Preparation and properties of polysulfone-clay composite membranes

Porous membranes and dense films were prepared from polysulfone solutions in N‐methyl‐2‐pyrrolidone (NMP) containing different types and amounts of clay. Commercial clays supplied by Southern Clay, either unmodified (Cloisite Na) or organically modified (Cloisite 30B and Cloisite 93A), were used. The clay behavior in the organic solvent was dependent on the presence and type of the organic compatibilizer: Cloisite containing Na ions did not swell in NMP, whereas those with the organic compatibilizer swelled, though to a different degree. Electron microscopy observations were made to examine the clay dispersion in the membrane structure. At variance with Cloisite Na and Cloisite 93A formed microaggregates, Cloisite 30B yielded nanostructures composed of both single sheets and well‐ordered multilayer silicate clusters, which were characterized by an interlayer distance higher than that of the neat clay. The increase in the distance between the layers of Cloisite 30B was related to the formation of intercalated nanocomposites, whereas the presence of single sheets well distributed in the polymer matrix supported the occurrence of delaminated nanocomposites. The intercalation of the polymer into clay layers was confirmed with wide‐angle X‐ray diffractometry. The addition of Cloisite 30B to the casting solution influenced the phase‐separation process in the coagulation bath. Therefore, by the variation of the layered‐silicate concentration in the casting solution, membranes with different morphological structures and ultrafiltration properties were obtained. Cloisite 30B was also found to improve the wettability and mechanical properties of dense films. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 3637–3644, 2007