Membranes with unprecedented solvent permeance and high retention of dissolved solutes are needed to reduce the energy consumed by separations in organic liquids. We used controlled interfacial polymerization to form free-standing polyamide nanofilms less than 10 nanometers in thickness, and incorporated them as separating layers in composite membranes. Manipulation of nanofilm morphology by control of interfacial reaction conditions enabled the creation of smooth or crumpled textures; the nanofilms were sufficiently rigid that the crumpled textures could withstand pressurized filtration, resulting in increased permeable area. Composite membranes comprising crumpled nanofilms on alumina supports provided high retention of solutes, with acetonitrile permeances up to 112 liters per square meter per hour per bar. This is more than two orders of magnitude higher than permeances of commercially available membranes with equivalent solute retention.

Thin-film composite membranes comprising a polyamide nanofilm separating layer on a support material are state of the art for desalination by reverse osmosis. Nanofilm thickness is thought to determine the rate of water transport through the membranes; although due to the fast and relatively uncontrolled interfacial polymerization reaction employed to form these nanofilms, they are typically crumpled and the separating layer is reported to be ≈50-200 nm thick. This crumpled structure has confounded exploration of the independent effects of thickness, permeation mechanism, and the support material. Herein, smooth sub-8 nm polyamide nanofilms are fabricated at a free aqueous-organic interface, exhibiting chemical homogeneity at both aqueous and organic facing surfaces. Transfer of these ultrathin nanofilms onto porous supports provides fast water transport through the resulting nanofilm composite membranes. Manipulating the intrinsic nanofilm thickness from ≈15 down to 8 nm reveals that water permeance increases proportionally with the thickness decrease, after which it increases nonlinearly to 2.7 L m h bar as the thickness is further reduced to ≈6 nm.

Membranes with high selectivity offer an attractive route to molecular separations, where technologies such as distillation and chromatography are energy intensive. However, it remains challenging to fine tune the structure and porosity in membranes, particularly to separate molecules of similar size. Here, we report a process for producing composite membranes that comprise crystalline porous organic cage films fabricated by interfacial synthesis on a polyacrylonitrile support. These membranes exhibit ultrafast solvent permeance and high rejection of organic dyes with molecular weights over 600 g mol−1. The crystalline cage film is dynamic, and its pore aperture can be switched in methanol to generate larger pores that provide increased methanol permeance and higher molecular weight cut-offs (1,400 g mol−1). By varying the water/methanol ratio, the film can be switched between two phases that have different selectivities, such that a single, ‘smart’ crystalline membrane can perform graded molecular sieving. We exemplify this by separating three organic dyes in a single-stage, single-membrane process.

Three imine-linked covalent organic framework (COF) films are incorporated as active layers into separate thin-film composite (TFC) membranes and tested for their ability to reject an organic pollutant surrogate and salt from water. The synthesized membranes consist of a polyacrylonitrile (PAN) support and a TAPB-PDA-H, TAPB-PDA-Me, or TAPB-PDA-Et COF thin film. The latter two COFs direct six methyl and ethyl substituents per tiled hexagon into the pores, respectively, while maintaining the same topology across the series. These substituents decrease the effective pore size of the COF compared to the parent TAPB-PDA-H COF. The TFC TAPB-PDA-Me membrane rejects Rhodamine-WT (R-WT) dye and NaCl better than the TFC TAPB-PDA-H membrane, and the TFC TAPB-PDA-Et membrane exhibits the best rejection overall. The solution-diffusion model used to analyze this permeation behavior indicates that there is a systematic difference in rejection as subsequent pendant groups are added to the interior of the COF pores. These findings demonstrate the concept of tuning the selectivity of COF membranes by systematically reducing the effective pore size within a given topology.