U.S. patent application number 15/030506 was filed with the patent office on 2016-09-22 for composite polyamide membrane treated with dihyroxyaryl compounds and nitrous acid.
The applicant listed for this patent is DOW GLOBAL TECHNOLOGIES LLC. Invention is credited to Patrick S. HANLEY, Mou PAUL, Abhishek ROY, Ian A. TOMLINSON.
Application Number | 20160271569 15/030506 |
Document ID | / |
Family ID | 51900989 |
Filed Date | 2016-09-22 |
United States Patent
Application |
20160271569 |
Kind Code |
A1 |
HANLEY; Patrick S. ; et
al. |
September 22, 2016 |
COMPOSITE POLYAMIDE MEMBRANE TREATED WITH DIHYROXYARYL COMPOUNDS
AND NITROUS ACID
Abstract
A method for making a composite polyamide membrane comprising a
porous support and a polyamide layer, including the steps of: i)
applying a polar solution including a polyfunctional amine monomer
and a non-polar solution including a polyfunctional acyl halide
monomer to a surface of a porous support and interfacially
polymerizing the monomers to form a polyamide layer; ii) applying a
dihydroxyaryl compound to the polyamide layer, wherein the
dihydroxyaryl compound is represented by: formula wherein D, D',
D'' and D''' are independently selected from: alkyl, alkoxy,
hydrogen, halogen, hydroxyl and amine, and L is a linking group;
and iii) exposing the thin film polyamide layer to nitrous acid.
##STR00001##
Inventors: |
HANLEY; Patrick S.;
(Midland, MI) ; PAUL; Mou; (Edina, MN) ;
ROY; Abhishek; (Edina, MN) ; TOMLINSON; Ian A.;
(Midland, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DOW GLOBAL TECHNOLOGIES LLC |
Midland |
MI |
US |
|
|
Family ID: |
51900989 |
Appl. No.: |
15/030506 |
Filed: |
October 29, 2014 |
PCT Filed: |
October 29, 2014 |
PCT NO: |
PCT/US2014/062836 |
371 Date: |
April 19, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61910557 |
Dec 2, 2013 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D 69/105 20130101;
B01D 2325/20 20130101; B01D 69/125 20130101; B01D 67/0097 20130101;
B01D 2323/30 20130101; B01D 67/0093 20130101; B01D 67/0006
20130101; B01D 2323/40 20130101; B01D 67/0095 20130101; B01D 71/56
20130101 |
International
Class: |
B01D 69/12 20060101
B01D069/12; B01D 69/10 20060101 B01D069/10; B01D 67/00 20060101
B01D067/00; B01D 71/56 20060101 B01D071/56 |
Claims
1. A method for making a composite polyamide membrane comprising a
porous support and a polyamide layer, wherein the method comprises:
i) applying a polar solution comprising a polyfunctional amine
monomer and a non-polar solution comprising a polyfunctional acyl
halide monomer to a surface of a porous support and interfacially
polymerizing the monomers to form a polyamide layer; wherein the
method is characterized by: ii) applying a dihydroxyaryl compound
to the polyamide layer, wherein the dihydroxyaryl compound
##STR00019## wherein D, D', D'' and D''40 are independently
selected from: alkyl, alkoxy, hydrogen, halogen, hydroxyl and
amine, E and E' are independently selected from: amide, amine, azo,
ether and ester, and L' is selected from at least one of: aliphatic
and arylene, and iii) exposing the thin film polyamide layer to
nitrous acid; wherein step ii) is performed before, during or after
step iii).
2. The method of claim 1 wherein steps i), ii) and iii) are
performed sequentially.
3. (canceled)
4. (canceled)
5. (canceled)
6. The method of claim 1 wherein D, D', D'', and D''' are
hydrogen.
7. (canceled)
8. The method of claim 1 wherein E and E' are independently
selected from: amide and ether.
9. The method of claim 1 wherein the non-polar solution further
comprises an acid-containing monomer comprising a C.sub.2-C.sub.20
hydrocarbon moiety substituted with at least one carboxylic acid
functional group or salt thereof and at least one amine-reactive
functional group selected from: acyl halide, sulfonyl halide and
anhydride, wherein the acid-containing monomer is distinct from the
polyfunctional acyl halide monomer
10. The method of claim 1 wherein the thin film polyamide layer has
a dissociated carboxylic acid content of at least 0.18 moles/kg at
pH 9.5 as measured by RBS prior to the step of exposing the thin
film polyamide layer to nitrous acid.
11. The method of claim 1 wherein at least one of the polar and
non-polar solutions further comprises a tri-hydrocarbyl phosphate
compound represented by Formula (I): ##STR00020## wherein R.sub.1,
R.sub.2 and R.sub.3 are independently selected from hydrogen and
hydrocarbyl groups comprising from 1 to 10 carbon atoms, with the
proviso that no more than one of R.sub.1, R.sub.2 and R.sub.3 are
hydrogen
12. The method of claim 1 wherein the dihydroxyaryl compound is
selected from at least one of:
N,N'-(benzene-1,3-diyldimethanediyl)bis(3,5-dihydroxybenzamide)
N,N'-(1,4-phenylenebis(methylene))bis(3,5-dihydroxybenzamide)
N,N'-[5-(trifluoromethyl)benzene-1,3-diyl]bis(3,5-dihydroxybenzamide)
N,N'-biphenyl-4,4'-diylbis(3,5-dihydroxybenzamide)
N,N'-ethane-1,2-diylbis(3,5-dihydroxybenzamide)
3,5-bis[(3,5-dihydroxybenzoyl)amino]benzoic acid
13. The method of claim 1 wherein the dihydroxyaryl compound is
represented by at least one of: ##STR00021## wherein Y is selected
from the aliphatic and arylene
14. The method of claim 1 wherein the dihydroxyaryl compound is
represented by at least one of: ##STR00022##
Description
FIELD
[0001] The present invention is generally directed toward composite
polyamide membranes along with methods for making and using the
same.
INTRODUCTION
[0002] Composite polyamide membranes are used in a variety of fluid
separations. One common class of membranes includes a porous
support coated with a "thin film" polyamide layer. The thin film
layer may be formed by an interfacial polycondensation reaction
between polyfunctional amine (e.g. m-phenylenediamine) and
polyfunctional acyl halide (e.g. trimesoyl chloride) monomers which
are sequentially coated upon the support from immiscible solutions,
see for example U.S. Pat. No. 4,277,344 to Cadotte. Various
constituents may be added to one or both of the coating solutions
to improve membrane performance. For example, U.S. Pat. No.
4,888,116 to Cadotte describes the use of combinations of bi- and
tri-functional acyl halide monomers, e.g. isophthaloyl chloride or
terephthaloyl chloride with trimesoyl chloride. The resulting
polyamide layer is subsequently treated with a reagent (nitrous
acid) to form diazonium salt groups and corresponding derivatives
(e.g. azo linkages). See also WO 2013/047398, US2013/0256215,
US2013/0126419, US2012/0305473, US2012/0261332 and US2012/0248027.
U.S. Pat. No. 6,878,278 to Mickols describes the addition of a wide
range of additives to one or both coating solutions including
various tri-hydrocarbyl phosphate compounds. WO2012/102942,
WO2012/102943, WO2012/102944, WO2013/048765 and WO2013/103666
describe the addition of various monomers that include both
carboxylic acid and amine-reactive functional groups in combination
with various tri-hydrocarbyl phosphate compounds. The search
continues for new combinations of monomers, additives and
post-treatments that further improve membrane performance.
SUMMARY
[0003] The invention includes a method for making a composite
polyamide membrane including a porous support and a thin film
polyamide layer. The method includes the steps of: i) applying a
polar solution including a polyfunctional amine monomer and a
non-polar solution including a polyfunctional acyl halide monomer
to a surface of a porous support and interfacially polymerizing the
monomers to form a polyamide layer, ii) applying a dihydroxyaryl
compound to the polyamide layer, wherein the dihydroxyaryl compound
is represented by Formula V,
##STR00002##
[0004] wherein D, D', D'' and D''' are independently selected from:
alkyl, alkoxy, hydrogen, halogen, hydroxyl and amine, and L is a
linking group; and iii) exposing the thin film polyamide layer to
nitrous acid. Step ii) may be performed before, during or after
step iii). Many additional embodiments are described.
