Pre-metered, unsupported multilayer microporous membrane

Abstract

An at least two layer, unsupported, continuous microporous membrane is disclosed. The at least two layer, unsupported, continuous microporous membrane may include at least two different membrane pore size layers or the pore sizes may have about the same pore size. Apparatus and processes for fabricating at least a two layer unsupported, continuous, microporous membrane are also disclosed. One representative process disclosed for forming a continuous, unsupported, multilayer phase inversion microporous membrane having at least two layers comprises of the acts of: operatively positioning at least one dope applying apparatus, having at least two polymer dope feed slots, relative to a continuous moving coating surface; applying polymer dopes from each of the dope feed slots onto the continuously moving coating surface so as to create a multiple layer polymer dope coating on the coating surface; subjecting the multiple dope layer to contact with a phase inversion producing environment so as to form a wet multilayer phase inversion microporous membrane; and then washing and drying the membrane. Other representative apparatuses and processes are also disclosed.

1 . A multilayer, unsupported, microporous membrane comprising: 
 a first layer and at least a second layer having a distinct change in pore size between each of the layers, the first and the at least second layers being connected at the interface such that the multilayer microporous membrane is continuous.    
   
   
       2 . The multilayer membrane of  claim 1  wherein the first layer is formed from a first polymer dope for producing one pore size and the at least a second layer is formed from at least a second polymer dope for producing at least one different pore size.  
   
   
       3 . The multilayer membrane of  claim 1  wherein the polymer dope comprises: 
 nylon.    
   
   
       4 . The multilayer membrane of  claim 1  wherein the polymer dope comprises: 
 polyvinylidene fluoride.    
   
   
       5 . The multilayer membrane of  claim 1  wherein the polymer dope comprises: 
 polyether sulfone.    
   
   
       6 . The multilayer membrane of  claim 1  wherein the multilayer membrane has a type I configuration.  
   
   
       7 . The multilayer membrane of  claim 1  wherein the multilayer membrane has a type III configuration.  
   
   
       8 . The multilayer membrane of  claim 1  wherein the multilayer membrane has a type IV configuration.  
   
   
       9 . The multilayer membrane of  claim 1  wherein the multilayer membrane has a type V configuration.  
   
   
       10 . The multilayer membrane of  claim 1  wherein the multilayer membrane has a type VI configuration.  
   
   
       11 . The multilayer membrane of  claim 1  wherein the multilayer membrane has a type VII configuration.  
   
   
       12 . The multilayer membrane of  claim 1  wherein the multilayer membrane has a type VIII configuration.  
   
   
       13 . The multilayer membrane of  claim 1  wherein the multilayer membrane has a type IX configuration.  
   
   
       14 . A two layer, unsupported, microporous membrane comprising: 
 a first layer having a first distinct pore size; and    a second layer having a distinct change in pore size between each of the layers, the first and the second layers being connected at the interface such that the two layer multilayer microporous membrane is continuous.    
   
   
       15 . A multilayer, unsupported, microporous membrane comprising: 
 a first layer having a first distinct pore size; and    at least a second layer having at least a second distinct pore size, each of the layers being connected at the interface therebetween such that the multilayer microporous membrane is continuous and has a distinct change in pore size at each interface therebetween.