Bubble Seeding Nanocavities: Multiple Polymer Foam Cell Nucleation by Polydimethylsiloxane-Grafted Designer Silica Nanoparticles

Poly(l-Histidine)-Mediated On-Demand Therapeutic Delivery of Roughened Ceria Nanocages for Treatment of Chemical Eye Injury

Development of topical bioactive formulations capable of overcoming the low bioavailability of conventional eye drops is critically important for efficient management of ocular chemical burns. Herein, a nanomedicine strategy is presented to harness the surface roughness-controlled ceria nanocages (SRCNs) and poly(l-histidine) surface coatings for triggering multiple bioactive roles of intrinsically therapeutic nanocarriers and promoting transport across corneal epithelial barriers as well as achieving on-demand release of dual drugs [acetylcholine chloride (ACh) and SB431542] at the lesion site. Specifically, the high surface roughness helps improve cellular uptake and therapeutic activity of SRCNs while exerting a negligible impact on good ocular biocompatibility of the nanomaterials. Moreover, the high poly(l-histidine) coating amount can endow the SRCNs with an ≈24-fold enhancement in corneal penetration and an effective smart release of ACh and SB431542 in response to endogenous pH changes caused by tissue injury/inflammation. In a rat model of alkali burn, topical single-dose nanoformulation can efficaciously reduce corneal wound areas (19-fold improvement as compared to a marketed eye drops), attenuate ≈93% abnormal blood vessels, and restore corneal transparency to almost normal at 4 days post-administration, suggesting great promise for designing multifunctional metallic nanotherapeutics for ocular pharmacology and tissue regenerative medicine.

In Situ Dispersion of Lignin in Polypropylene via Supercritical CO2 Extrusion Foaming: Effects of Lignin on Cell Nucleation and Foam Compression Properties

Supercritical CO₂ (scCO₂) extrusion foamed high-melt-strength (HMS) polypropylene (PP) often suffers from low cell density, large cell sizes, and poor cell structure uniformity due to the poor nucleation rates of CO₂ in the PP. To remedy this, various inorganic fillers have been used as heterogeneous nucleation agents. Although their efficient nucleation effects have been demonstrated, the preparation of these fillers causes some adverse effects on the environment/human health or involves relatively expensive processes or non-eco-friendly chemicals. In this work, biomass-based lignin is studied as a sustainable, lightweight, and cost-effective nucleating agent. It is found that scCO₂ could assist in situ dispersion of lignin in the PP in the foaming process, leading to significantly increased cell density, smaller cells, and improved cell uniformity. The Expansion Ratio is also simultaneously improved due to reduced diffusive gas loss. The PP/lignin foams with low lignin loadings exhibit higher compression moduli and plateau strengths than the PP foams with the same densities owing to the improved cell uniformity and probably also the reinforcing effect of the small lignin particles in cell walls. Moreover, the energy absorption capability of the PP/lignin foam with 1 wt% lignin could match the PP foam with similar compression plateau strengths; even the density of the former is 28% lower than the latter. Therefore, this work provides a promising approach to a cleaner and more sustainable production of HMS PP foams.

Strengthening Interfacial Adhesion and Foamability of Immiscible Polymer Blends via Rationally Designed Reactive Macromolecular Compatibilizers

Foams made of immiscible polymer blends have attracted great interest in both academia and industry, because of the integration of desirable properties of different polymers in a hybrid foam. However, the foamability and end-use properties are hampered because of the poor interfacial strength within the immiscible blends. Furthermore, few investigations have been carried out on the mechanisms by which interfacial strength and structure affect the foamability of polymer blends. In this work, two different reactive interfacial compatibilizers, i.e., poly(styrene-co-glycidyl methacrylate)-graft-poly(l-lactide) and poly(styrene-co-glycidyl methacry-late)-graft-poly(d-lactide), abbreviated as SG-g-PLLA and SG-g-PDLA, respectively, were designed and synthesized through reactive melt blending and subsequently applied to strengthen the interfacial strength and foamability of immiscible poly(butylene adipate-co-terephthalate) (PBAT)/poly(l-lactide) (PLLA) blends. Both compatibilizers could remarkably enhance the interfacial strength and foamability of the PBAT/PLLA blends, as evidenced by the significantly elongated dispersed phase in the resulting cocontinuous phase and more than 7000-fold increase in the cell density. Furthermore, the improved foamability was quantitively explained by the reduced gas diffusion and increased melt strength. Strikingly, the SG-g-PDLA introduced a stereocomplex crystal at the interface (i-SC), providing highly strengthened interfaces and nanoscale heterogeneous nucleation sites, which led to an energetically favorable cell nucleation. Moreover, foams with specifically laminated cell structures were fabricated by combining pressure-induced flow processing and i-SC strengthened interfaces. This work provides insight into the relationship between interfacial strength and formability of immiscible polymer blends and offers new possibilities for controlling cell morphologies and designing unique cell structures for polymer foams.