DETAILED DESCRIPTION
[0005] The invention is not particularly limited to a specific
type, construction or shape of membrane or application. For
example, the present invention is applicable to flat sheet, tubular
and hollow fiber polyamide membranes useful in a variety of
applications including forward osmosis (FO), reverse osmosis (RO),
nano filtration (NF), ultra filtration (UF), micro filtration (MF)
and pressure retarded fluid separations. However, the invention is
particularly useful in the preparation of asymmetric membranes
designed for RO and NF separations. RO membranes are relatively
impermeable to virtually all dissolved salts and typically reject
more than about 95% of salts having monovalent ions such as sodium
chloride. RO composite membranes also typically reject more than
about 95% of inorganic molecules as well as organic molecules with
molecular weights greater than approximately 100 AMU (Daltons). NF
membranes are more permeable than RO membranes and typically reject
less than about 95% of salts having monovalent ions while rejecting
more than about 50% (and often more than 90%) of salts having
divalent ions--depending upon the species of divalent ion. NF
membranes also typically reject particles in the nanometer range as
well as organic molecules having molecular weights greater than
approximately 200 to 500 AMU.
[0006] Examples of composite polyamide membranes include FilmTec
Corporation FT-30.TM. type membranes, i.e. a flat sheet composite
membrane comprising a bottom layer (back side) of a nonwoven
backing web (e.g. PET scrim), a middle layer of a porous support
having a typical thickness of about 25-125 .mu.m and top layer
(front side) comprising a thin film polyamide layer having a
thickness typically less than about 1 micron, e.g. from 0.01 micron
to 1 micron but more commonly from about 0.01 to 0.1 .mu.m. The
porous support is typically a polymeric material having pore sizes
which are of sufficient size to permit essentially unrestricted
passage of permeate but not large enough so as to interfere with
the bridging over of a thin film polyamide layer formed thereon.
For example, the pore size of the support preferably ranges from
about 0.001 to 0.5 .mu.m. Non-limiting examples of porous supports
include those made of: polysulfone, polyether sulfone, polyimide,
polyamide, polyetherimide, polyacrylonitrile, poly(methyl
methacrylate), polyethylene, polypropylene, and various halogenated
polymers such as polyvinylidene fluoride. For RO and NF
applications, the porous support provides strength but offers
little resistance to fluid flow due to its relatively high
porosity.
[0007] Due to its relative thinness, the polyamide layer is often
described in terms of its coating coverage or loading upon the
porous support, e.g. from about 2 to 5000 mg of polyamide per
square meter surface area of porous support and more preferably
from about 50 to 500 mg/m.sup.2. The polyamide layer is preferably
prepared by an interfacial polycondensation reaction between a
polyfunctional amine monomer and a polyfunctional acyl halide
monomer upon the surface of the porous support as described in U.S.
Pat. No. 4,277,344 and U.S. Pat. No. 6,878,278. More specifically,
the polyamide membrane layer may be prepared by interfacially
polymerizing a polyfunctional amine monomer with a polyfunctional
acyl halide monomer, (wherein each term is intended to refer both
to the use of a single species or multiple species), on at least
one surface of a porous support. As used herein, the term
"polyamide" refers to a polymer in which amide linkages
(--C(O)NH--) occur along the molecular chain. The polyfunctional
amine and polyfunctional acyl halide monomers are most commonly
applied to the porous support by way of a coating step from
solution, wherein the polyfunctional amine monomer is typically
coated from an aqueous-based or polar solution and the
polyfunctional acyl halide from an organic-based or non-polar
solution. Although the coating steps need not follow a specific
order, the polyfunctional amine monomer is preferably first coated
on the porous support followed by the polyfunctional acyl halide.
Coating can be accomplished by spraying, film coating, rolling, or
through the use of a dip tank among other coating techniques.
Excess solution may be removed from the support by air knife,
dryers, ovens and the like.
[0008] The polyfunctional amine monomer comprises at least two
primary amine groups and may be aromatic (e.g., m-phenylenediamine
(mPD), p-phenylenediamine, 1,3,5-triaminobenzene,
1,3,4-triaminobenzene, 3,5-diaminobenzoic acid, 2,4-diaminotoluene,
2,4-diaminoanisole, and xylylenediamine) or aliphatic (e.g.,
ethylenediamine, propylenediamine, cyclohexanne-1,3-diameine and
tris (2-diaminoethyl) amine). One particularly preferred
polyfunctional amine is m-phenylene diamine (mPD). The
polyfunctional amine monomer may be applied to the porous support
as a polar solution. The polar solution may contain from about 0.1
to about 10 wt % and more preferably from about 1 to about 6 wt %
polyfunctional amine monomer. In one set of embodiments, the polar
solutions includes at least 2.5 wt % (e.g. 2.5 to 6 wt %) of the
polyfunctional amine monomer. Once coated on the porous support,
excess solution may be optionally removed.
[0009] The polyfunctional acyl halide monomer comprises at least
two acyl halide groups and preferably no carboxylic acid functional
groups and may be coated from a non-polar solvent although the
polyfunctional acyl halide may be alternatively delivered from a
vapor phase (e.g., for polyfunctional acyl halides having
sufficient vapor pressure). The polyfunctional acyl halide is not
particularly limited and aromatic or alicyclic polyfunctional acyl
halides can be used along with combinations thereof. Non-limiting
examples of aromatic polyfunctional acyl halides include: trimesic
acyl chloride, terephthalic acyl chloride, isophthalic acyl
chloride, biphenyl dicarboxylic acyl chloride, and naphthalene
dicarboxylic acid dichloride. Non-limiting examples of alicyclic
polyfunctional acyl halides include: cyclopropane tri carboxylic
acyl chloride, cyclobutane tetra carboxylic acyl chloride,
cyclopentane tri carboxylic acyl chloride, cyclopentane tetra
carboxylic acyl chloride, cyclohexane tri carboxylic acyl chloride,
tetrahydrofuran tetra carboxylic acyl chloride, cyclopentane
dicarboxylic acyl chloride, cyclobutane dicarboxylic acyl chloride,
cyclohexane dicarboxylic acyl chloride, and tetrahydrofuran
dicarboxylic acyl chloride. One preferred polyfunctional acyl
halide is trimesoyl chloride (TMC). The polyfunctional acyl halide
may be dissolved in a non-polar solvent in a range from about 0.01
to 10 wt %, preferably 0.05 to 3% wt % and may be delivered as part
of a continuous coating operation. In one set of embodiments
wherein the polyfunctional amine monomer concentration is less than
3 wt %, the polyfunctional acyl halide is less than 0.3 wt %.
[0010] Suitable non-polar solvents are those which are capable of
dissolving the polyfunctional acyl halide and which are immiscible
with water; e.g. paraffins (e.g. hexane, cyclohexane, heptane,
octane, dodecane), isoparaffins (e.g. ISOPAR.TM. L), aromatics
(e.g. Solvesso.TM. aromatic fluids, Varsol.TM. non-dearomatized
fluids, benzene, alkylated benzene (e.g. toluene, xylene,
trimethylbenzene isomers, diethylbenzene)) and halogenated
hydrocarbons (e.g. FREON.TM. series, chlorobenzene, di and
trichlorobenzene) or mixtures thereof. Preferred solvents include
those which pose little threat to the ozone layer and which are
sufficiently safe in terms of flashpoints and flammability to
undergo routine processing without taking special precautions. A
preferred solvent is ISOPAR.TM. available from Exxon Chemical
Company.
[0011] The non-polar solution may include additional constituents
including co-solvents, phase transfer agents, solubilizing agents,
complexing agents and acid scavengers wherein individual additives
may serve multiple functions. Representative co-solvents include:
benzene, toluene, xylene, mesitylene, ethyl benzene-diethylene
glycol dimethyl ether, cyclohexanone, ethyl acetate, butyl
Carbitol.TM. acetate, methyl laurate and acetone. A representative
acid scavenger includes N,N-diisopropylethylamine (DIEA). The
non-polar solution may also include small quantities of water or
other polar additives but preferably at a concentration below their
solubility limit in the non-polar solution.
