HETEROGENEOUS MEMBRANE AND METHOD

Abstract: A novel, heterogeneous ion exchange membrane, methods for making such a membrane, and devices containing such a membrane are disclosed. Such membranes comprise linear low or linear medium density polyethylene or high molecular weight high density polyethylene as a binder and can incorporate a wide variety of ion exchange resin materials. The membranes can be fabricated using extrusion or other melt processing procedures to produce a product, which upon conditioning in water, exhibits properties adapted for use in numerous applications.

Description: HETEROGENEOUS MEMBRANE AND METHOD Field of the Invention The invention relates to novel heterogeneous membranes, methods for producing such membranes, and apparatus employing such membranes. Background of the Invention Membranes that selectively allow diffusion and adsorption of ions while excluding certain other ions and non-ionized solutes and solvents, typically referred to as ion exchange membranes, have numerous important industrial applications. Such membranes are used in electrodialysis and electrodeionization equipment as well as in devices for fractionation, transport depletion and electro-regeneration, and purification or treatment of water, food, beverages, chemicals and waste streams. The membranes are also used in electrochemical devices such as caustic/chlorine electrolysis equipment, electropaint purification equipment, and electro-organic synthesis equipment. Additionally, ion exchange membranes are used in electrophoresiε devices and analytical equipment as adsorbents, and as suppressor devices for ion chromatography. They are used in chemical treatment and concentration applications via the processes of Donnan dialysis and diffusion dialysis, and they are also used in batteries and fuel cells for the production of electricity. In each of the applications described above, numerous membrane properties must be balanced against one another in order to achieve a membrane that satisfies the desired objecriveε of the particular application. Among these, it is an objective to employ ion exchange membranes that have high selectivity, low solvent and non-ionized solute transfer, low diffusion resistance of the ions selected, high physical strength, and good chemical resistance. Addi ionally, it is desirable that such membranes be easily manufactured at low cost without the use of hazardous substances. Furthermore, ideal membranes should be easy to handle and process and should also be amenable to low cost assembly techniques during the production of devices containing such membranes. Current commercially available ion exchange membranes are primarily of two general types: homogeneous membranes and heterogeneous membranes. A homogeneous membrane is one in which the entire volume of the membrane (excluding any support material that may be used to improve strength) is made from the reactive polymer. Examples include membranes made of sulfonated or aminated styrene-divinylbenzene polymers (SDVB membranes), polymerized perfluorosulfonic acids (PFSO membranes) or various thermoplastics with active groups grafted onto the base polymer. Unfortunately, homogeneous membranes tend to be difficult to manufacture. They also tend to employ the use of hazardous materials during their manufacturing process since, for the most part, they must be made from base monomers. Additionally, they are difficult to modify chemically because each modification requires a change in the fundamental chemistry of the membrane. Homogeneous membranes also tend to have limited physical strength (therefore often requiring a screen or cloth support) because the polymer produced cannot readily combine both the required physical and electrochemical properties to operate efficiently in a fabricated device. Homogeneous membranes may be either crosslinked (to provide the membrane with dimensional stability, but increased brittleness and sensitivity upon drying), or they may be non-crossiinked (to provide membranes which may be dried, but lack dimensional stability and resistance to swelling and various solvents). In contrast, heterogeneous membranes are formed of 1) a composite containing an ion exchange resin to impart electrochemical properties and 2) a binder to impart physical strength and integrity. Typical heterogeneous membranes may be produced as "micro-heterogeneous" membranes by the paste method (in which ion exchange resin monomers are reacted to form the ultimate ion exchange resin polymer in the presence of a finely-ground inert binder polymer), or in the alternative, as "macro-heterogeneous" membranes by the physical blending of pre-polymerized ion exchange resin and binder . Present macro-heterogeneous membranes tend to have inferior electrochemical properties as compared to homogeneous or micro-heterogeneous membranes, but they do offer a number of advantages as compared to such membranes. In particular, macro-heterogeneous membranes are easy to manufacture and can be readily chemically modified since, within limits, the binder and resin types and content can be varied without significantly modifying the manufacturing process. Macro-heterogeneous membranes also tend to be stronger than homogeneous membranes, although they still generally require a screen or cloth support. Finally, macro-heterogeneous membranes can be dried without damage to the membrane. Unfortunately, present heterogeneous membranes are still difficult to manufacture. They