:30.8:6.2:23.0 (mass ratio) was
extruded from the inner-layer slit. As a result of cross-sectional observation using an
electron microscope, it was confirmed that the resulting porous hollow fiber membrane
had an isotropic three-dimensional mesh structure without macro-voids. The property
evaluation results of the resulting membrane are shown in Table 2. The porous hollow
fiber membrane had a high latex blocking rate and high mechanical strength, but showed
a significantly low pure water permeation rate.
[0101]
FIG. 22 shows an electron microscope image of the outer surface of the porous
hollow fiber membrane at a magnification of 5000. FIG. 23 shows an electron
microscope image of a portion around the outer surface of the cross section at a
magnification of 5000. FIG. 24 shows an electron microscope image of the center of the
cross section at a magnification of 5000. FIG. 25 shows an electron microscope image of
a portion around the inner surface of the cross section at a magnification of 5000. FIG.
26 shows an electron microscope image of the inner surface at a magnification of 5000.
[0102]
The porous hollow fiber membrane was wetted by the method (2), and immersed
in a 4 mass% sodium hydroxide aqueous solution containing sodium hypochlorite (free
chlorine concentration: 0.5 mass%) at room temperature for 10 days. The elongation at
break of the porous two-layer hollow fiber membrane was measured before and after
immersion. The elongation at break after immersion was 90% of the elongation at break
51
before immersion.
Comparative Example 3
A porous hollow fiber membrane was obtained in the same manner as in Example
1 except that only the inner-layer molten mixture (b) was extruded without extruding the
outer-layer molten mixture (a). As a result of cross-sectional observation using an
electron microscope, it was confirmed that the resulting porous hollow fiber membrane
had an isotropic three-dimensional mesh structure without voids. The property
evaluation results of the resulting membrane are shown in Table 2. The porous hollow
fiber membrane had a high pure water permeation rate and high mechanical strength, but
showed a significantly low blocking rate.
[0103]
FIG. 27 shows an electron microscope image of the outer surface of the porous
hollow fiber membrane at a magnification of 5000. FIG. 28 shows an electron
microscope image of a portion around the outer surface of the cross section at a
magnification of 5000. FIG. 29 shows an electron microscope image of the center of the
cross section at a magnification of 5000. FIG. 30 shows an electron microscope image of
a portion around the inner surface of the cross section at a magnification of 5000. FIG.
31 shows an electron microscope image of the inner surface at a magnification of 5000.
The porous hollow fiber membrane was wetted by the method (2), and immersed
in a 4 mass% sodium hydroxide aqueous solution containing sodium hypochlorite (free
chlorine concentration: 0.5 mass%) at room temperature for 10 days. The elongation at
break of the porous two-layer hollow fiber membrane was measured before and after
immersion. The elongation at break after immersion was 90% of the elongation at break
before immersion.
Comparative Example 4
A porous hollow fiber membrane was obtained in the same manner as in Example
1 except that the outer-layer molten mixture (a) was not extruded, and only an inner-layer
52
molten mixture (b) having a composition in which polyethylene resin:bis(2-ethylhexyl)
phthalate:silica fine powder = 20.0:56.0:24.0 (mass ratio) (volume ratio: 23.5:64.2:12.3)
was extruded. The property evaluation results of the resulting membrane are shown in
Table 2.
Reference Example
A porous hollow fiber membrane was obtained in the same manner as in Example
1 except that the outer-layer molten mixture (a) was not extruded, and only an inner-layer