[0012] One or both of the polar and non-polar coating solutions may
additional include tri-hydrocarbyl phosphate compounds as
represented by Formula I:
##STR00003##
[0013] wherein "P" is phosphorous, "O" is oxygen and R.sub.1,
R.sub.2 and R.sub.3 are independently selected from hydrogen and
hydrocarbyl groups comprising from 1 to 10 carbon atoms, with the
proviso that no more than one of R.sub.1, R.sub.2 and R.sub.3 are
hydrogen. R.sub.1, R.sub.2 and R.sub.3 are preferably independently
selected from aliphatic and aromatic groups. Applicable aliphatic
groups include both branched and unbranched species, e.g. methyl,
ethyl, propyl, isopropyl, butyl, isobutyl, pentyl, 2-pentyl,
3-pentyl. Applicable cyclic groups include cyclopentyl and
cyclohexyl. Applicable aromatic groups include phenyl and naphthyl
groups. Cyclo and aromatic groups may be linked to the phosphorous
atom by way of an aliphatic linking group, e.g., methyl, ethyl,
etc. The aforementioned aliphatic and aromatic groups may be
unsubstituted or substituted (e.g., substituted with methyl, ethyl,
propyl, hydroxyl, amide, ether, sulfone, carbonyl, ester, cyanide,
nitrile, isocyanate, urethane, beta-hydroxy ester, etc); however,
unsubstituted alkyl groups having from 3 to 10 carbon atoms are
preferred. Specific examples of tri-hydrocarbyl phosphate compounds
include: tripropyl phosphate, tributyl phosphate, tripentyl
phosphate, trihexyl phosphate, triphenyl phosphate, propyl biphenyl
phosphate, dibutyl phenyl phosphate, butyl diethyl phosphate,
dibutyl hydrogen phosphate, butyl heptyl hydrogen phosphate and
butyl heptyl hexyl phosphate. The species selected should be at
least partially soluble in the solution from which it is coated,
i.e. polar versus non-polar coating solution. Additional examples
are as such compounds are described in U.S. Pat. No. 6,878,278,
U.S. Pat. No. 6,723,241, U.S. Pat. No. 6,562,266 and U.S. Pat. No.
6,337,018.
[0014] In one preferred embodiment, the non-polar solution may
include from 0.001 to 10 wt % and more preferably from 0.01 to 1 wt
% of the tri-hydrocarbyl phosphate compound. In another embodiment,
the non-polar solution includes the tri-hydrocarbyl phosphate
compound in a molar (stoichiometric) ratio of 1:5 to 5:1 and more
preferably 1:1 to 3:1 with the polyfunctional acyl halide
monomer.
[0015] In another preferred embodiment, the non-polar solution may
include an acid-containing monomer comprising a C.sub.2-C.sub.20
hydrocarbon moiety substituted with at least one carboxylic acid
functional group or salt thereof and at least one amine-reactive
functional group selected from: acyl halide, sulfonyl halide and
anhydride, wherein the acid-containing monomer is distinct from the
polyfunctional acyl halide monomer. In one sub-set of embodiments,
the acid-containing monomer comprises an arene moiety. Non-limiting
examples include mono and di-hydrolyzed counterparts of the
aforementioned polyfunctional acyl halide monomers including two to
three acyl halide groups and mono, di and tri-hydrolyzed
counterparts of the polyfunctional halide monomers that include at
least four amine-reactive moieties. A preferred species includes
3,5-bis(chlorocarbonyl)benzoic acid (i.e. mono-hydrolyzed trimesoyl
chloride or "mhTMC"). Additional examples of monomers are described
in WO 2012/102942 and WO 2012/102943 (see Formula III wherein the
amine-reactive groups ("Z") are selected from acyl halide, sulfonyl
halide and anhydride). Specific species including an arene moiety
and a single amine-reactive group include: 3-carboxylbenzoyl
chloride, 4-carboxylbenzoyl chloride, 4-carboxy phthalic anhydride
and 5-carboxy phthalic anhydride, and salts thereof. Additional
examples are represented by Formula II:
##STR00004##
[0016] wherein A is selected from: oxygen (e.g. --O--); amino
(--N(R)--) wherein R is selected from a hydrocarbon group having
from 1 to 6 carbon atoms, e.g. aryl, cycloalkyl, alkyl--substituted
or unsubstituted but preferably alkyl having from 1 to 3 carbon
atoms with or without substituents such as halogen and carboxyl
groups); amide (--C(O)N(R))-- with either the carbon or nitrogen
connected to the aromatic ring and wherein R is as previously
defined; carbonyl (--C(O)--); sulfonyl (--SO.sub.2--); or is not
present (e.g. as represented in Formula III); n is an integer from
1 to 6, or the entire group is an aryl group; Z is an amine
reactive functional group selected from: acyl halide, sulfonyl
halide and anhydride (preferably acyl halide); Z' is selected from
the functional groups described by Z along with hydrogen and
carboxylic acid. Z and Z' may be independently positioned meta or
ortho to the A substituent on the ring. In one set of embodiments,
n is 1 or 2. In yet another set of embodiments, both Z and Z' are
both the same (e.g. both acyl halide groups). In another set of
embodiments, A is selected from alkyl and alkoxy groups having from
1 to 3 carbon atoms. Non-limiting representative species include:
2-(3,5-bis(chlorocarbonyl)phenoxy)acetic acid,
3-(3,5-bis(chlorocarbonyl)phenyl) propanoic acid,
2-((1,3-dioxo-1,3-dihydroisobenzofuran-5-yl)oxy)acetic acid,
3-(1,3-dioxo-1,3-dihydroisobenzofuran-5-yl)propanoic acid,
2-(3-(chlorocarbonyl) phenoxy)acetic acid,
3-(3-(chlorocarbonyl)phenyl)propanoic acid,
3-((3,5-bis(chlorocarbonyl)phenyl) sulfonyl) propanoic acid,
3-((3-(chlorocarbonyl)phenyl)sulfonyl)propanoic acid,
3-((1,3-dioxo-1,3-dihydroisobenzofuran-5-yl)sulfonyl)propanoic
acid, 3-((1,3-dioxo-1,3-dihydroisobenzofuran-5-yl)amino) propanoic
acid,
3-((1,3-dioxo-1,3-dihydroisobenzofuran-5-yl)(ethyl)amino)propanoic
acid, 3-((3,5-bis(chlorocarbonyl) phenyl)amino) propanoic acid,
3-((3,5-bis(chlorocarbonyl) phenyl)(ethyl)amino) propanoic acid,
4-(4-(chlorocarbonyl)phenyl)-4-oxobutanoic acid,
4-(3,5-bis(chlorocarbonyl)phenyl)-4-oxobutanoic acid,
4-(1,3-dioxo-1,3-dihydroisobenzofuran-5-yl)-4-oxobutanoic acid,
2-(3,5-bis(chlorocarbonyl) phenyl)acetic acid,
2-(2,4-bis(chlorocarbonyl)phenoxy) acetic acid,
4-((3,5-bis(chlorocarbonyl) phenyl)amino)-4-oxobutanoic acid,
2-((3,5-bis(chloro carbonyl)phenyl)amino)acetic acid,
2-(N-(3,5-bis(chlorocarbonyl)phenyl)acetamido)acetic acid,
2,2'-((3,5-bis(chlorocarbonyl)phenylazanediyl) diacetic acid,
N-[(1,3-dihydro-1,3-dioxo-5-isobenzofuranyl)carbonyl]-glycine,
4-[[(1,3-dihydro-1,3-dioxo-5-isobenzofuranyl)carbonyl]amino]-benzoic
acid, 1,3-dihydro-1,3-dioxo-4-isobenzofuran propanoic acid,
5-[[(1,3-dihydro-1,3-dioxo-5-isobenzofuranyl)carbonyl]amino]-1,3-benzened-
icarboxylic acid and
3-[(1,3-dihydro-1,3-dioxo-5-isobenzofuranyl)sulfonyl]-benzoic acid.
Another embodiment is represented by Formula III.
##STR00005##
[0017] wherein the carboxylic acid group may be located meta, para
or ortho upon the phenyl ring.
[0018] Representative examples where the hydrocarbon moiety is an
aliphatic group are represented by Formula IV:
##STR00006##
[0019] wherein X is a halogen (preferably chlorine) and n is an
integer from 1 to 20, preferably 2 to 10. Representative species
include: 4-(chlorocarbonyl) butanoic acid, 5-(chlorocarbonyl)
pentanoic acid, 6-(chlorocarbonyl) hexanoic acid,
7-(chlorocarbonyl) heptanoic acid, 8-(chlorocarbonyl) octanoic
acid, 9-(chlorocarbonyl) nonanoic acid, 10-(chlorocarbonyl)
decanoic acid, 11-chloro-11-oxoundecanoic acid,
12-chloro-12-oxododecanoic acid,
3-(chlorocarbonyl)cyclobutanecarboxylic acid,
3-(chlorocarbonyl)cyclopentane carboxylic acid,
2,4-bis(chlorocarbonyl)cyclopentane carboxylic acid,
3,5-bis(chlorocarbonyl) cyclohexanecarboxylic acid, and
4-(chlorocarbonyl) cyclohexanecarboxylic acid. While the acyl
halide and carboxylic acid groups are shown in terminal positions,
one or both may be located at alternative positions along the
aliphatic chain. While not shown in Formula (IV), the
acid-containing monomer may include additional carboxylic acid and
acyl halide groups.
