# US 9,517,433 B2 · Selective water vapour transport membranes comprising a nanofibrous layer and methods for making the same

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- Number: US 9,517,433 B2
- Document ID: US9517433B2
- Status: Granted
- Kind: B2
- Application number: 14/535,160
- Filed: 2014-11-06
- Published: 2015-03-05
- Granted: 2016-12-13
- Earliest claimed: 2011-06-07
- Assignees: DPoint Technologies Inc.
- Applicants: Dpoint Technologies Inc.
- Inventors: Ryan Nicholas Huizing; Frank K. Ko
- Web page: https://patentgrep.com/patent/US9517433B2

## CPC

- B01D 53/22: by diffusion (manufacturing semi-permeable membranes B01D67/00; form, structure or properties of semi-permeable membranes B01D69/00; material for semi-permeable membranes B01D71/00)
- B01D 53/228: {characterised by specific membranes}
- B01D 53/268: {by diffusion}
- B01D 69/106: {Membranes in the pores of a support, e.g. polymerized in the pores or voids}
- B01D 69/1071: {Woven, non-woven or net mesh}
- B01D 71/32: containing fluorine atoms
- B01D 71/36: Polytetrafluoroethylene
- B01D 71/421: {Polyacrylonitrile}
- B01D 71/5211: {Polyethylene glycol or polyethyleneoxide}
- B01D 71/54: Polyureas; Polyurethanes
- B01D 71/82: characterised by the presence of specified groups, e.g. introduced by chemical after-treatment
- B29D 99/005: {Producing membranes}
- B32B 1/00: Layered products having a non-planar shape
- B32B 3/28: characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence)
- B32B 5/022: {Non-woven fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 15/02: {Layer formed of wires, e.g. mesh}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- D01D 5/0076: {characterised by the collecting device, e.g. drum, wheel, endless belt, plate or grid (D01D5/0046 takes precedence)}
- D01F 6/18: from polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
- F24F 12/001: {with heat-exchange between supplied and exhausted air}
- F24F 12/006: {using an air-to-air heat exchanger (F24F12/002 takes precedence)}
- B01D 2053/221: {Devices}
- B01D 2257/80: Water
- B01D 2259/4508: for cleaning air in buildings
- B01D 2323/30: Cross-linking
- B01D 2323/39: Electrospinning
- B01D 2325/48: Antimicrobial properties
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/0276: Polyester fibres
- B32B 2307/7242: Non-permeable
- Y02B 30/56: Heat recovery units
- Y02P 70/62: related technologies for production or treatment of textile or flexible materials or products thereof, including footwear
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D01D: MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01F: CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- F24F: AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING (removing dirt or fumes from areas where they are produced B08B15/00; vertical ducts for carrying away waste gases from buildings E04F17/02; tops for chimneys or ventilating shafts, terminals for flues F23L17/02)
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A water vapor transport membrane comprises a nanofibrous layer disposed on a macroporous support layer, the nanofibrous layer coated with a water permeable polymer. A method for making a water vapor transport membrane comprises forming a nanofibrous layer on a macroporous support layer and applying a water permeable polymer to the nanofibrous layer. The water permeable polymer can be applied for so that the nanofibrous layer is substantially or partially filled with the water permeable polymer, or so that the coating forms a substantially continuous layer on one surface of the nanofibrous layer. In some embodiments of the method, the nanofibrous layer is formed by electro-spinning at least one polymer on at least one side of the porous support layer. In some embodiments, the support layer is formable and the method further comprises forming a three-dimensional structure from the water vapor transport membrane, for example, by compression molding, pleating or corrugating.

## Claims

### Claim 1

A composite membrane comprising:
a macroporous support layer;
a framework layer comprising nanofibres, the framework layer supported on one surface of the macroporous support layer; and
a water-vapour-permeable, substantially air-impermeable coating supported by the framework layer;
wherein the composite membrane is formable to provide a self-supporting three-dimensional structure that is water-vapour-permeable and substantially air-impermeable.

### Claim 2 (depends on 1)

The composite membrane of claim 1 wherein the composite membrane has water vapour transport of at least 15 kg/m2/day and oxygen crossover less than 1%.