molten mixture (b) having a composition in which vinylidene fluoride
homopolymeny-butyrolactone = 40.0:60.0 (mass ratio) (volume ratio: 29.4:70.6) was
extruded referring to Journal of Membrane Science, 52 (1990), pp. 239 to 261 (D. Lloyd)
and ACS Symp. Sen, 269 (1985), pp. 229 to 244 (W. C. Hiatt et.al.). The property
evaluation results of the resulting membrane are shown in Table 2. The membrane had a
low pure water permeation rate, blocking rate, and mechanical strength.
[0104]
The hollow fiber membrane did not have a three-dimensional mesh structure, but
had a structure in which spherulites were connected. FIG. 32 shows an electron
micrograph (magnification: 1000) of the center of the cross section of the porous hollow
fiber membrane. The wet porous hollow fiber membrane was immersed in a 4 mass%
sodium hydroxide aqueous solution containing sodium hypochlorite (free chlorine
concentration: 0.5 mass%) at room temperature for 10 days. The elongation at break of
the porous two-layer hollow fiber membrane was measured before and after immersion.
The elongation at break after immersion decreased to 10% of the elongation at break
before immersion.
53
INDUSTRIAL APPLICABILITY
[0107]
According to the present invention, a porous hollow fiber membrane which has
minute pores and high water permeability suitable for filtration and exhibits excellent
strength can be provided. According to the present invention, the porous multilayer
hollow fiber membrane can be stably produced.
56
CLAIMS
1. A process for producing a porous multilayer hollow fiber membrane by a hollow
fiber molding nozzle with a circular discharge port, the process comprising discharging a
molten mixture including a thermoplastic resin and an organic liquid from a circular
discharge port of a hollow fiber molding nozzle to obtain a multilayer hollow fiber, and
removing the organic liquid from the multilayer hollow fiber by extraction to obtain a
porous multilayer hollow fiber membrane, the hollow fiber molding nozzle having two or
more circular discharge ports which are disposed concentrically, molten mixtures which
differ in composition being discharged from the adjacent discharge ports, the molten
mixture discharged from at least one of the circular discharge ports further including an
inorganic fine powder, and the inorganic fine powder being also removed fromthe
resulting multilayer hollow fiber by extraction.
2. The process for producing a porous multilayer hollow fiber membrane according
to claim 1, wherein the thermoplastic resin, the organic liquid, and further the inorganic
fine powder are mixed in at least a molten mixture which is discharged in a largest
amount among the molten mixtures discharged from the circular discharge ports.
3. The process for producing a porous multilayer hollow fiber membrane according
to claim 1 or 2, wherein the inorganic fine powder is a silica fine powder.
4. The process for producing a porous multilayer hollow fiber membrane according
to any one ofclaims 1 to 3, wherein the molten mixture discharged from a circular
discharge port includes the inorganic fine powder in an amount of 5 mass% or more and
40 mass% or less.
57
5. The process for producing a porous multilayer hollow fiber membrane according
to any one of claims 1 to 4, wherein a mass ratio D of the organic liquid and a mass ratio
S of the inorganic fine powder with respect to the molten mixture and a maximum mass
M of the organic liquid absorbed by the inorganic fine powder per unit mass satisfy
0.2=(D/S)/M=2.
6. The process for producing a porous multilayer hollow fiber membrane according
to any one of claims 1 to 5, wherein the molten mixtures discharged from the adjacent
circular discharge ports include at least one common organic liquid.
7. The process for producing a porous multilayer hollow fiber membrane according
to any one of claims 1 to 5, whereinorganic liquids contained in the molten mixtures