[0020] Representative examples of acid-containing monomers include
at least one anhydride group and at least one carboxylic acid
groups include: 3,5-bis(((butoxycarbonyl)oxy)carbonyl)benzoic acid,
1,3-dioxo-1,3-dihydroisobenzofuran-5-carboxylic acid,
3-(((butoxycarbonyl)oxy)carbonyl)benzoic acid, and
4-(((butoxycarbonyl)oxy)carbonyl)benzoic acid.
[0021] The upper concentration range of acid-containing monomer may
be limited by its solubility within the non-polar solution and may
be dependent upon the concentration of the tri-hydrocarbyl
phosphate compound, i.e. the tri-hydrocarbyl phosphate compound is
believed to serve as a solubilizer for the acid-containing monomer
within the non-polar solvent. In most embodiments, the upper
concentration limit is less than 1 wt %. In one set of embodiments,
the acid-containing monomer is provided in the non-polar solution
at concentration of at least 0.01 wt %, 0.02 wt %, 0.03 wt %, 0.04
wt %, 0.05 wt %, 0.06 wt %, 0.07 wt %, 0.08 wt %, 0.1 wt % or even
0.13 wt % while remaining soluble in solution. In another set of
embodiments, the non-polar solution comprises from 0.01 to 1 wt %,
0.02 to 1 wt %, 0.04 to 1 wt % or 0.05 to 1 wt % of the
acid-containing monomer. The inclusion of the acid-containing
monomer during interfacial polymerization between the
polyfunctional amine and acyl halide monomers results in a membrane
having improved performance. And, unlike post hydrolysis reactions
that may occur on the surface of the thin-film polyamide layer, the
inclusion of the acid-containing monomer during interfacial
polymerization is believed to result in a polymer structure that is
beneficially modified throughout the thin-film layer.
[0022] Once brought into contact with one another, the
polyfunctional acyl halide and polyfunctional amine monomers react
at their surface interface to form a polyamide layer or film. This
layer, often referred to as a polyamide "discriminating layer" or
"thin film layer," provides the composite membrane with its
principal means for separating solute (e.g. salts) from solvent
(e.g. aqueous feed). The reaction time of the polyfunctional acyl
halide and the polyfunctional amine monomer may be less than one
second but contact times typically range from about 1 to 60
seconds. The removal of the excess solvent can be achieved by
rinsing the membrane with water and then drying at elevated
temperatures, e.g. from about 40.degree. C. to about 120.degree.
C., although air drying at ambient temperatures may be used.
However, for purposes of the present invention, the membrane is
preferably not permitted to dry and is simply rinsed with or dipped
in water and optionally stored in a wet state.
[0023] The polyamide layer is subsequently treated with a
dihydroxyaryl compound as represented by Formula V.
##STR00007##
[0024] wherein D, D', D'' and D''' are independently selected from:
alkyl, alkoxy, hydrogen, halogen, hydroxyl and amine (preferably
all are hydrogen), L is a linking group, and the hydroxyl groups
are located meta, ortho or para (preferably meta) to each other on
both rings. The selection of linking group is not particularly
limited but the resulting dihydroxyaryl compound preferably has a
mass of 24 to 1000 AMU (more preferably 75 to 1000 AMU). In a
preferred embodiment, the dihydroxyaryl compound has a solubility
of 50 to 5000 ppm (more preferably 50-750 ppm) in pure water at
25.degree. C. and pH 10. In another embodiment, L is selected from
at least one of: amide, amine, azo, ether, ester, aliphatic and
arylene. Aliphatic and arylene groups may be unsubstituted or
substituted, e.g. substituted with alkyl groups, hydroxyl groups,
amine groups, carboxylic acid groups etc. In yet another
embodiment, L satisfies all the preceding criteria.
[0025] A preferred class of dihydroxyaryl compounds is represented
by Formula VI.
##STR00008##
[0026] In another class of embodiments are represented by Formula
VII.
##STR00009##
[0027] wherein E and E' are independently selected from: amide,
amine, azo, ether and ester (preferably amide or ether), and L' is
selected from at least one of: aliphatic and arylene groups which
may be unsubstituted or substituted, e.g. substituted with alkyl
groups, hydroxyl groups, amine groups, carboxylic acid groups, etc.
Aliphatic groups preferably comprise from 1 to 12 carbon atoms.
Arylene groups preferably comprise from 6 to 18 carbon atoms. The
hydroxyl groups are preferably located at meta positions to one
another on each ring, (i.e. 1,3 position with E and E' located at
the 5 position). D, D', D'' and D''' are preferably hydrogen.
Another set of preferred subclasses are represented by Formulae
VIII-X.
##STR00010##
[0028] wherein Y is selected from the aliphatic and arylene groups
described above. Preferred species are represented by formulae
(XI-XIV).
##STR00011##
[0029] wherein the amide groups are located meta, ortho or para
(prerably meta or para) to each other.
##STR00012##
[0030] wherein the hydroxyl groups are located meta, ortho or para
(prerably meta or para) to each other.
[0031] Additional examples include:
N,N-(benzene-1,3-diyldimethanediyl)bis(3,5-dihydroxy benzamide);
N,N-(benzene-1,4-diyldimethanediyl)bis(3,5-dihydroxybenzamide);
N,N-[5-(trifluoro
methyl)benzene-1,3-diyl]bis(3,5-dihydroxybenzamide);
N,N-biphenyl-4,4'-diylbis(3,5-dihydroxy benzamide);
N,N-ethane-1,2-diylbis(3,5-dihydroxybenzamide);
3,5-bis[(3,5-dihydroxybenzoyl) amino]benzoic acid;
5-bis{[(3,5-dihydroxybenzoyl)amino]methyl}benzoic acid;
3,5-bis{[(3,5-di hydroxbenzoyl) amino]methyl}benzenesulfonic acid;
3,5-bis[(3,5-dihydroxybenzoyl) amino]benzene sulfonic acid;
N,N-biphenyl-2,2'-diylbis(3,5-dihydroxybenzamide); N,N'-(5-methoxy
benzene-1,3-diyl)bis(3,5-dihydroxybenzamide);
N,N'-(5-nitrobenzene-1,3-diyl)bis(3,5-dihydroxy benzamide);
5,5'-[(2-hydroxypropane-1,3-diyl)bis(oxy)]dibenzene-1,3-diol;
1,1'-(4-methylbenzene-1,3-diyl)bis[3-(3,5-dihydroxyphenyl)urea];
ethane-1,2-diyl bis(3,5-dihydroxy benzoate); N,N-bis(3,5-dihydroxy
phenyl) benzene-1,3-dicarboxamide;
N.sup.2,N.sup.6-bis(3,5-dihydroxybenzoyl)lysine; and
5,5'-[(2,7-dihydroxy
octane-1,8-diyl)bis(oxy)]dibenzene-1,3-diol.
[0032] The subject dihydroxyaryl compounds may be synthesized using
conventional techniques. Several representative examples are
provided below:
Example Preparation 1
N,N'-(benzene-1,3-diyldimethanediyl)bis(3,5-dihydroxybenzamide)
##STR00013##
[0034] Preparation of
benzene-1,3-diylbis(methanediylcarbamoylbenzene-5,1,3-triyl)
tetraacetate: A 250 mL round bottom flask was charged with
m-xylylene diamine (1.00 g; 7.34 mmol) and dichloromethane (25 mL).
To this mixture was added 40 mL sodium bicarbonate solution and the
reaction mixture was cooled in an ice bath to 0.degree. C. In a
separate 30 mL vial, 5-(chlorocarbonyl)-1,3-phenylene diacetate
(2.83 g; 11.0 mmol) was dissolved in 25 mL dichloromethane. The
5-(chlorocarbonyl)-1,3-phenylene diacetate solution was added to
the stirring reaction mixture, and the ice bath was removed and the
entire mixture was allowed to warm to 25.degree. C. The reaction
mixture was stirred for 2 h, and then was acidified by the drop
wise addition of HCl until the pH=1. Bubbles of CO.sub.2 were
observed during the addition of HCl. The organic layer was
separated, dried with MgSO.sub.4 and the mixture was filtered
through a syringe filter. The volatiles were removed by vacuum.