typically are produced from a solvent-containing lacquer that is dangerous to handle and becomes hazardous waste. Furthermore, such membranes are often limited to the use of a binder that can be dissolved in a relatively non-toxic solvent. Finally, although not damaged upon drying, they do undergo substantial dimensional changes, thus making it difficult to fabricate them into devices in which drying may occur . The most common macro-heterogeneous membrane is a composite containing a styrene-divinylbenzene (SDVB) based resin, a polyvinylidenefluoride (PVDF) binder, and a polypropylene cloth support. The SDVB is usually mixed into a solution of PVDF dissolved in a solvent such as N-methyl pyrrolidone (NMP) to form a suspension. The suspension is coated onto the polypropylene support, dried in an oven and pressed in a heated press. The method described above suffers from numerous disadvantages. The PVDF, NMP, and polypropylene cloth are very expensive, as is the manufacture of the suspension and the equipment required for coating, drying and pressing. The suspension itself is moisture sensitive and has a limited shelf life due to settling of the resin. Also, the NMP, after drying and extraction, is a hazardous waste material. Furthermore, although PVDF is reasonably chemically resistant in use, it can be attacked by strong bases and solvents. The use of the polypropylene cloth, since it is not ionically conductive, has the effect of further restricting the diffusion of ions through the membrane, thereby decreasing the electrochemical properties of the membrane as compared to competitive homogeneous membranes. Also, upon cutting the membrane to a desired size for a particular application, strands from the cloth tend to become exposed, and liquid within the membrane tends to diffuse to the membrane edges through the strands (a problem common to both homogeneous and heterogeneous membranes) . This causes a liquid "weeping" or leaking phenomenon that detracts from the appearance and performance of devices such as plate and frame type equipment that have membrane edges exposed to the exterior of the device. An alternative way to manufacture heterogeneous ion exchange membranes using heat and pressure, as opposed to dissolution coating, described above is also well-known in the art. Such a method is usually used if the binder polymer is not readily dissolvable in a solvent. For example, U.S. Patents Nos. 2,681,319 and 2,681,320 describe methods for producing heterogeneous membranes and methods for producing a film of controlled thickness. These references also describe post-conditioning of the membrane film using water. U.S. Patent No. 3,627,703 extended the heat and pressure technique of forming heterogeneous ion exchange membranes to include polypropylene binders and described numerous film-forming processes including extrusion. The reference deεcribes the use of microscopically foamed and molecularly oriented polypropylene to reduce resin brittleneεs, thereby overcoming one of the disadvantages associated with such membranes. The reference also notes that if low crosslinked ion exchange resins are used and a hot acid or alkali conditioning procedure is followed, the conditioned membrane is dimensionally stable and pliable even when maintained in an ambient environment. However, the process was found to be ineffective with polyethylene binders, producing a brittle polyethylene membrane. Subsequently, U.S. Patent No. 3,876,565 sought to enhance the pliability of the heterogeneous membranes by expanding the ion exchange resins during conditioning. This was done by subjecting the membrane treatment in hot water at greater than 80°C. Further improvements were described in U.S. Patent No. 4,294,933 which sought to prevent micro-cracks, said to be produced during the formation process described in U.S. Patent No. 3,876,565, by creating siloxane bridging linkages between the ion exchange resin and a vinyl-silane polyolefin copolymer binder. The reference also describes the use of lubricants in the formulation. In view of the foregoing, it is clear that a need exists for techniques to allow the manufacture of polyolefin-based heterogeneous ion exchange membranes that are crack-free and pliable and that do not require a support screen to provide strength and integrity. In addition, a need exists for polyolefin based heterogeneous ion exchange membranes that can be formed simply, inexpensively, and without the use or generation of hazardous materials. Objects and Summary of the Invention It is one object of the present invention to provide a polyolefin-based heterogeneous ion exchange membrane that is pliable and substantially crack-free. It is another object of the present invention to provide a polyolefin-based heterogeneous ion exchange membrane that can be formed from numerous melt technologies that include heat pressing, extrusion, and the like. It is a still further object of the present invention to provide a polyolefin-based heterogeneous ion exchange membrane that retains its physical, chemical, and dimensional properties upon drying. It is yet another object of the present invention to provide a polyolefin-based heterogeneous ion exchange membrane that, during its manufacture, uses and generates a minimum of toxic or otherwise hazardous materials. It is still a further object of the present invention to provide a polyolefin-based heterogeneous ion exchange membrane adapted for use in numerous applications. It is another