Tough interconnected polymerized medium and high internal phase emulsions reinforced by silica particles

Highly Porous Polymer Beads Coated with Nanometer-Thick Metal Oxide Films for Photocatalytic Oxidation of Bisphenol A

Highly porous metal oxide-polymer nanocomposites are attracting considerable interest due to their unique structural and functional features. A porous polymer matrix brings properties such as high porosity and permeability, while the metal oxide phase adds functionality. For the metal oxide phase to perform its function, it must be fully accessible, and this is possible only at the pore surface, but functioning surfaces require controlled engineering, which remains a challenge. Here, highly porous nanocomposite beads based on thin metal oxide nanocoatings and polymerized high internal phase emulsions (polyHIPEs) are demonstrated. By leveraging the unique properties of polyHIPEs, i.e., a three-dimensional (3D) interconnected network of macropores, and high-precision of the atomic-layer-deposition technique (ALD), we were able to homogeneously coat the entire surface of the pores in polyHIPE beads with TiO2-, ZnO-, and Al2O3-based nanocoatings. Parameters such as nanocoating thickness, growth per cycle (GPC), and metal oxide (MO) composition were systematically controlled by varying the number of deposition cycles and dosing time under specific process conditions. The combination of polyHIPE structure and ALD technique proved advantageous, as MO-nanocoatings with thicknesses between 11 ± 3 and 40 ± 9 nm for TiO2 or 31 ± 6 and 74 ± 28 nm for ZnO and Al2O3, respectively, were successfully fabricated. It has been shown that the number of ALD cycles affects both the thickness and crystallinity of the MO nanocoatings. Finally, the potential of ALD-derived TiO2-polyHIPE beads in photocatalytic oxidation of an aqueous bisphenol A (BPA) solution was demonstrated. The beads exhibited about five times higher activity than nanocomposite beads prepared by the conventional (Pickering) method. Such ALD-derived polyHIPE nanocomposites could find wide application in nanotechnology, sensor development, or catalysis.

Surfactant-free gelatin-stabilised biodegradable polymerised high internal phase emulsions with macroporous structures

High internal phase emulsion (HIPE) templating is a well-established method for the generation of polymeric materials with high porosity (>74%) and degree of interconnectivity. The porosity and pore size can be altered by adjusting parameters during emulsification, which affects the properties of the resulting porous structure. However, there remain challenges for the fabrication of polyHIPEs, including typically small pore sizes (∼20-50 μm) and the use of surfactants, which can limit their use in biological applications. Here, we present the use of gelatin, a natural polymer, during the formation of polyHIPE structures, through the use of two biodegradable polymers, polycaprolactone-methacrylate (PCL-M) and polyglycerol sebacate-methacrylate (PGS-M). When gelatin is used as the internal phase, it is capable of stabilising emulsions without the need for an additional surfactant. Furthermore, by changing the concentration of gelatin within the internal phase, the pore size of the resulting polyHIPE can be tuned. 5% gelatin solution resulted in the largest mean pore size, increasing from 53 μm to 80 μm and 28 μm to 94 µm for PCL-M and PGS-M respectively. In addition, the inclusion of gelatin further increased the mechanical properties of the polyHIPEs and increased the period an emulsion could be stored before polymerisation. Our results demonstrate the potential to use gelatin for the fabrication of surfactant-free polyHIPEs with macroporous structures, with potential applications in tissue engineering, environmental and agricultural industries.

Porous Hydrogels: Present Challenges and Future Opportunities

In this feature article, we critically review the physical properties of porous hydrogels and their production methods. Our main focus is nondense hydrogels that have physical pores besides the space available between adjacent cross-links in the polymer network. After reviewing theories on the kinetics of swelling, equilibrium swelling, the structure-stiffness relationship, and solute diffusion in dense hydrogels, we propose future directions to develop models for porous hydrogels. The aim is to show how porous hydrogels can be designed and produced for studies leading to the modeling of physical properties. Additionally, different methods that are used for making hydrogels with physically incorporated pores are briefly reviewed while discussing the potentials, challenges, and future directions for each method. Among kinetic methods, we discuss bubble generation approaches including reactions, gas injection, phase separation, electrospinning, and freeze-drying. Templating approaches discussed are solid-phase, self-assembled amphiphiles, emulsion, and foam methods.

