Ultra-thin composite
carbon molecular sieve (CMS) membranes were fabricated on well-defined
inorganic alumina substrates using a polymer of intrinsic microporosity
(PIM) as a precursor. Details of the pyrolysis-related structural
development were elucidated using focused-beam, interference-enhanced
spectroscopic ellipsometry (both in the UV–vis and IR range),
which allowed accurate determination of the film thickness, optical
properties as well as following the chemical transformations. The
pyrolysis-induced collapse of thin and bulk PIM-derived CMS membranes
was compared with CMS made from a well-known non-PIM precursor 6FDA–DABA.
Significant differences between the PIM and non-PIM precursors were
discovered and explained by a much larger possible volume contraction
in the PIM. In spite of the differences, surprisingly, the gas separation
properties did not fundamentally differ. The high-temperature collapse
of the initially amorphous and isotropic precursor structure was accompanied
by a significant molecular orientation within the formed turbostratic
carbon network guided by the laterally constraining presence of the
substrate. This manifested itself in the development of uniaxial optical
anisotropy, which was shown to correlate with increases in gas separation
selectivity for multiple technologically important gas pairs. Reduction
of CMS skin thickness significantly below ∼1 μm induced
large losses in permeability coefficients with only small to moderate
effects on selectivity. Remarkably, skin thickness reduction and physical
aging seemed to superimpose onto the same trend, which explains and
strengthens some of the earlier fundamental insights.