object of the present invention to provide a polyolefin-based heterogeneous ion exchange membrane that can be easily chemically modified during the membrane fabrication process. It is yet another object of the present invention to provide methods for fabricating the membranes described above. It is still a further object of the present invention to provide apparatus incorporating the membranes described above. In general, the invention comprises an improved heterogeneous ion exchange membrane using a binder comprising a linear low density polyethylene (LLDPE) or a high molecular weight high density polyethylene (HM HDPΞ) and methods for making the same. The membrane is fabricated from granules or pellets of ion exchange resin and either LLDPE or HMWHDPΞ binder that are used as a raw material in a thermoplastic extrusion process, a heat pressing process, or another, similar process employing pressure and heat to create a dry composite sheet of constant width and thickness or having other controlled, formed dimensions. Membrane sheets formed by such processes are then conditioned and activated using a water treatment. -1- The resulting membranes are physically stronger than typical commercially available membranes to the extent that they can be readily employed within numerous devices without any need for an integral support screen. Additionally, such membranes exhibit enhanced chemical resistance over currently available commercial membranes, are low cost, and can be manufactured without the use or generation of toxic and/or hazardous materials. Processing of such membranes is very simple since after conditioning, the membranes maintain their dimensional stability, even under normal device fabrication conditions. Furthermore, such membranes are amenable to low cost fabrication processes such as heat welding. The inventive membranes are very smooth, which minimizes pressure losses when used in numerous applications. Additionally, such membranes present a hydrophobic surface to liquids and particles upon contact, thereby being non-fouling and easily cleanable. Finally, the manufacturing methodology of the inventive membranes makes it very easy to modify or change the active polymers that impart the electrochemical properties to the membrane, thereby allowing the manufacture of a wide variety of anionic, cationic, amphoteric and neutral membranes of various chemistries, crosslinkings, etc., all using the same general manufacturing processes. These and other objects and features of the present invention are more fully described in the accompanying detailed description of the invention. Detailed Description of the Invention Heterogeneous, polyolefin-based, crack-free, pliable ion exchange membranes formed by heat pressing, extrusion and the like may be fabricated using either linear low density polyethylene (LLDPE) or high molecular weight high density polyethylene (HMWHDPΞ) as the binder component. Any of a wide variety of ion exchange resins may be used to provide the membrane with desired electrochemical properties. The degree of croεslinking of the ion exchange resins contained in the membranes is not critical and conditioning can be carried out in water, preferably at a temperature of 80-95°C. Such membranes preferably contain 0.4-1.2 parts per weight of ion exchange resin per part of LLDPE or HMWHDPE, depending upon the relative importance, for a particular application, of physical strength or low electrical resistivity. In applications in which physical strength is the overriding concern, a lower ratio is used, and in applications in which low electrical resistivity is more important, a higher ratio is preferred. Such membranes are well adapted for use in electrodeionization devices. In such applications, membranes having 0.9-1.1 parts by weight of ion exchange reεin to one part by weight LLDPE or HMWHDPE are preferred. Prior to heat forming, it is preferred that the ion exchange resins have a moisture content of less than about 10%. This low moisture content can be achieved either prior to mixing the resins with the LLDPE or HMWHDPE binder material, or alternatively, during a process in which the ion exchange reεin and the binder are formulated into pellets at the melting point of the binder. In a preferred embodiment, a lubricant, such aε glyceroi iε added to the formulation at 1-15% by weight (preferably 5-10% by weight as compared to the weight) of the resin/binder mixture. Glyceroi (or another such lubricant), lowers the required extrusion or forming temperature, thereby reducing heat damage to the ion exchange resinε during the heat forming process. Furthermore, the use of glyceroi also tends to speed the rate of water conditioning and tends to cause the wetted surfaces to "open" during activation to a greater extent, thereby exposing a greater fraction of the ion exchange resin material to process fluids in devices in which the membrane is used. Excellent membrane properties may be obtained using films in the 0.007-0.050 inch thickness range. The resulting membranes do not require a support screen for physical integrity and can be maintained in a dimensionally stable state under ambient conditions following the hot water conditioning step. It is surprising that membranes having LLDPE or HMWHDPE reεin binders having satisfactory properties can be produced using the methods above, since membranes produced using thiε method but employing binderε εuch aε polypropylene, regular high denεity polyethylene, or low