Hierarchical Macroporous PolyDCPD Composites from Surface-Modified Calcite-Stabilized High Internal Phase Emulsions

High Internal Phase Emulsions (HIPEs) of dicyclopentadiene (DCPD) were prepared using mixtures of surface-modified calcite (mCalcite) and a non-ionic surfactant. Twelve different emulsion formulations were created using an experimental design methodology. Three distinctive levels of the internal phase ratio, the amount of mCalcite loading, and the surfactant were used to prepare the HIPEs. Accordingly, macroporous polyDCPD composites were synthesized by performing ring-opening metathesis polymerization (ROMP) on the HIPEs. The variations in the morphological and physical properties of the composites were investigated in terms of experimental parameters. In the end, five different model equations were derived with a confidence level of 95%. The main and binary interaction effects of the experimental parameters on the responses, such as the average cavity size, interconnecting pore size, specific surface area, foam density, and compression modulus, were demonstrated. The synergistic interaction between the amount of surfactant, the amount of mCalcite loading, and the internal phase ratio appeared to have a dominant role in the average cavity diameter. The solo effect of the internal phase ratio on the interconnecting pore size, foam density, and compression modulus was confirmed. In addition, it was demonstrated that the specific surface area of the composites was mainly changed depending on the amount of mCalcite loading.

Novel gel-like Pickering emulsions stabilized solely by hydrophobic starch nanocrystals

The development of gel-like Pickering emulsions stabilized by edible particles has attracted significant interest in the food colloid field. This work reported that starch nanocrystals (SNCs), modified by octenyl succinic anhydride (OSA), could introduced as a natural stabilizer for gel-like Pickering emulsions. The formation, microstructure and stability of Pickering emulsions were characterized by visual observations and optical microscopy. The results indicated that surface modification improved the hydrophobicity and aqueous re-dispersibility of SNCs, as well as the emulsification performance of them. The stable gel-like Pickering emulsions were formed at different oil volume fractions (range from 40% to 74%), increasing the degree of substitution (DS: from 0.010 to 0.018) led to gel-like emulsion stronger stiffness. These findings offer a promising opportunity to develop a kind of novel edible gel-like Pickering emulsions stabilized by OS-SNCs for the food and pharmaceutical industries.

Air Templated Macroporous Epoxy Foams with Silica Particles as Property-Defining Additive

Nonaqueous foams were successfully produced by mechanically beating air into liquid epoxy resin, surfactant, and silica particle mixtures and used as templates to produce macroporous polymers. The air bubbles introduced into the epoxy formulations served as templates for the pores of the cured epoxy foams. The addition of silica particles into the resin mixture resulted in an increased viscosity of the formulation, thus enhancing the stability of the liquid epoxy froths, which could then be thermally cured at 60 °C. Increasing the silica loading in the formulation resulted in an increase of the foam density and decrease of the average pore size of the epoxy foams. The epoxy foams containing silica exhibited a hierarchical pore structure, where large pores were surrounded by smaller pores, and enhanced stiffness as compared to the control epoxy foams with a monomodal pore size distribution.

