POROUS FILM PRODUCTION METHOD

• US 20110024935A1
• Filed: 07/29/2010
• Published: 02/03/2011
• Est. Priority Date: 07/30/2009
• Status: Active Grant

• Current Assignee: Fujifilm Corporation (Fujifilm Holdings Corporation)
• Original Assignee: Fujifilm Corporation (Fujifilm Holdings Corporation)
• Inventors: YAMAZAKI, Hidekazu, ITO, Koju
• Granted Patent: US 9,044,899 B2
• Time in Patent Office: Days
• US Class Current: 264/48
• CPC Class Codes: B29C 67/202 comprising elimination of a solid or a liquid ingredient

Abstract

A solution of polymer uniformly dissolved into a solvent is prepared in a solution preparing step. The solvent contains good and poor solvent components for the polymer. The solution is discharged from a coating die to a support to be a coating film thereon in a primary body forming step. A water drop generating step and a fluidity decreasing step are performed in parallel with each other while wet air is applied to the coating film. Water drops are generated on a surface of the coating film in the water drop generating step. The good solvent component is evaporated from the coating film to decrease fluidity of the solution for forming the coating film in the fluidity decreasing step. In the water drop evaporating step, dry air is applied to the coating film. The solvent and the water drops are evaporated from the coating film to obtain the porous film.

Claims

1. A production method of porous film having a plurality of pores comprising the steps of:

(A) forming a primary body having film form from a solution containing a hydrophobic polymer and a solvent on a support, said solvent including a good solvent component for said hydrophobic polymer and a poor solvent component for said hydrophobic polymer;

(B) condensing water vapor from ambient air on said primary body to generate water drops on said primary body;

(C) evaporating said solvent from said primary body such that fluidity of said solution for forming said primary body is decreased, the evaporation of said solvent being performed in parallel with the step B, and said good solvent component being evaporated in the evaporation of said solvent; and

(D) evaporating said water drops from said primary body subjected to the step C, said pores being made by said water drops as a template for a porous structure.

2. A production method as defined in claim 1, wherein said poor solvent component has hydrophobic character.

3. A production method as defined in claim 1, wherein an evaporation speed of said good solvent component is made faster than an evaporation speed of said poor solvent component.

4. A production method as defined in claim 3, wherein a value of Δ

Tsr obtained by subtracting TA from TRr is made smaller than a value of Δ

Tsh obtained by subtracting TA from TRh in the step C, in which said TRr is a condensation point of vapor of said good solvent component, said TA is an atmospheric temperature around said primary body, and said TRh is a condensation point of vapor of said poor solvent component.

5. A production method as defined in claim 3, wherein timing for completing the evaporation of said good solvent component is made earlier than timing for completing the evaporation of said poor solvent component.