denεity polyethylene do not result in membranes with comparable strength, pliability, or integrity. Polyethylene homopolymer varies in density in large part depending on the degree to which each polymer chain is branched. High density polyethylene (HDPE) is normally classified as a polyethylene with a denεity greater than 0.940 and typically aε high as 0.974. The high density is cauεed by a low degree of branching, thereby allowing the polymer chainε to more closely align with one another. HDPE is therefore a relatively crystalline polymer and is considered a linear polymer. Polyethylenes with a density in the range of 0.926-0.940 are sometimes referred to as medium density polyethylene (MDPE), and those with a density below 0.926 are referred to as low density polyethylene (LDPΞ) . Throughout this diεcloεure, the term LDPΞ iε intended to refer to polyethylenes having a denεity below 0.940, thereby incorporating MDPEε aε well. In contrast to HDPEs, LDPΞs are highly branched and have a low cryεtallinity, resulting in their lower denεity. Common LDPEs are not considered to be linear polymers. Within recent years a new claεε of LDPΞε having a high degree cf linearity have been produced. These linear LDPΞs are referred to herein as LLDPEs. Included in the class of LLDPEs are the linear very low denεity polyethylenes (LVLDPEs) having a density of below about 0.915. The highest denεity linear LDPΞ iε the homopolymer with a density of about 0.940. Lower denεity linear polyethyleneε are produced via copolymerization of substances such aε propylene, butene, 4-methyl-l pentene, hexene, or octene. These "hybrid" polymers exhibit short-chain branching, imparting the density of LDPΞ with much more of the linearity of HDPE. It haε been found that the combination of linearity and low denεity provides ideal properties for producing a high quality, heterogeneous ion exchange membrane. Another clasε of polyethyleneε that have been found to yield deεirable properties are the high molecular weight high density polyethylenes (HMWHDPEs) having a denεity in the range of 0.94-0.96. These materials have been found to be useful in the manufacture of heterogeneouε ion exchange membraneε becauεe the high molecular weight, to some extent, offsets the brittleneεε that is found in membranes using common high denεity polyethyleneε. Typical high denεity polyethylenes have an average molecular weight of approximately 40,000-500,000. Aε used herein, the term HMWHDPΞε referε to thoεe polyethyleneε having an average weight greater than 200,000 and density of 0.940 or above. HMWHDPΞs having a denεity of 0.952 have been found to yield εatiεfactory membraneε. An important property of all polyethylenes iε the average molecular weight and molecular weight distribution. Both LLDPΞε and HMWHDPEs have a relatively narrow weight distribution and tend to have a higher melting temperature than LDPΞs or HDPEs of similar molecular weight. By use of LLDPΞs or HMWHDPEs of selected molecular weight and comonomer, it iε possible to vary the specific melting temperature of the binder used in any given membrane. This feature iε important in producing an LLDPΞ or HMWHDPE membrane that can be heat welded to variouε εtructural componentε of a membrane device. The reεulting LLDPΞ or HMWHDPΞ membraneε can be heat welded to LDPΞ, HDPΞ, other LLDPΞε, and even other polymer familieε εuch as polypropylene, by matching the melting temperatures of the membrane binder to the structural polymer to which it iε to be bonded. Heterogeneouε ion exchange membraneε employing LLDPE or HMWHDPE as a binder may be fabricated by providing granulated or powdered LLDPE or HMWHDPE to a mixer and heating until the material becomes molten. Ion exchange resins may then be added in powder form, preferably having a particle size leεε than about 100-150 micrometerε. The reεulting compoεition is then mixed to evenly distribute the ion exchange resins throughout the melt. In a preferred embodiment, a procesεing aid such as glyceroi iε mixed in. A typical weight ratio of (binder/ion exchange reεin)/glycerol iε (55%/45%)/5%. However, the mixture of reεin/binder may include anywhere from 25-65% by weight of the ion exchange resin component. The molten mixture may then be cast aε a 0.25 inch thick sheet, cooled, and then pelletized. Alternatively, the ion exchange powder, the LLDPE or HMWHDPE resin, and the glyceroi may be mixed and sent directly to an extruder or other similar apparatus. The pellets or powder/polyethylene mixture are dried and fed to an extruder or other polymer processing device that combines heat and pressure. Melting and film formation is preferably carried out in the 300-350°F range to form a sheet having an extruded thicknesε of approximately 0.007-0.050 inches. After extrusion, the dry rolls are typically slit, sheeted and placed into a water bath at about 90°C for at least one hour to condition and activate the membrane. Aε an alternative, the formed material may be immersed directly in the water bath prior to shaping. Although not wishing to be bound by a particular theory, the activation and conditioning step is believed to provide the membrane with its deεirable properties as the result of ion exchange resin swelling during the immersion. This swelling iε believed to cause cracks in the binder material which, when filled with liquid, interconnect domains of ion exchange resin and provide the membrane with its electrically conductive properties. The cracks are large enough to allow