Benzene-1,3-diylbis(methanediylcarbamoylbenzene-5,1,3-triyl)
tetraacetate was collected as a white powder (2.13 g; 67% yield).
.sup.1H NMR (400 MHz, CDCl.sub.3) .delta. 7.38 (d, J=2.1 Hz, 4H),
7.28-7.26 (m, 1H), 7.23-7.18 (m, 3H), 7.04 (t, J=2.1 Hz, 2H), 6.89
(t, J=5.7 Hz, 2H), 4.50 (d, J=5.8 Hz, 4H), 2.25 (s, 12H).
[0035] Preparation of
N,N'-(benzene-1,3-diyldimethanediyl)bis(3,5-dihydroxybenzamide): To
a 2 L round-bottom flask was charged
benzene-1,3-diylbis(methanediylcarbamoylbenzene-5,1,3-triyl)
tetraacetate (15.0 g; 0.0261 mol) and methanol (250 mL). To the
stirring reaction mixture was added potassium carbonate (14.4 g;
0.104 mol). The heterogeneous reaction mixture was stirred for 2 h
at 25.degree. C., and the mixture turned a light yellow color and
became homogeneous. To the reaction mixture was added 400 mL of
ethyl acetate and 400 mL water. The reaction mixture was acidified
with HCl (20 mL) until the pH=1. The yellow color was observed to
move to the organic layer, which was extracted, washed with 250 mL
brine, and dried with MgSO.sub.4. The mixture was filtered through
glass filter frit, and the volatiles were removed by vacuum.
N,N'-(benzene-1,3-diyldimethanediyl)bis(3,5-dihydroxybenzamide) was
collected as a white solid (9.26 g; 87% yield). .sup.1H NMR (400
MHz, DMSO-d.sub.6) .delta. 9.42 (s, 4H), 8.80 (t, J=6.0 Hz, 2H),
7.28-7.13 (m, 4H), 6.71 (d, J=2.2 Hz, 4H), 6.36 (t, J=2.2 Hz, 2H),
4.38 (d, J=6.0 Hz, 4H).
Example Preparation 2
N,N'-(1,4-phenylenebis(methylene))bis(3,5-dihydroxybenzamide)
##STR00014##
[0037] Preparation of
benzene-1,4-diylbis(methanediylcarbamoylbenzene-5,1,3-triyl)
tetraacetate: A 500 mL round bottom flask was charged with
p-xylylenediamine (4.00 g; 29.4 mmol) and dichloromethane (125 mL).
To this mixture was added 100 mL sodium bicarbonate solution and
the reaction mixture was cooled in an ice bath to 0.degree. C. In a
separate 30 mL vial, 5-(chlorocarbonyl)-1,3-phenylene diacetate
(12.06 g; 47.0 mmol) was dissolved in 25 mL dichloromethane. The
5-(chlorocarbonyl)-1,3-phenylene diacetate solution was added to
the stirring reaction mixture, the ice bath was removed, and the
entire mixture was allowed to warm to 25.degree. C. The reaction
mixture was stirred for 18 h, and then was acidified by the drop
wise addition of HCl until the pH=1. Bubbles of CO.sub.2 were
observed during the addition of HCl. The organic layer was
separated, dried with MgSO.sub.4 and the mixture was filtered
through a syringe filter. The volatiles were removed by vacuum to
reveal 11.4 g of white powder. The product was suspended in 250 mL
of ethyl acetate and stirred for 2 h. The slurry was filtered and
dried by vacuum.
benzene-1,4-diylbis(methanediylcarbamoylbenzene-5,1,3-triyl)
tetraacetate was isolated as a white solid (7.45 g; 55%).sup.1H NMR
(400 MHz, CDCl.sub.3) .delta. 7.40 (d, J=2.1 Hz, 4H), 7.22 (s, 4H),
7.05 (t, J=2.1 Hz, 2H), 6.69 (t, J=5.6 Hz, 2H), 4.52 (d, J=5.7 Hz,
4H), 2.27 (s, 12H).
[0038] Preparation of
N,N'-(benzene-1,4-diyldimethanediyl)bis(3,5-dihydroxybenzamide): To
a 2 L round-bottom flask was charged
benzene-1,4-diylbis(methanediylcarbamoylbenzene-5,1,3-triyl)
tetraacetate (6.45 g; 0.0112 mol) and methanol (200 mL). To the
stirring reaction mixture was added potassium carbonate (6.19 g;
0.104 mol). The heterogeneous reaction mixture was stirred for 2 h
at 25.degree. C., and the mixture turned a light yellow color and
became homogeneous. To the reaction mixture was added 600 mL of
ethyl acetate and 300 mL water. The reaction mixture was acidified
with HCl (20 mL) until the pH=1. The yellow color was observed to
move to the organic layer, which was extracted, and dried with
MgSO.sub.4. The mixture filtered through glass filter frit, and the
volatiles were removed by vacuum.
N,N'-(benzene-1,4-diyldimethanediyl)bis(3,5-dihydroxybenzamide) was
collected as a white solid (4.80 g) that contained 10% water, thus
94% yield of the desired product. .sup.1H NMR (400 MHz,
DMSO-d.sub.6) .delta. 9.38 (bs, 4H), 8.78 (t, J=6.0 Hz, 2H), 7.23
(s, 4H), 6.70 (d, J=2.2 Hz, 4H), 6.38 (t, J=2.2 Hz, 2H), 4.38 (d,
J=6.0 Hz, 4H).
Example Preparation 3
N,N'-[5-(trifluoromethyl)benzene-1,3-diyl]bis(3,5-dihydroxybenzamide)
##STR00015##
[0040] Preparation of
[5-(trifluoromethyl)benzene-1,3-diyl]bis(carbamoylbenzene-5,1,3-triyl)
tetraacetate: To a 500 mL round bottom flask was added
5-(chlorocarbonyl)-1,3-phenylene diacetate (8.74 g; 34.1 mmol) and
200 mL dichloromethane. To this mixture was added 85 g sodium
bicarbonate solution. To the stirring mixture was added
5-(trifluoromethyl) benzene-1,3-diamine (4.00 g; 22.7 mmol). The
reaction mixture was stirred overnight (18 h) at 25.degree. C. HCl
(15 mL) was added to acidify the mixture (pH=1). The product was
extracted by separating the organic phase and drying with
MgSO.sub.4. The mixture was filtered through a glass filter frit
and the volatiles were removed by vacuum. The isolated brown powder
contained 16% starting acid chloride by .sup.1H NMR. The brown
powder was dissolved into 200 mL dichloromethane and 100 mL sodium
bicarbonate was added to the mixture. To this mixture was added
5-(trifluoromethyl) benzene-1,3-diamine (0.5 g) and
5-(chlorocarbonyl)-1,3-phenylene diacetate (2.0 g). The reaction
mixture was stirred 3 h at 25.degree. C. The mixture was acidified
with HCl, and the organic layer was isolated and dried with
MgSO.sub.4. The mixture was filtered through a glass filter frit
and concentrated by vacuum. .sup.1H and .sup.19F NMR spectroscopy
of this brown powder showed a small amount of impurity that did not
contain fluorine. The crude product was purified by flash
chromatography (ethyl acetate/hexane). The purified product was
dried overnight by vacuum.
[5-(trifluoromethyl)benzene-1,3-diyl]bis(carbamoylbenzene-5,1,3-triyl)
tetraacetate was collected as a light tan solid (8.02 g; yield
62%). This material contained 5% ethyl acetate by weight. .sup.1H
NMR (400 MHz, CDCl.sub.3) .delta. 8.71 (s, 2H), 8.21 (s, 1H), 7.50
(d, J=1.3 Hz, 2H), 7.33 (d, J=2.1 Hz, 4H), 7.01 (t, J=2.1 Hz, 2H),
2.20 (d, J=6.7 Hz, 12H). .sup.19F NMR (376 MHz, CDCl.sub.3) .delta.
-62.86.
