Systems and methods for manufacturing dual-layer polymer films

A method of manufacturing a polymer membrane, the method comprising:

• positioning a first polymer-bearing aqueous phase in a vessel;
• flowing a second polymer-bearing aqueous phase in the vessel, wherein the second polymer-bearing aqueous phase is immiscible with the first polymer-bearing aqueous phase and has a lesser density, to form an aqueous biphasic system (ABS) with an interfacial zone therebetween;
• positioning a polymerization initiator in the interfacial zone;
• activating the polymerization initiator to cross-link polymers of at least one of the first polymer-bearing aqueous phase and the second polymer-bearing aqueous phase;
• polymerizing at least a portion of the interfacial zone to create a polymer film;
• and
• moving the polymer film from the vessel in a lateral direction relative to the interfacial zone.

A system for manufacturing a polymer film, the system comprising:

• a vessel containing:
• a first polymer-bearing aqueous phase,
• a second polymer-bearing aqueous phase, wherein the second polymer-bearing aqueous phase is immiscible with the first polymer-bearing aqueous phase and forms an interfacial zone, and
• a polymerization activator in the interfacial zone;
• and
• an energy source configured to activate the polymerization activator.