ion paεεage upon imposition of a voltage gradient, but are too small to allow significant bulk flow of solvent upon imposition of a pressure gradient acrosε the membrane. Following activation and conditioning, the membrane iε removed from the water bath for εubεequent use or fabrication into a device. In deionization applications, ion exchange membranes should have moderate to high ionic permselectivity (depending on whether low to high salinity water is fed to the membrane device, respectively), low water permeability, and low electrical resiεtivity. Tabulated below are typical valueε for membraneε of different manufacturers aε compared to the preεent invention. Aε can be seen in the tables, anion exchange membraneε made in connection with the present invention have similar permselectivity and permeability to other commercially available membranes, lower to equal electrical reεiεtivity aε compared to other heterogeneouε membranes depending on membrane thickness, and equal to greater electrical resistivity as compared to homogeneous membranes (depending on membrane thicknesε and ratio of ion exchange reεin to LLDPE) . Similarly, the cation exchange membraneε made in accordance with the present invention have similar permselectivity to other membranes, lower to similar electrical resiεtivity as compared to other heterogeneous membranes, and equal to higher electrical resistivity aε compared to the homogeneouε membraneε. Permeability iε lower than the other membraneε aε well. Since permeability iε a measure of micro-cracks, it can be seen that the invention has overcome the problem of micro-cracks reported in the orior art. TABLΞ 1: ANION SELECTIVE MEMBRANES Membrane Permselectivity Permeability Reεistivity Type (0.1/0.05M KC1) (ml/hr-ft 2 (ohm-cm 2 ) (in at 5psid) 100 umho water) Invention 83% 22-52 3 60 9 40 19 55 3 80 22 35 23 22 22 TABLE 2: CATION SELECTIVE MEMBRANΞS Membrane Permselectivity Permeability Reεiεtivity Type (0.1/0.05M KC1) (ml/hr-ft 2 (ohm-cm 2 ) ( in at 5pεid) 100 umho water) Invention 89'- 27 4 41 57 50 39 32 11 55 12 27 26 22 22 The characteristics of the membraneε listed in the Tables are aε followε: PVDF 1 = Ionpure supported heterogeneous membrane with PVDF binder. MA-3475, MC-3470 = Sybron supported heterogeneous membrane with PVDF binder. AMI-7001, CMI-7000 = Membrane International supported heterogeneous membrane with PVDF binder. PVDF 2 = Hydro supported heterogeneous membrane with PVDF binder. AMT, CMT = Asahi Glasε εupported homogeneouε membrane. MA-40, MK-40 = Rusεian ion exchange membrane. Anion 3, Cation 3 = Czechoεlovakian ion exchange membrane. SXZL, QZL, AZL, CZL = Ionics supported homogeneous membrane. Each of the commercial membraneε described above requires a supporting cloth to have the physical strength to be fabricated into devices. In contrast, the present invention haε the strength to function in a satisfactory manner without a supporting cloth or screen. Additionally, the absence of the cloth or screen support iε the primary reaεon that LLDPE and HMWHDPE membraneε can be produced having electrical reεistivity comparable to the generally more conductive homogeneous membraneε. The inventive membrane is dimensionally stable after conditioning, at which point it can be exposed to ambient environments with little or no shrinkage or damage. In contrast, other heterogeneous membranes εhrink to a εignificant extent. Upon drying, homogeneouε membranes crack and become damaged. The membrane of the present invention tends to lay flat after conditioning. The ability to lay flat is critical for maintaining close dimensional tolerances within membrane devices, and greatly simplifies device fabrication. The inventive membrane iε also extremely chemically resistant. LLDPE and HMWHDPE are known for their organic and inorganic chemical resistance. In contrast, other binder materialε εuch aε PDVF are much more εusceptible to attack by alkaline compounds (which is crucial in many electrochemical procesεeε becauεe hydroxide ionε are often produced) and εolventε. Similarly, polypropylene binderε are more susceptible to chlorine attack. Homogeneous membranes are much more susceptible to chlorine and solvent attack because the active reεin εurface iε not shielded from reactive species and upon subsequent losε of water content they can shrink and crack. In addition, many homogeneous membraneε uεe PVC-like supporting cloth, which also has limited solvent reεiεtance. In εome inεtanceε, the membraneε of the preεent invention are even more chemically reεistant than the PFSO-based membraneε due to the fact that the preεent membraneε uεe croεslinked resins which are more dimensionally stable. In contrast, non-crosslinked PFSO membrane performance can be severely degraded in the presence of swelling agents such as solvents or acids. In another aspect of the invention, the inventive membranes display enhanced fouling reεiεtance over homogeneouε membraneε becauεe the active εurfaces of such homogeneous membranes are more exposed to slow diffusing foulants. Heterogeneouε membranes tend to be lower in fouling becauεe they present a macrosurface of the binder material rather than the active reεin. The membranes of the present invention display very little fouling because LLDPΞ and HMWHDPΞ binderε exhibit hydrophobicity. This effect alεo allows the membrane to be more easily cleaned than conventional membranes. Among the membraneε deεcribed above, the inventive membrane is the lowest in cost and eaεieεt to