Gas separation polymer
membranes play a pivotal role in various
industrial processes including carbon capture and hydrogen production.
However, the inherent trade-off between permeability and selectivity
coupled with challenges in membrane manufacturing has hindered their
widespread industrial deployment. To address the permselectivity challenges,
researchers have explored increasingly complex polymers, composite
systems, and other materials. In this study, we introduce a novel
membrane manufacturing technique called “electro-casting”
that not only enables efficient membrane fabrication but also enhances
the trade-off of traditional polymer-based membranes. We fabricated
cellulose acetate (CA) membranes embedded with 1-ethyl-3-methyl imidazolium
via electro-casting and performed a comparative analysis of structural,
morphological, and gas transport characteristics against membranes
made via conventional casting techniques. We discovered that electro-casted
membranes exhibited a unique crystalline structure, surface topology
that induced a remarkable 200% improvement in CO
2
/N
2
selectivity and a 110% increase in CO
2
/CH
4
selectivity. The electric field generated during the manufacturing
process played a crucial role in altering the supramolecular structure
of the polymer, thereby increasing the separation properties of the
membranes as well as their thermal and mechanical features. Electro-casting
induced a polymer crystallization effect that disrupted the permeability-selectivity
trade-off observed in conventional membranes, while producing highly
stable membranes. Moreover, the simplicity of this manufacturing method
and its significant impact on membrane properties have the potential
to accelerate the deployment of gas separation membranes, facilitating
the transition toward a NetZero chemical industry.