discharged from the adjacent circular discharge ports are the same in kind but differ in
ratio.
8. The process for producing a porous multilayer hollow fiber membrane according
to any one of claims 1 to 7, wherein the molten mixture is discharged so that at least one
spinning nozzle discharge parameter R (1/sec) is 10 or more and 1000 or less, the
spinning nozzle discharge parameter R being a value obtained by dividing a linear
velocity V (m/scc) when discharging the molten mixture by a slit width d (m) of the
discharge port.
9. The process for producing a porous multilayer hollow fiber membrane according
to any one of claims 1 to 8, wherein the multilayer hollow fiber is stretched in a
longitudinal direction of the hollow fiber at a stretch ratio of 1.1 or more and 3 or less
before or after removing the organic liquid and/or the inorganic fine powder by
extraction.
58
10. The process for producing a porous multilayer hollow fiber membrane according
to any one of claims 1 to 9, wherein the thermoplastic resin is selected from a polyolefin
and polyvinylidene fluoride.
11. A porous multilayer hollow fiber membrane comprising at least two layers i.e., an
inner layer and an outer layer, the porous multilayer hollow fiber membrane being formed
of a thermoplastic resin, at least one layer (A) among the two layers having an isotropic
three-dimensional mesh structure and a surface pore diameter 0.6 to 1.4 times a
cross-sectional center pore diameter, and the other layer (B) among the two layers having
a surface pore diameter less than half of the cross-sectional center pore diameter.
12. The porous multilayer hollow fiber membrane according to claim 11, wherein the
layer (B) has an isotropic three-dimensional mesh structure.
13. The porous multilayer hollow fiber membrane according to claim 11 or 12,
wherein the layer (B) has a surface pore diameter of 0.01 um or more and less than 5 ^im.
14. The porous multilayer hollow fiber membrane according to any one of claims 11
to 13, wherein the cross-sectional center pore diameter is 0.1 um or more and 10 urn or
less.
15. The porous multilayer hollow fiber membrane according to any one of claims 11
to 14, wherein the layer (B) has a surface porosity of 20% or more and 80% or less.
16. The porous multilayer hollow fiber membrane according to any one of claims 11
to 15, wherein the layer (B) has a thickness of 1/100 or more and 40/100 or less of the
thickness of the porous multilayer hollow fiber membrane.
59
17. The porous multilayer hollow fiber membrane according to any one of claims 11
to 16, wherein the layer (A) and the layer (B) both have a degree of isotropy of 80% or
more.
18. The porous multilayer hollow fiber membrane according to any one of claims 11
to 17, wherein the number of parameters Q which satisfy -0.2=Q=0.2 is 80% or more of
the total number of average pore diameter measured values, the parameter Q being a
value which indicates an average pore diameter change rate at each position from an outer
surface to an inner surface of the porous multilayer hollow fiber membrane in its
thickness direction.
19. The porous multilayer hollow fiber membrane according to any one of claims 11
to 18, wherein the thermoplastic resin is selected from a polyolefin and polyvinylidene
fluoride.
20. The porous multilayer hollow fiber membrane according to any one of claims 11
to 19, wherein the porous multilayer hollow fiber membrane has an inner diameter of 0.4
mm or more and 5 mm or less and a thickness of 0.2 mm or more and 1 mm or less.
21. A porous multilayer hollow fiber membrane produced by the process according to
any one of claims 1 to 10.
22. The porous multilayer hollow fiber membrane according to any one of claims 11
to 20, the porous multilayer hollow fiber membrane being produced by the process
according to any one of claims 1 to 10.