manufacture becauεe it does not make use of the support cloth, and because LLDPΞ are HMWHDPE are generally inexpenεive and readily available from a number of suppliers. Furthermore, no modification of the LLDPΞ or HMWHDPΞ is required during the membrane fabrication procesε. Additionally, the inventive membrane can use mass-produced relatively low cost ion exchange reεinε for moεt applicationε. Aεide from raw material coεtε, the preεent membrane iε also inexpensive due to itε simple manufacturing procesε. The inventive membrane is manufactured using the steps of formulation, extrusion or heat processing, and hot water conditioning, all of which use standard low cost manufacturing equipment. The manufacturing procesε uses no hazardous solvents or chemicals and allows the membrane chemistry to be readily modified, since esεentially any commercially available ion exchange reεin can be used aε an active ingredient. The ability to extrude and mold the formulated compoεite allowε flexibility in the final shape and function of the membrane. Therefore, membranes of the preεent invention can be used not only as chemically active materials, but they can also be formed into a εhape that allowε a combination of chemical activity with the phyεical εtructure of a device. For example, the active membrane can be εhaped into a εupport spacer, a εcreen or a water conduit. The inventive membrane can alεo be formed in the εhape of a hollow fiber or cylinder, εhapeε which at preεent cannot be readily created uεing homogeneous membraneε containing crosslinked ion exchange reεinε. Alεo, the materialε of the inventive membraneε can be shaped into a monofilament or yarn and can be woven into a εcreen or cloth to be used as a conductor or chemically active woven material. Furthermore, the inventive material can be molded into powder, beads or pellets, thereby allowing it to be used in adεorption columnε or aε a component of a filter matrix. Granuleε or equivalent particleε or εcreen can alεo be uεed in electrodionization reεin packing or as a packing in other devices, similar to the packings of conventional commercially available ion exchanαers . Bonding is extremely difficult with crosslinked homogeneous membranes because they are not heat weldable. Furthermore, although PVDF heterogeneous membranes are heat bondable to PVDF formε, since PVDF is extremely expensive as a general conεtruction material, it makes heat bonding unattractive in most applications. To date, this difficulty with commercially available membranes has limited the designs of fabricated devices because commercially available membranes can either not be bonded (oftentimes causing the potential for device leaks), or must be bonded using adhesives. Adheεive bonding is a costly and difficult procesε that often limits temperature and chemical resistance. In addition, adhesive bonding may add extractables to the product liquid being treated. In contraεt, inventive membraneε of the type deεcribed herein are readily bondable uεing low coεt standard heat welding techniques becauεe they preεent an LLDPE or HMWHDPE εurface to the welding machine, are dimenεionally stable, and do not have an interfering support screen. The uεe of heat welding techniques means that external leakε can be eliminated from devices containing LLDPE or HMWHDPE membranes because the membranes can be integrally heat bonded to device components and becauεe there is no internal supporting material to channel liquidε to the exterior of deviceε employing the membraneε. LLDPE or HMWHDPE membranes of the type described herein exhibit a εmoothneεε and hydrophobicity which combine to result in a low liquid presεure loεε acroεs the membrane's surface. Thiε low preεεure loεε reduceε energy conεumption for pumping water through the device and reduces the structural strength requirements of the device. Alternatively, at a given presεure differential acroεs a device, the membranes of the invention allow a higher liquid throughput. The membranes of the preεent invention may be readily applied to apparatus for electrodialyεiε (ΞD) and electrodialyεis reversal (EDR) processes. ED and EDR membranes must be low cost, resistant to fouling, and resistant to chlorine and cleaning chemicals. Ideally, εuch membraneε εhould be resistant to elevated temperatures, result in a low presεure loεs, and result in low internal and external leakε. The low preεsure loss reduces pumping requirements and also allows the membraneε to be εpaced more cloεely to each other, thereby reducing power conεumption cauεed by the electrical reεiεtance of the water εtreamε. For selective ion electrodialysiε, selective ion exchange resins can be used as the resin component of the inventive membrane. For tranεport depletion electrodialyεiε, mixed anion and cation reεinε, or amphoteric resins can be used in place of the resin component of one of the anion or cation membranes. For transport of large, multivalent or εlow diffuεing ionε, low croεεlinked ion exchange reεinε can be uεed in the membrane. The low electrical resistance of the membranes deεcribed herein not only improveε power conεumption, but also reduces the εize and coεt of DC power εupplieε that provide the ionic driving force to the proceεε . For electrodeionization and electrodeionization reversal applications, the inventive membrane exhibits those advantages listed above. In such apparatus, the reduction in leakage and presεure loss advantages become even more important, along with the advantage of