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Membrane distillation (MD) can treat high-salinity brine. However, the system’s efficiency is hindered by obstacles, including salt scaling and temperature polarization. When properly implemented, surface patterns can improve the mass and heat transfer in the boundary layer, which leads to higher MD efficiency. In this work, the performance of direct contact membrane distillation (DCMD) using Sharklet-patterned poly (vinylidene fluoride) (PVDF) membranes is investigated. Both non-patterned and patterned PVDF membranes are prepared by lithographically templated thermally induced phase separation (lt-TIPS) process with optimized conditions. Sharklet patterns on the membranes improve the DCMD performance: up to 17 % higher water flux and 35 % increased brine-side heat transfer coefficient. The scaling resistance of the membranes during DCMD is tested by both saturated CaSO4 solution and hypersaline NaCl solutions. Patterned PVDF membranes show an average of 30 % higher water flux and up to 45 % lessened flux decline over time compared with non-patterned membranes when treating high-concentration brines. Post-mortem analysis reveals that Sharklet-patterned membranes display less salt-scaling on surfaces with smaller-sized CaSO4 and NaCl crystals, maintain a relatively cleaner surface, and exhibit better retention of hydrophobicity. 

Membrane technologies that enable the efficient purification of impaired water sources are needed to address growing water scarcity. However, state-of-the-art engineered membranes are constrained by a universal, deleterious trade-off where membranes with high water permeability lack selectivity. Current membranes also poorly remove low–molecular weight neutral solutes and are vulnerable to degradation from oxidants used in water treatment. We report a water desalination technology that uses applied pressure to drive vapor transport through membranes with an entrapped air layer. Since separation occurs due to a gas-liquid phase change, near-complete rejection of dissolved solutes including sodium chloride, boron, urea, andN-nitrosodimethylamine is observed. Membranes fabricated with sub-200-nm-thick air layers showed water permeabilities that exceed those of commercial membranes without sacrificing salt rejection. We also find the air-trapping membranes tolerate exposure to chlorine and ozone oxidants. The results advance our understanding of evaporation behavior and facilitate high-throughput ultraselective separations.