A novel polyethylene microfiltration membrane with highly permeable ordered 'wine bottle' shaped through-pore structure fabricated via imprint and thermal field induction

A novel microfiltration membrane with ordered 'wine bottle' shaped through-pores from inexpensive thermoplastic linear low-density polyethylene (LLDPE) was fabricated via imprint and thermal field induction. At 110°C, a softened bilayer with a top LLDPE film on a bottom polymer buffer layer was imprinted by a silicon micropillar array template. Under an optimized imprint pressure of 1.4 MPa, the micropillars penetrated through the LLDPE film and into the buffer layer, forming cylindrical through-pores (pore diameter: 2 μm) in the LLDPE film without damaging the template. The establishment of this bilayer can effectively avoid the problem of residual layer which usually exists in conventional single-layer imprints and hinders the formation of perforation. After the imprint, the LLDPE membrane laid flat on a smooth glass substrate was heated in a homogeneous thermal field of 140°C and melted. The melt can spread over the substrate, inducing the shrinkage of pores. With the increase of heating time, the shrinkage of the membrane top versus bottom surface and the change of membrane thickness and porosity were studied. At 90 s, a thin membrane with ordered 'wine bottle' shaped through-pores (pore size: 1 μm on the top surface and 450 nm on the bottom surface) can be achieved. The experimental results of pure-water permeation and the separation of bacteria-water and oil-water have demonstrated the excellent performance of the membrane.