being able to readily bond the membranes within the device. Chemical resistance is particularly important because hydrogen and hydroxide ions are produced in situ in electrodeionization devices. Furthermore, the smoothnesε of the membrane simplifies automation of resin filling and removal or backwaεhing of the reεin between membranes. Finally, the elimination of adhesives reduces the level of extractables, a significant advantage when electrodeionization apparatus iε uεed in ultrapure water production. The membranes of the present invention are alεo well εuited for fractionation becauεe of their low electrical reεiεtance and their ability to readily incorporate different εelectivity ion exchange resins. The resistance to chemicals and solvents is also advantageous. Similarly, the membranes are well suited for electroregeneration of ion exchange resins because of their chemical reεiεtance. In particular, in the electroregeneration application, membranes must be able to withstand high concentrations of acids and bases at high current densitieε. Liquids to be uεed in food, beverage, and chemical applications and liquid waste streamε may be readily purified and modified uεing apparatuε containing the membraneε described herein. Such membranes are alεo well suited for purification and modification of non-water εtreamε becauεe of their resistance to fouling, chemicals, and elevated temperatures. Also, such membranes are desirable because they allow devices to be fabricated without adhesives and with low internal and external leakage potential. The low presεure characteristics of the membrane are also important when proceεεing high viscosity streamε (εuch aε εugarε, and electropaintε) . Furthermore, the solvent resistance offers advantageε in the proceεsing of alcohols and other organic chemical containing εtreamε . In the treatment of waεte εtreamε (εuch aε plating waεte treatment) the advantage of low coεt iε important not only for initial coεtε but alεo for replacement of damaged equipment cauεed by upεetε in the water to be treated. Devices which make uεe of electrochemical proceεεeε εuch aε chlorine/cauεtic cells, electrolysiε devices, and electro-organic syntheεiε deviceε are improved through the use of the present membranes becauεe of the bondability and chemical and temperature reεiεtance of the membrane. At the high operating current denεitieε of most electrochemical devices, the low electrical resiεtivity of the membranes offers a large advantage. In chlorine/cauεtic cells, the membrane can resist oxidation (at least under some circumεtanceε) even when incorporating εtandard ion exchange resins. However, even if PFSO resinε are incorporated, the use of an LLDPΞ or HMWHDPE binder without the need for a cloth support (such as iε needed in εtandard PSFO membraneε), reεultε in a number of advantageε including a very large coεt reduction, improved di enεional εtability, and a much improved and εimplified fabricated device. It is contemplated that specially tailored analytical resins can be readily incorporated into LLDPE or HMWHDPΞ binders. This allows the use of specialty reactive media in combination with an inert binder so that activity iε maintained without interference by the binder with the chemical analyεiε. Furthermore, the ease of molding hollow fibers and shapeε from the materialε of the preεent invention are an advantage in the deεign of εuppreεεor columnε. The solvent resiεtance of the membrane alεo offerε an advantage in analyεiε applicationε. Donnan and diffuεion dialyεiε εyεtemε may be improved by the uεe of the inventive membranes as a reεult of their excellent chemical reεistance, permselectivity, low cost, low- permeability, and ability to be readily fabricated into various devices. Likewiεe, the inventive membrane iε well εuited for battery and fuel cell applicationε because of its low electrical reεiεtance, chemical and temperature reεiεtance, low cost, and its ability to be readily fabricated into various devices. Ξxampleε Ξxample 1 : Ξlectrodeionization - Preεεure Loss Two electrodeionization deviceε, each containing four cell pairε with a 13 inch flow path length, a 0.1 inch εpacing between membraneε, and an approximately 3.5 inch flow path width per cell were operated at a conεtant flow of 2 approximately 650 ml/minute-mch effective croεε-εectional area. Water temperature waε maintained at approximately 26°C. Reεin beads uεed aε filler were the same for both deviceε and. had approximately uniform diameters of approximately 500 μm. The first device contained heterogeneouε supported PVDF membranes. The second device contained LLDPΞ membranes made in accordance with the present invention. The ion exchange resins within the membranes were identical for both devices. Presεure loεε for the firεt device waε meaεured at 7 pεi whereas in the second device the presεure loεε waε measured at only 4 psi. Example 2: Electrodeionization - Throughput Two electrodeionization devices, described in example l above, were fed water with an equivalent conductivity of 20 microsiemenε. The first device produced 17 megohm-cm 2 deionized water at a rate of 650 ml/mm-inch croεε-εectional area at two voltε per cell pair applied voltage. In contraεt, the εecond device, employing the membranes of the present invention, produced 17 megohm-cm 2 deionized water at a rate of 1300 ml-inch cross-εectional area at one volt per cell pair applied voltage. External leakε of 0.2 ml/minute were meaεured from the firεt device, whereaε