High Internal Phase Emulsion Gels Stabilized by Natural Casein peptides

The surface and interfacial properties of casein-hydrolyzed peptides were evaluated using measurement of surface and interfacial tensions, surface viscosity, dynamic light scattering (DLS), and freeze-fracture transmission electron microscopy (FF-TEM). In this study, high internal oil phase emulsion (HIPE) gels were successfully prepared, using the surface and interfacial properties of casein peptides. The casein peptides exhibited surface and interfacial activities. The estimated critical micelle concentration (CMC) and γ_CMC values were 3.0 mg/mL and 47.8 mN/m, and the average size of casein peptide micelles was 13.2 ± 1.7 nm. The surface shear viscosity of an aqueous casein peptide solution at 10 mg/mL was 1603 µPa ms, which is fifteen times larger than that of sodium dodecyl sulfate (SDS, 106 µPa ms). The larger surface viscosity of casein peptide adsorbed layer could stabilize emulsions and prevent flocculation and coalescence. High internal oil phase gel emulsions were then prepared by slowly adding oil and polyisobutene into an aqueous casein peptide solution/glycerol mixture with different compositions. Based on the pseudo ternary 15 wt% aqueous casein peptide solution/polyisobutene/glycerol phase diagram, the HIPE containing the maximum 88.1 wt% (91.5 vol%) of oil is obtained by the addition of 0.36 wt% of casein peptides. The use of only a small amount of protein-hydrolyzed peptides instead of the commonly used synthetic surfactants for HIPE preparation has great advantages for the widespread application of HIPE technology.

Toward Maximizing the Mechanical Property of Interconnected Macroporous Polystyrenes Made from High Internal Phase Emulsions

Macroporous materials polymerized from high internal phase emulsions (PolyHIPEs) possess well-defined interconnected porous structures and tunable device shapes. This provides interesting property characteristics well-suited for a variety of applications. However, such materials also demonstrate poor mechanical performances, which limit their potential use. As will be demonstrated, this results from the high surfactant content required by PolyHIPEs. Herein, a new approach is introduced for designing a highly efficient polymeric surfactant, which generates interconnected pores in PolyHIPEs through designing an incompatible surfactant and skeleton material. The surfactant also possesses a hyperbranched topology, which combines the strong amphipathy of small molecular surfactants and the nanosphere structure of Pickering emulsifiers to provide an excellent colloidal stability to HIPEs. A hyperbranched polyethylene having pendant sodium sulfonate groups (HBPE-SO₃Na) was thus designed and synthesized via chain walking copolymerization of ethylene and 2-trimethylsilyloxyethyl acrylate followed by sulfonation. Stable HIPEs of styrene/divinylbenzene and water at a weight ratio of 1 to 5 were obtained with using HBPE-SO₃Na. The polymerization of HIPEs produced interconnected macroporous polystyrenes (PSs) at a substantially lower surfactant content, for example, 0.5 wt % HBPE-SO₃Na. The compressive Young's moduli of PolyHIPEs reached 104-111 MPa with 0.5-2 wt % HBPE-SO₃Na, which is the first reported case of a PS-based PolyHIPE achieving its theoretical modulus. The PolyHIPE was used to support Au nanoparticles and embed in a column for oxidation of dimethylphenylsilane. A complete conversion of dimethylphenylsilanol was achieved with low column back pressure in a 50 h continuous reaction with no degradation of PolyHIPE integrity and mechanical property.

Fabrication of biomimetic bone grafts with multi-material 3D printing

Extrusion deposition is a versatile method for the 3D printing of biomaterials such as hydrogels, ceramics, and suspensions. Recently, a new class of emulsion inks were developed that can be used to create tunable, hierarchically porous materials with a cure-on-dispense method. Propylene fumarate dimethacrylate (PFDMA) was selected to fabricate bone grafts using this technology due to its established biocompatibility, osteoconductivity, and good compressive properties. Scaffolds fabricated from PFDMA emulsion inks displayed compressive modulus and yield strength of approximately 15 and 1 MPa, respectively. A decrease in infill (from 100% to 70%) resulted in a six-fold increase in permeability; however, there was also a corollary decrease in mechanical properties. In order to generate scaffolds with increased permeability without sacrificing mechanical strength, a biomimetic approach to scaffold design was used to reinforce the highly porous emulsion inks with a dense cortical shell of thermoplastic polyester. Herein, we present an open source method for printing multi-material bone grafts based on PFDMA polyHIPEs with hierarchical porosity and reinforced with a dense shell of poly(ε-caprolactone) (PCL) or poly(lactic acid) (PLA). A multi-modal printing setup was first developed that combined paste extrusion and high temperature thermoplastic extrusion with high positional accuracy in dual deposition. Scaffolds printed with a PCL shell displayed compressive modulus and yield strength of approximately 30 and 3 MPa, respectively. Scaffolds printed with a PLA shell showed compressive modulus and yield strength of approximately 100 and 10 MPa, respectively. By combining this new paste extrusion of emulsion inks with traditional thermoplastic extrusion printing, we have created scaffolds with superior strength that promote cell viability and proliferation of human mesenchymal stem cells. The development of this technique shows great promise for the fabrication of a myriad of other complex tissue engineered scaffolds.