A porous hollow fiber membrane which has high blocking performance and high
water permeability suitable for filtration and the like and exhibits excellent strength, and a
process for stably producing the porous hollow fiber membrane are disclosed. The
process utilizes a hollow fiber molding nozzle having two or more circular discharge
ports which are disposed concentrically. Multilayer melt-extrusion is performed by
discharging molten mixtures which include a thermoplastic resin and an organic liquid
and differ in composition from the adjacent discharge ports. The resulting product is
cooled to solidify to obtain a hollow fiber. The organic liquid is then removed from the
hollow fiber by extraction to produce a porous hollow fiber membrane. The molten
mixture discharged from at least one circular discharge port includes an inorganic fine
powder in addition to the thermoplastic resin and the organic liquid. The inorganic fine
powder is removed by extraction after cooling in addition to the organic liquid.

Documents:

01317-kolnp-2008-abstract.pdf

01317-kolnp-2008-claims.pdf

01317-kolnp-2008-correspondence others.pdf

01317-kolnp-2008-description complete.pdf

01317-kolnp-2008-drawings.pdf

01317-kolnp-2008-form 1.pdf

01317-kolnp-2008-form 2.pdf

01317-kolnp-2008-form 3.pdf

01317-kolnp-2008-form 5.pdf

01317-kolnp-2008-gpa.pdf

01317-kolnp-2008-international publication.pdf

01317-kolnp-2008-international search report.pdf

01317-kolnp-2008-priority document.pdf

1317-KOLNP-2008-(20-06-2014)-CLAIMS.pdf

1317-KOLNP-2008-(20-06-2014)-CORRESPONDENCE.pdf

1317-KOLNP-2008-(20-06-2014)-FORM-1.pdf

1317-KOLNP-2008-(20-06-2014)-FORM-13.pdf

1317-KOLNP-2008-(20-06-2014)-FORM-3.pdf

1317-KOLNP-2008-(24-02-2014)-CORRESPONDENCE.pdf

1317-KOLNP-2008-(27-12-2011)-CLAIMS.pdf

1317-KOLNP-2008-(27-12-2011)-CORRESPONDENCE.pdf

1317-KOLNP-2008-(27-12-2011)-DESCRIPTION (COMPLETE).pdf

1317-KOLNP-2008-(27-12-2011)-DRAWINGS.pdf

1317-KOLNP-2008-(27-12-2011)-FORM-1.pdf

1317-KOLNP-2008-(27-12-2011)-FORM-2.pdf

1317-KOLNP-2008-(28-08-2014)-FORM-13.pdf

1317-KOLNP-2008-ABSTRACT 1.1.pdf

1317-KOLNP-2008-AMANDED CLAIMS.pdf

1317-KOLNP-2008-CORRESPONDENCE 1.1.pdf

1317-KOLNP-2008-CORRESPONDENCE 1.2.pdf

1317-KOLNP-2008-DESCRIPTION (COMPLETE) 1.1.pdf

1317-KOLNP-2008-DRAWINGS 1.1.pdf

1317-KOLNP-2008-FORM 1-1.1.pdf

1317-kolnp-2008-form 18.pdf

1317-KOLNP-2008-FORM 2-1.1.pdf

1317-KOLNP-2008-FORM 3.pdf

1317-KOLNP-2008-OTHERS 1.1.pdf

1317-KOLNP-2008-OTHERS.pdf

1317-KOLNP-2008-REPLY TO EXAMINATION REPORT.pdf

1317-KOLNP-2008-TRANSLATED COPY OF PRIORITY DOCUMENT.pdf

abstract-1317-kolnp-2008.jpg


Patent Number 263240
Indian Patent Application Number 1317/KOLNP/2008
PG Journal Number 42/2014
Publication Date 17-Oct-2014
Grant Date 15-Oct-2014
Date of Filing 01-Apr-2008
Name of Patentee ASAHI KASEI CHEMICALS CORPORATION
Applicant Address 1-2, YURAKU-CHO 1-CHOME, CHIYODA-KU, TOKYO
Inventors:
# Inventor's Name Inventor's Address
1 FUJIMURA, HIROKAZU 1-2, YURAKU-CHO 1-CHOME, CHIYODA-KU, TOKYO 100-8440
2 HASHINO, MASATOSHI 1-2, YURAKU-CHO 1-CHOME, CHIYODA-KU, TOKYO 100-8440
3 SHIMIZU, TETSUO 1-2, YURAKU-CHO 1-CHOME, CHIYODA-KU, TOKYO 100-8440
4 KUBOTA, NOBORU 1-2, YURAKU-CHO 1-CHOME, CHIYODA-KU, TOKYO 100-8440
PCT International Classification Number B01D 69/12
PCT International Application Number PCT/JP2006/320251
PCT International Filing date 2006-10-11
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2006-128119 2006-05-02 Japan
2 2005-298374 2005-10-13 Japan