no external leakε were detected in the εecond device. Example 3 : Electrodeionization - Fouling and Chemical Resistance The electrodeionization devices deεcribed in the previouε exampleε were operated on a water feed aε deεcribed above at the εame electrical current efficiencieε. After εix monthε of operation, the two deviceε were disassembled and inspected. The first device showed darkening, discoloration, and εpalling of the anion membrane due to the _in εitu formation of hydroxide ions. There was no darkening, discoloration, or spalling of the anion membrane within the second unit. Equivalents Although the specific featureε of the invention are deεcribed in some exampleε and not in others, it is for convenience only and each feature may be combined with any or all of the other features in accordance with the invention. It should be understood, however, that the foregoing description of the invention is intended merely to be illustrative by way of example only and that other modifications, embodiments, and equivalents may be apparent to those skilled in the art without departing from its spirit. Having thus deεcribed the invention, what we deεire to claim and secure by Letters Patent is:

Claims: CLAIMS 1. A heterogeneous ion exchange material which compriεeε an ion exchange reεin incorporated within a binder, the binder compriεing a material selected from the group consiεting of linear low denεity polyethylene and high molecular weight high denεity polyethylene. 2. A heterogeneous ion exchange material as in claim 1 wherein the linear low density polyethylene has a maximum density of approximately 0.940. 3. A heterogeneous ion exchange material aε in claim 1 wherein the high molecular weight high denεity polyethylene haε a minimum denεity of approximately 0.940. 4. A heterogeneouε ion exchange material as in claim 1 wherein the ion exchange reεin comprises a material selected from the group consiεting of anionic ion exchange resins, cationic ion exchange resins, amphoteric ion exchange resinε, and mixtureε thereof. 5. A heterogeneouε ion exchange material aε in claim 1 wherein the material containε approximately 25-65% by weight ion exchange reεin. 6. A heterogeneouε ion exchange material aε in claim 5 wherein the material containε approximately 44-55% by weight ion exchange reεin. 7. A method for forming a heterogeneous ion exchange material, the method compriεing: a) providing a mixture of solid particles of an ion exchange resin and a binder material selected from the group conεiεting of linear low denεity polyethylene and high molecular weight high denεity polyethylene, b) melt procesεing the mixture to provide a product which comprises the binder having an ion exchange resin incorporated therein, and c) submerεing the product in an aqueous solution for a time and temperature sufficient to activate the product. 8. A method as in claim 7 wherein the melt processing comprises extruding the mixture. 9. A method as in claim 7 wherein the mixture contains approximately 25-65% by weight ion exchange resin. 10. A method aε in claim 7 wherein the mixture further comprises glyceroi. 11. A method as in claim 10 wherein the glyceroi compriεeε approximately 1-15% by weight relative to the weight of the mixture. 12. A method aε in claim 7 which further includeε the εtepε of melt forming the mixture into pellets of binder material and ion exchange reεin prior to heat processing the mixture. 13. A method as in claim 7 wherein the a ueouε activating medium compriεeε water. 14. A method aε in claim 13 wherein the water iε maintained at a temperature of between approximately 80-95°C. 15. A method aε in claim 14 wherein the product iε maintained within the aqueouε medium for approximately one hour . 16. A method aε in claim 7 wherein the product haε a thickness of between approximately 0.007-0.050 inches. 17. A method as in claim 7 wherein the ion exchange resin is selected from the group consisting of anionic ion exchange reεinε, cationic ion exchange reεinε, amphoteric ion exchange resins, and mixtures thereof. 18. An apparatus for the treatment of fluid streams which includes a heterogeneous ion exchange material comprising an ion exchange resin incorporated within a binder, the binder comprising a material selected from the group conεiεting of linear low denεity polyethylene and high molecular weight high density polyethylene. 19. An apparatus as in claim 18 wherein the material is adhered to a structural element of the apparatus. 20. An apparatuε as in claim 19 wherein the material is heat bonded to a structural element of the apparatuε. 21. An apparatuε aε in claim 18 which compriεes an electrodeionization apparatus. 22. A heterogeneous ion exchange material as in claim 1 which compriεeε a membrane. 23. A heterogeneouε ion exchange material aε in claim 1 which comprises a flat sheet. 24. A heterogeneouε ion exchange material aε in claim l wherein the material compriεes a hollow fiber. 25. A heterogeneouε ion exchange material aε in claim 1 wherein the material compriεeε a solid filament. 26. A heterogeneouε ion exchange material as in claim 25 wherein the filament iε woven into a εcreen or cloth. 27. A heterogeneous ion exchange material as in claim 1 wherein the material compriseε a particle, bead, or pellet.

Inventors: GIUFFRIDA ANTHONY, GIUFFRIDA, ANTHONY
Applicants: IONPURE TECHN CORP, IONPURE TECHNOLOGIES CORPORATION
Application year: 1993
Main classification: C08J5
IPC codes: B01D67, B01J39, B01J41, B01J43, C08J5