### Claim 3 (depends on 1)

The composite membrane of claim 1 wherein the support layer comprises a material that is formable by thermal molding at temperatures of 100 C or less.

### Claim 4 (depends on 1)

The composite membrane of claim 1 wherein the composite membrane is formable by compression molding and the water-vapour-permeable, substantially air-impermeable coating is stretchable to accommodate dimensional changes caused by the forming without compromising the substantial air-impermeability of the coating.

### Claim 5 (depends on 1)

The composite membrane of claim 1 wherein the composite membrane is stretchable by an amount in the range of 6.1 to 11.7 percent.

### Claim 6 (depends on 1)

The composite membrane of claim 1 formed to have a self-supporting three-dimensional structure comprising a plurality of flow channels.

### Claim 7 (depends on 1)

The composite membrane of claim 1 wherein the water-vapour-permeable coating is at least one of flexible and elastomeric.

### Claim 8 (depends on 1)

The composite membrane of claim 1 wherein the water-vapour-permeable coating comprises a thermoplastic elastomer.

### Claim 9 (depends on 1)

The composite membrane of claim 1 wherein the water vapor permeable coating comprises an amorphous polymer.

### Claim 10 (depends on 1)

The composite membrane of claim 1 wherein the water vapor permeable coating comprises a copolymer.

### Claim 11 (depends on 10)

The composite membrane of claim 10 wherein the copolymer comprises a cross-linked polyurethane-polyether copolymer.

### Claim 12 (depends on 1)

The composite membrane of claim 1 wherein the water vapor permeable coating comprises a sulfonated polymer.

### Claim 13 (depends on 1)

The composite membrane of claim 1 wherein the water vapor permeable coating comprises a polymer blend.

### Claim 14 (depends on 1)

The composite membrane of claim 1 wherein the framework layer is substantially filled with the water-vapour-permeable coating.

### Claim 15 (depends on 1)

The composite membrane of claim 1 wherein the water-vapour-permeable coating contacts the macroporous support layer.

### Claim 16 (depends on 1)

The composite membrane of claim 1 wherein the framework layer is partially filled with the water-vapour-permeable coating.

### Claim 17 (depends on 1)

The composite membrane of claim 1 wherein a loading of the water-vapour-permeable coating on the composite membrane is in the range of 0.5-10 g/m2.

### Claim 18 (depends on 1)

The composite membrane of claim 1 wherein the macroporous support layer is thermoplastic.

### Claim 19 (depends on 1)

The composite membrane of claim 1 wherein the macroporous support layer comprises a polymeric non-woven material.

### Claim 20 (depends on 1)

The composite membrane of claim 1 wherein the macroporous support layer comprises a polyester spunbond non-woven fabric.

### Claim 21 (depends on 1)

The composite membrane of claim 1 wherein the macroporous support layer comprises a polymer mesh or a metal mesh.

### Claim 22 (depends on 1)

The composite membrane of claim 1 wherein a thickness of the composite membrane is less than 200 microns.

### Claim 23 (depends on 1)

The composite membrane of claim 1 wherein a thickness of the composite membrane is less than 100 microns.

### Claim 24 (depends on 1)

The composite membrane of claim 1 wherein a thickness of the framework layer with the water-vapour-permeable, substantially air-impermeable coating is less than 15 microns.

### Claim 25 (depends on 1)

An enthalpy exchanger plate that is water-vapour-permeable and substantially air-impermeable, the enthalpy exchanger plate consisting essentially of a molded composite membrane according to claim 1.

### Claim 26 (depends on 25)

The enthalpy exchanger plate of claim 25 wherein the enthalpy exchanger plate comprises a flow field region having a plurality of channels molded therein and a manifold region having support ribs molded therein.

### Claim 27 (depends on 25)

The enthalpy exchanger plate of claim 25 where the composite membrane is molded by compression molding.

### Claim 28 (depends on 25)

The enthalpy exchanger plate of claim 25 where the composite membrane is thermally molded.

### Claim 29 (depends on 25)

The enthalpy exchanger plate of claim 25 where the composite membrane is molded at a temperature of less than 100 C.

### Claim 30 (depends on 25)

An enthalpy exchanger core comprising a plurality of the enthalpy exchanger plates according to claim 25.