[0041] Preparation of
N,N'-[5-(trifluoromethyl)benzene-1,3-diyl]bis(3,5-dihydroxybenzamide):
A 500 mL round-bottom flask was charged with potassium carbonate
(7.20 g; 52.0 mmol) and methanol (150 mL). To the stirring reaction
mixture was added
[5-(trifluoromethyl)benzene-1,3-diyl]bis(carbamoylbenzene-5,1,3-tri-
yl) tetraacetate (8.02 g; 13.0 mmol). The heterogeneous reaction
mixture was stirred for 3 h at 25.degree. C. The reaction mixture
turned a light yellow color and became homogeneous. To the reaction
mixture was added 400 mL of ethyl acetate and 100 mL water, and the
mixture was acidified with HCl (13 mL) until the pH=1. The yellow
color was observed to move to the organic layer. The organic layer
was separated, dried with MgSO.sub.4, and filtered through a glass
filter frit. The volatiles were removed by vacuum.
N,N'-[5-(trifluoro
methyl)benzene-1,3-diyl]bis(3,5-dihydroxybenzamide) was isolated as
an off-white solid (5.59 g; 96%). .sup.1H NMR (400 MHz, DMSO)
.delta. 10.41 (s, 2H), 9.61 (s, 4H), 8.59 (s, 1H), 7.90 (d, J=1.4
Hz, 2H), 6.82 (d, J=2.2 Hz, 4H), 6.46 (t, J=2.2 Hz, 2H). .sup.19F
NMR (376 MHz, DMSO) .delta. -61.
Example Preparation 4
N,N'-biphenyl-4,4'-diylbis(3,5-dihydroxybenzamide)
##STR00016##
[0043] Preparation of
biphenyl-4,4'-diylbis(carbamoylbenzene-5,1,3-triyl) tetraacetate:
To a 500 mL round bottom flask was added benzidine (5.00 g; 27.1
mmol) and 5-(chlorocarbonyl)-1,3-phenylene diacetate (13.9 g; 54.3
mmol). To this mixture was added 200 mL dichloromethane and sodium
bicarbonate (100 g). The reaction mixture was stirred overnight at
25.degree. C. and a grey precipitate formed. The reaction mixture
was acidified with HCl until the pH=1. The grey precipitate was
collected by filtration. The precipitate was washed with a small
amount dichloro-methane (20 mL) and water (100 mL). The grey solid
was dried overnight by vacuum.
biphenyl-4,4'-diylbis(carbamoylbenzene-5,1,3-triyl) tetraacetate
was isolated as grey solid (17.0 g) that contains approx. 20% water
(yield=80%). .sup.1H NMR (400 MHz, DMSO) .delta. 10.44 (s, 2H),
7.87 (d, J=8.7 Hz, 4H), 7.73-7.68 (m, 8H), 7.29 (t, J=2.1 Hz, 2H),
3.40 (s, 24H), 2.33 (s, 12H).
[0044] Preparation of
N,N'-biphenyl-4,4'-diylbis(3,5-dihydroxybenzamide): A 500 mL
round-bottom flask was charged with potassium carbonate (12.30 g;
89.2 mmol) and methanol (150 mL). To the stirring reaction mixture
was added biphenyl-4,4'-diylbis(carbamoylbenzene-5,1,3-triyl)
tetraacetate (13.93 g; 22.3 mmol). The heterogeneous reaction
mixture was stirred for 3 h at 25.degree. C. To the reaction
mixture was added 400 mL of ethyl acetate and 100 mL of water. The
reaction mixture was acidified with HCl (15 mL) until the pH=1.
Clean separation of the organic and aqueous layers was not
observed. The organic layer was separated, dried with MgSO.sub.4,
and filtered through a glass filter frit. The volatiles were
removed by vacuum but only .about.1.5 g of orange solid was
collected. The volatiles were then removed from the aqueous layer
to reveal a light brown solid. The solid was suspended in 100 mL
water, and collected by filtration. The solid was washed with water
and dried by vacuum for 3 days.
N,N'-biphenyl-4,4'-diylbis(3,5-dihydroxybenzamide) was isolated as
a light brown solid (5.89 g; 72%). .sup.1H NMR (400 MHz, DMSO)
.delta. 10.16 (s, 2H), 9.57 (s, 4H), 7.86 (d, J=8.8 Hz, 4H), 7.65
(d, J=8.8 Hz, 4H), 6.81 (d, J=2.2 Hz, 4H), 6.44 (t, J=2.1 Hz,
2H).
Example Preparation 5
N,N'-ethane-1,2-diylbis(3,5-dihydroxybenzamide)
##STR00017##
[0046] Preparation of
ethane-1,2-diylbis(carbamoylbenzene-5,1,3-triyl) tetraacetate: To a
1 L round bottom flask was added 5-(chlorocarbonyl)-1,3-phenylene
diacetate (15.35 g; 79.1 mmol), which was dissolved in 250 mL
dichloromethane. The reaction mixture was added 100 mL of sodium
bicarbonate. Ethylene diamine (3.17 g; 52.7 mmol) was added drop
wise to the reaction mixture via a gas tight syringe. The reaction
mixture stirred for 3 h at 25.degree. C. HCl (25 mL) was added to
acidify the reaction mixture to pH=1. The organic phase was
separated, washed with brine, and dried with MgSO.sub.4. The
volatiles were removed by vacuum to reveal the product as a white
solid. To remove soluble impurities, the solid was suspended in 100
mL ethyl acetate and the mixture was stirred for 1 h. The slurry
was filtered and the product washed with ethyl acetate and dried by
vacuum overnight. ethane-1,2-diylbis(carbamoylbenzene-5,1,3-triyl)
tetraacetate was isolated as a white solid (7.47 g; 99%). .sup.1H
NMR (400 MHz, CDCl.sub.3) .delta. 7.42 (d, J=2.1 Hz, 4H), 7.40 (s,
2H), 7.04 (t, J=2.1 Hz, 2H), 3.57 (bs, 4H), 2.27 (s, 12H).
[0047] Preparation of
N,N'-ethane-1,2-diylbis(3,5-dihydroxybenzamide): To a 250 mL round
bottom flask was added
ethane-1,2-diylbis(carbamoylbenzene-5,1,3-triyl) tetraacetate (5.37
g; 10.7 mmol), which was dissolved into 100 mL methanol. To this
mixture was added potassium carbonate (5.25 g; 42.9 mmol). The
reaction mixture was stirred at 25.degree. C. for 4 h. The pH of
the mixture was adjusted to pH=5 by the addition of 1M HCl (65 mL).
The volatiles were removed by vacuum leaving a white solid residue.
To the residue was added 45 mL of water, and the mixture was
stirred for 1 h. The solid product was isolated by filtration to
collect 5.3 g of wet product. The wet cake was dried overnight.
N,N'-ethane-1,2-diylbis(3,5-dihydroxybenzamide) was isolated as
white solid (3.97 g) that contained 29% water. (Yield=85%). This
yield corresponds to the product containing 29% water (by .sup.1H
NMR spectroscopy). .sup.1H NMR (400 MHz, DMSO) .delta. 9.44 (s,
4H), 8.30 (s, 2H), 6.67 (d, J=2.1 Hz, 4H), 6.35 (t, J=2.0 Hz, 2H),
3.34 (s, 4+17H).
Example Preparation 6
3,5-bis[(3,5-dihydroxybenzoyl)amino]benzoic acid
##STR00018##
[0049] Preparation of
3,5-bis({[3,5-bis(acetyloxy)benzoyl]amino}methyl)benzoic acid: To a
1 L round bottom flask was added 5-(chlorocarbonyl)-1,3-phenylene
diacetate (15.96 g), 200 mL THF, and sodium bicarbonate (100 g). To
the stirring reaction mixture was added 3,5-diaminobenzoic acid
dihydrochloride (7.01 g) portion wise. After each addition of
3,5-diaminobenzoic acid dihydrochloride, CO.sub.2 bubbles were
observed. The reaction mixture was stirred for 4 h, and then
acidified with HCl (15 mL). To the mixture was added EtOAc (300
mL). The organic layer was extracted and dried over MgSO.sub.4. The
volatiles were removed by vacuum to reveal off-white powder.
.sup.1H NMR shows primarily a single product and some unreacted
5-(chlorocarbonyl)-1,3-phenylene diacetate. The solid was suspended
in 150 mL of ethyl acetate and stirred for 1 h. The solid was
collected triturated with ethyl acetate (150 mL) and collected by
filtration twice. The isolated solid was dried by vacuum.
3,5-bis({[3,5-bis(acetyloxy)benzoyl]amino}methyl)benzoic acid was
isolated as a white solid (7.09 g; 38% yield). .sup.1H NMR (400
MHz, DMSO) .delta. 10.56 (s, 2H), 8.65 (s, 1H), 8.15 (d, J=2.0 Hz,
2H), 7.71 (d, J=2.1 Hz, 4H), 7.29 (t, J=2.1 Hz, 2H), 2.32 (s, 12H).