Monodisperse polystyrene foams via polymerization of foamed emulsions: structure and mechanical properties

A study on how to control the pore size of polystyrene foams generated from foamed emulsion templates and their mechanical properties.

Interconnected Porous Polymers with Tunable Pore Throat Size Prepared via Pickering High Internal Phase Emulsions

Interconnected macroporous polymers were prepared by copolymerizing methyl acrylate (MA) via Pickering high internal phase emulsion (HIPE) templates with modified silica particles. The pore structure of the obtained polymer foams was observed by field-emission scanning electron microscopy (FE-SEM). Gas permeability was characterized to evaluate the interconnectivity of macroporous polymers. The polymerization shrinkage of continuous phase tends to form open pores while the solid particles surrounding the droplets act as barriers to produce closed pores. These two conflicting factors are crucial in determining the interconnectivity of macroporous polymers. Thus, poly-Pickering HIPEs with high permeability and well-defined pore structure can be achieved by tuning the MA content, the internal phase fraction, and the content of modified silica particles.

Hierarchical polymerized high internal phase emulsions synthesized from surfactant-stabilized emulsion templates

In building construction, structural elements, such as lattice girders, are positioned specifically to support the mainframe of a building. This arrangement provides additional structural hierarchy, facilitating the transfer of load to its foundation while keeping the building weight down. We applied the same concept when synthesizing hierarchical open-celled macroporous polymers from high internal phase emulsion (HIPE) templates stabilized by varying concentrations of a polymeric non-ionic surfactant from 0.75 to 20 w/vol %. These hierarchical poly(merized)HIPEs have multimodally distributed pores, which are efficiently arranged to enhance the load transfer mechanism in the polymer foam. As a result, hierarchical polyHIPEs produced from HIPEs stabilized by 5 vol % surfactant showed a 93% improvement in Young's moduli compared to conventional polyHIPEs produced from HIPEs stabilized by 20 vol % of surfactant with the same porosity of 84%. The finite element method (FEM) was used to determine the effect of pore hierarchy on the mechanical performance of porous polymers under small periodic compressions. Results from the FEM showed a clear improvement in Young's moduli for simulated hierarchical porous geometries. This methodology could be further adapted as a predictive tool to determine the influence of hierarchy on the mechanical properties of a range of porous materials.

High internal phase emulsion gels (HIPE-gels) from polymer dispersions reinforced with quadruple hydrogen bond functionality

A convenient route to organogels templated by high internal phase emulsions has been developed. Key is the use of a waterborne polymer latex loaded with a multiple hydrogen bond (MHB) functionality that becomes disentangled and transfers across the oil-water interface forming a gel network in the oil phase via hydrogen bond interactions.

Controlling phase distributions in macroporous composite materials through particle-stabilized foams

Aqueous foams stabilized by ceramic and thermoplastic polymeric particles provide a general method for producing novel porous materials because their extraordinary stability against disproportionation and drainage allows them to be dried and sintered into solid materials. Here, we report the different microstructures that can be obtained from liquid foams stabilized by binary mixtures of particles when the interfacial energies between the particles and the air-liquid interfaces are manipulated to promote either preferential or competitive self-assembly of the particles at the foam interface. Modification of the interfacial energies was accomplished through surface modification of the particles or by decreasing the surface tension of the aqueous phase. Materials derived from liquid foams stabilized by poly(vinylidene fluoride) (PVDF) and alumina (Al(2)O(3)) particles are investigated. However, as is shown, the method can be extended to other polymeric and ceramic particles and provides the possibility to manufacture a wide range of porous composite materials.