NOTE: The resonance corresponding to the carboxylic acid proton was
not observed.
[0050] Preparation of 3,5-bis[(3,5-dihydroxybenzoyl)amino]benzoic
acid: A 500 mL round-bottom flask was charged with potassium
carbonate (6.50 g; 47.2 mmol) and methanol (100 mL). To the
stirring reaction mixture was added
3,5-bis({[3,5-bis(acetyloxy)benzoyl]amino}methyl)benzoic acid (6.99
g; 11.8 mmol). The heterogeneous reaction mixture was stirred for 3
h at 25.degree. C. To the reaction mixture was added 400 mL of
ethyl acetate and 100 mL of water. The reaction mixture was
acidified with HCl (15 mL) until the pH=1. The organic layer was
extracted, dried with MgSO.sub.4, and the volatiles were removed by
vacuum. Isolated 5.87 g of light pink solid that was contaminated
with salts. Suspended the solid in 100 mL water, and collected by
filtration. The solid was dried overnight by vacuum.
3,5-bis[(3,5-dihydroxybenzoyl)amino]benzoic acid was isolated as a
light pink solid (4.45 g; 88%). .sup.1H NMR (400 MHz, DMSO) .delta.
10.28 (s, 2H), 9.57 (s, 4H), 8.53 (t, J=2.0 Hz, 1H), 8.11 (d, J=2.0
Hz, 2H), 6.82 (d, J=2.2 Hz, 4H), 6.78 (d, J=2.2 Hz, 1H), 6.44 (t,
J=2.2 Hz, 2H). NOTE: The resonance corresponding to the carboxylic
acid proton was not observed.
[0051] The method of treating the polyamide layer with the subject
dihydroxyaryl compounds is not particularly limited and includes
applying the dihydroxyaryl compound (e.g. 10-20000 ppm) from an
aqueous solution with a pH range of 3-11, which may further include
1-20 wt % alcohol such as methanol, isopropanol and polar aprotic
solvents such as DMSO, DMF, DMAc, NMP, etc, such that the compound
remains predominately on the outer surface (surface opposite to
that contacting the porous support) of the polyamide layer, or
soaking the polyamide layer in a dip tank containing the
dihydroxyaryl compound such that the polyamide layer becomes
impregnated with the compound. The dihydroxyaryl compound is
applied to the polyamide layer in combination with the step of
exposing the polyamide layer to nitrous acid, (e.g. the
dihydroxyaryl compound may be applied to the polyamide layer
before, during or after exposure to nitrous acid, but preferably
before).
[0052] A variety of applicable techniques for exposing the
polyamide layer to nitrous acid are described in U.S. Pat. No.
4,888,116 and are incorporated herein by reference. It is believed
that the nitrous acid reacts with the residual primary amine groups
present in the polyamide discrimination layer to form diazonium
salt groups, a portion of which react with the dihydoxy-substituted
aromatic rings of the subject dihydroxyaryl compounds and residual
unreacted amines in the polyamide layer to form azo groups, i.e.
form crosslinks in the polyamide structure.
[0053] In one embodiment, an aqueous solution of nitrous acid is
applied to the thin film polyamide layer. Although the aqueous
solution may include nitrous acid, it preferably includes reagents
that form nitrous acid in situ, e.g. an alkali metal nitrite in an
acid solution or nitrosyl sulfuric acid. Because nitrous acid is
volatile and subject to decomposition, it is preferably formed by
reaction of an alkali metal nitrite in an acidic solution in
contact with the polyamide discriminating layer. Generally, if the
pH of the aqueous solution is less than about 7, (preferably less
than about 5), an alkali metal nitrite will react to liberate
nitrous acid. Sodium nitrite reacted with hydrochloric or sulfuric
acid in an aqueous solution is especially preferred for formation
of nitrous acid. The aqueous solution may further include wetting
agents or surfactants. The concentration of the nitrous acid in the
aqueous solution is preferably from 0.01 to 1 wt %. Generally, the
nitrous acid is more soluble at 5.degree. than at 20.degree. C. and
somewhat higher concentrations of nitrous acid are operable at
lower temperatures. Higher concentrations are operable so long as
the membrane is not deleteriously affected and the solutions can be
handled safely. In general, concentrations of nitrous acid higher
than about one-half (0.5) percent are not preferred because of
difficulties in handling these solutions. Preferably, the nitrous
acid is present at a concentration of about 0.1 weight percent or
less because of its limited solubility at atmospheric pressure. The
temperature at which the membrane is contacted can vary over a wide
range. Inasmuch as the nitrous acid is not particularly stable, it
is generally desirable to use contact temperatures in the range
from about 0.degree. to about 30.degree. C., with temperatures in
the range from 0.degree. to about 20.degree. C. being preferred.
Temperatures higher than this range can increase the need for
ventilation or super-atmospheric pressure above the treating
solution. Temperatures below the preferred range generally result
in reduced reaction and diffusion rates.
[0054] One preferred application technique involves passing the
aqueous nitrous acid solution over the surface of the membrane in a
continuous stream. This allows the use of relatively low
concentrations of nitrous acid. When the nitrous acid is depleted
from the treating medium, it can be replenished and the medium
recycled to the membrane surface for additional treatment. Batch
treatments are also operable. The specific technique for applying
aqueous nitrous acid is not particularly limited and includes
spraying, film coating, rolling, or through the use of a dip tank
among other application techniques. Once treated the membrane may
be washed with water and stored either wet or dry prior to use.
[0055] The reaction between the nitrous acid and the primary amine
groups of the polyamide layer occurs relatively quickly once the
nitrous acid has diffused into the membrane. The time required for
diffusion and the desired reaction to occur will depend upon the
concentration of nitrous acid, any pre-wetting of the membrane, the
concentration of primary amine groups present, the 3 dimensional
structure of the membrane and the temperature at which contact
occurs. Contact times may vary from a few minutes to a few days.
The optimum reaction time can be readily determined empirically for
a particular membrane and treatment. The dihydroxyaryl compound is
added to the membrane as a basic aqueous solution either prior to
treatment with nitrous acid or immediately following the addition
of nitrous acid. After the residual amine moieties have been
converted to the diazonium salts, the pH is raised to 9 and the
temperature is increased to 25.degree. C. to initiate the diazo
coupling. The nucleophilic dihydroxyaryl group reacts with the
diazonium salt to form a new C--N bond via a diazo linkage. The
dihydroxyaryl compounds are sufficiently more reactive than simple
phenols formed from hydrolysis of the diazonium salts, and are
therefore incorporated into the membrane. In a preferred
embodiment, the size of the dihydroxyaryl compound isolates its
coupling to the surface of the membrane, i.e. because it is too
large to diffuse into the polyamide layer. The dihydroxyaryl
compounds are bifunctional, (i.e. contain at least two
dihydroxyaryl groups), and can therefore form crosslinks on the
surface of the membrane.
[0056] The thin film polyamide layer may optionally include
hygroscopic polymers upon at least a portion of its surface. Such
polymers include polymeric surfactants, polyacrylic acid, polyvinyl
acetate, polyalkylene oxide compounds, poly(oxazoline) compounds,
polyacrylamides and related reaction products as generally
described in U.S. Pat. No. 6,280,853; U.S. Pat. No. 7,815,987; U.S.
Pat. No. 7,918,349 and U.S. Pat. No. 7,905,361. In some
embodiments, such polymers may be blended and/or reacted and may be
coated or otherwise applied to the polyamide membrane from a common
solution, or applied sequentially.
[0057] Many embodiments of the invention have been described and in
some instances certain embodiments, selections, ranges,
constituents, or other features have been characterized as being
"preferred." Characterizations of "preferred" features should in no
way be interpreted as deeming such features as being required,
essential or critical to the invention.
EXAMPLES
[0058] Sample membranes were prepared using a pilot scale membrane
manufacturing line. Polysulfone supports were cast from 16.5 wt %
solutions in dimethylformamide (DMF) and subsequently soaked in an
aqueous solution meta-phenylene diamine (mPD). The resulting
support was then pulled through a reaction table at constant speed
while a thin, uniform layer of a non-polar coating solution was
applied. The non-polar coating solution included a isoparaffinic
solvent (ISOPAR L) and a combination of trimesoyl acid chloride
(TMC) with or without 1-carboxy-3,5-dichloroformyl benzene (mhTMC)
and tri butyl phosphate (TBP). Excess non-polar solution was
removed and the resulting composite membrane was passed through
water rinse tanks and drying ovens. Sample membrane sheets were
then either (i) stored in pH 9 deionized water until testing; or
(ii) soaked for approximately 15 minutes in a solution at
0-10.degree. C. prepared by combining 0.05% w/v NaNO.sub.2 and 0.1
w/v % HCl and thereafter rinsed and stored in pH 9 deionized water
until testing or (iii) first impregnated with solutions of 500 ppm
of dihydroxyaryl compounds "DHA" at pH 10-11 for 15 minutes and
then soaked for approximately 15 minutes in a solution at
0-10.degree. C. prepared by combining 0.05% w/v NaNO.sub.2 and 0.1
w/v % HCl and thereafter rinsed and stored in pH 9 deionized water
at 25.degree. C. until testing. DHA-1 was
N,N'-(benzene-1,3-diyldimethanediyl)bis(3,5-dihydroxy benzamide),
DHA-2 was N,N'-(benzene-1,4-diyldimethanediyl)bis(3,5-dihydroxy
benzamide), DHA-3 was
N,N'-[5-(trifluoromethyl)benzene-1,3-diyl]bis(3,5-dihydroxybenz
amide), DHA-4 was
N,N'-biphenyl-4,4'-diylbis(3,5-dihydroxybenzamide), DHA-5 was
N,N'-ethane-1,2-diylbis(3,5-dihydroxy benzamide), DHA-6 was
3,5-bis[(3,5-dihydroxybenzoyl)amino]benzoic acid. Testing was
conducted with an aqueous mixture of 2000 ppm NaCl and 5 ppm boron
solution at 25.degree. C., pH 8 and 150 psi.
[0059] Table 1-1 shows the flux and NaCl passage data and table 1-2
shows the boron passage data of DHA-1 and DHA-2 compounds. Table 2
shows the flux and NaCl passage data of DHA-3 and DHA-5. Table 3
shows the flux and NaCl passage data of DHA-4 and DHA-6.
TABLE-US-00001 TABLE 1-1 Mean Std Std (Avg Mean Dev Dev Mean Mean
Std Std Flux) (Avg (Avg (Avg (Avg A) (Avg B) Dev (Avg Dev (Avg
Sample GFD SP) Flux) SP) (GFD/psi) (psi) A) B) Control 7.9 2.77%
0.71 0.23% 0.06 0.23 0.005 0.040 Post-treated Control 8.3 3.26%
0.43 0.23% 0.07 0.28 0.003 0.035 Post-treated Control 5.2 1.41%
0.99 0.37% 0.04 0.07 0.008 0.016 with DHA-1 Post-treated Control
4.2 1.39% 0.18 0.24% 0.03 0.06 0.002 0.011 with DHA-2 Control w/
TBP 43.9 1.82% 2.79 0.32% 0.35 0.81 0.022 0.093 Post-treated
Control 50.1 2.05% 3.11 0.15% 0.39 1.05 0.025 0.035 with TBP
Post-treated Control 31.6 0.67% 4.49 0.00% 0.25 0.21 0.035 0.030
with TBP & DHA-1 Post-treated Control 26.7 0.69% 3.76 0.10%
0.21 0.18 0.030 0.002 with TBP & DHA-2 Control with TBP &
40.1 0.76% 4.22 0.05% 0.32 0.31 0.033 0.014 mh-TMC Post-treated
Control 53.5 0.99% 1.13 0.07% 0.42 0.54 0.009 0.050 with TBP &
mh- TMC Post-treated Control 37.3 0.42% 1.95 0.01% 0.30 0.16 0.016
0.008 w/ TBP, mh-TMC & DHA-1 Post-treated Control 35.3 0.38%
0.98 0.03% 0.28 0.14 0.008 0.009 w/ TBP, mh-TMC & DHA-2
TABLE-US-00002 TABLE 1-2 Mean Mean Std Dev Std Dev (Boron (Boron
(Boron (Boron Sample SP) B) (psi) SP) B) Control 58% 11.1 2.1% 1.01
Post-treated Control 63% 13.9 1.1% 1.22 Post-treated Control with
DHA-1 44% 4.4 11.0% 2.37 Post-treated Control with DHA-2 46% 3.6
2.1% 0.44 Control with TBP 48% 40.7 1.9% 0.60 Post-treated Control
with TBP 55% 60.5 1.0% 1.97 Post-treated Control with TBP & 40%
20.7 0.3% 2.83 DHA-1 Post-treated Control with TBP & 41% 18.6
1.1% 1.77 DHA-2 Control with TBP & mh-TMC 50% 39.5 1.8% 1.37
Post-treated Control with TBP & 55% 65.8 1.6% 4.36 mh-TMC
Post-treated Control w/TBP, mh- 41% 26.2 1.0% 1.74 TMC & DHA-1
Post-treated Control w/TBP, mh- 47% 36.6 15.0% 25.28 TMC &
DHA-2
TABLE-US-00003 TABLE 2 Mean Std Std (Avg Mean Dev Dev Mean Mean Std
Std Flux) (Avg (Avg (Avg (Avg A) (Avg B) Dev Dev Sample GFD SP)
Flux) SP) (GFD/psi) (psi) (Avg A) (Avg B) Control 15.5 1.47% 0.12
0.23 1.20 0.07% 0.009 0.020 Post-treated 16.3 2.15% 0.13 0.36 1.00
0.13% 0.008 0.028 Control Post-treated 14.2 1.50% 0.11 0.22 0.65
0.09% 0.005 0.022 Control with DHA-3 Post-treated 12.8 1.71% 0.10
0.22 0.31 0.05% 0.002 0.006 Control with DHA-5 Control w/ TBP 50.6
1.41% 0.40 0.72 1.49 0.05% 0.012 0.045 Post-treated 65.3 2.02% 0.51
1.34 1.36 0.09% 0.011 0.041 Control with TBP Post-treated 50.3
1.22% 0.40 0.62 2.38 0.10% 0.019 0.077 Control with TBP & DHA-3
Post-treated 49.1 1.35% 0.39 0.67 1.65 0.02% 0.013 0.032 Control
with TBP & DHA-5 Control with 52.6 0.68% 0.42 0.36 1.65 0.03%
0.013 0.023 TBP & mh- TMC Post-treated 66.3 0.98% 0.52 0.65
1.32 0.09% 0.010 0.050 Control with TBP & mh- TMC Post-treated
60.3 0.68% 0.48 0.42 3.57 0.06% 0.028 0.054 Control w/ TBP, mh-TMC
& DHA-3 Post-treated 59.6 0.79% 0.47 0.48 1.35 0.06% 0.011
0.033 Control w/ TBP, mh-TMC & DHA-5
TABLE-US-00004 TABLE 3 Mean Std Std (Avg Mean Dev Dev Mean Mean Std
Std Flux) (Avg (Avg (Avg (Avg A) (Avg B) Dev Dev Sample GFD SP)
Flux) SP) (GFD/psi) (psi) (Avg A) (Avg B) Control 14.1 1.37% 0.25
0.09% 0.11 0.20 0.002 0.013 Post-treated 14.4 1.57% 0.15 0.10% 0.11
0.23 0.001 0.014 Control Post-treated 10.0 1.30% 0.20 0.03% 0.08
0.13 0.001 0.002 Control w/ DHA-4 Post-treated 10.1 1.12% 0.48
0.12% 0.08 0.11 0.004 0.012 Control w/ DHA-6 Control w/ TBP 51.5
1.72% 1.86 0.07% 0.41 0.90 0.015 0.027 Post-treated 58.7 2.04% 2.44
0.17% 0.46 1.22 0.019 0.066 Control w/ TBP Post-treated 42.0 1.36%
1.93 0.13% 0.33 0.58 0.015 0.069 Control w/ TBP & DHA-4
Post-treated 37.7 1.22% 5.31 0.19% 0.30 0.46 0.042 0.029 Control w/
TBP & DHA-6 Control w/ TBP 49.8 0.68% 1.30 0.06% 0.39 0.34
0.010 0.029 & mh-TMC Post-treated 57.8 0.65% 2.29 0.03% 0.46
0.38 0.018 0.030 Control w/ TBP & mh-TMC Post-treated 54.7
0.58% 1.37 0.07% 0.43 0.32 0.011 0.040 Control w/ TBP, mh-TMC &
DHA-4 Post-treated 50.0 0.51% 0.60 0.02% 0.40 0.26 0.005 0.014
Control w/ TBP, mh-TMC & DHA-6
* * * * *