Printable and Versatile Superhydrophobic Paper via Scalable Nonsolvent Armor Strategy

Despite great scientific and industrial interest in waterproof cellulosic paper, its real world application is hindered by complicated and costly fabrication processes, limitations in scale-up production, and use of organic solvents. Furthermore, simultaneously achieving nonwetting properties and printability on paper surfaces still remains a technical and chemical challenge. Herein, we demonstrate a nonsolvent strategy for scalable and fast fabrication of waterproofing paper through in situ surface engineering with polysilsesquioxane nanorods (PSNRs). Excellent superhydrophobicity is attained on the functionalized paper surface with a water contact angle greater than 160°. Notably, the engineered paper features outstanding printability and writability, as well as greatly enhanced strength and integrity upon prolonged exposure to water (tensile strength ≈ 9.0 MPa). Additionally, the PSNRs concurrently armor paper-based printed items and artwork with waterproofing, self-cleaning, and antimicrobial functionalities without compromising their appearance, readability, and mechanical properties. We also demonstrate that the engineered paper holds the additional advantages of easy processing, low cost, and mechanochemical robustness, which makes it particularly promising for real world applications.

Open-Celled Foams of Polyethersulfone/Poly(N-vinylpyrrolidone) Blends for Ultrafiltration Applications

Since membranes made of open porous polymer foams can eliminate the use of organic solvents during their manufacturing, a series of previous studies have explored the foaming process of various polymers including polyethersulfone (PESU) using physical blowing agents but failed to produce ultrafiltration membranes. In this study, blends containing different ratios of PESU and poly(N-vinylpyrrolidone) (PVP) were used for preparation of open-celled polymer foams. In batch foaming experiments involving a combination of supercritical CO₂ and superheated water as blowing agents, blends with low concentration of PVP delivered uniform open-celled foams that consisted of cells with average cell size less than 20 µm and cell walls containing open pores with average pore size less than 100 nm. A novel sample preparation method was developed to eliminate the non-foamed skin layer and to achieve a high porosity. Flat sheet membranes with an average cell size of 50 nm in the selective layer and average internal pore size of 200 nm were manufactured by batch foaming a PESU blend with higher concentration of PVP and post-treatment with an aqueous solution of sodium hypochlorite. These foams are associated with a water-flux up to 45 L/(h m² bar). Retention tests confirmed their applicability as ultrafiltration membranes.

Nanostructure of PMMA/MAM Blends Prepared by Out-of-Equilibrium (Extrusion) and Near-Equilibrium (Casting) Self-Assembly and Their Nanocellular or Microcellular Structure Obtained from CO2 Foaming

Blends of poly(methyl methacrylate) (PMMA) and a triblock copolymer poly(methyl methacrylate)-b-poly(butyl acrylate)-b-poly(methyl methacrylate) (MAM) have been obtained following both out-of-equilibrium (extrusion) and near-equilibrium (solvent casting) production routes. The self-assembly capability and the achievable nanostructures of these blends are analyzed by transmission electron microscopy (TEM) regarding their production route and potential for the achievement of nanocellular foams by CO₂ gas dissolution foaming. The influence of the initial nanostructure of the solids on the obtained cellular structure of bulk and film samples is determined by high-resolution scanning electron microscopy (HRSEM) for diverse foaming conditions (saturation pressure, saturation temperature, and post-foaming stage), taking into account the required use of a foaming mold to achieve foams from films. Moreover, the influence of the nanostructuration on the presence of solid outer layers, typical of the selected foaming process, is addressed. Finally, consideration of a qualitative model and the obtained results in terms of nanostructuration, cellular structure, and foaming behavior, allow proposing a detailed cell nucleation, growth, and stabilization scheme for these materials, providing the first direct evidence of the cell nucleation happening inside the poly(butyl acrylate) phase in the PMMA/MAM blends.

Effect of the Molecular Structure of TPU on the Cellular Structure of Nanocellular Polymers Based on PMMA/TPU Blends

In this work, the effects of thermoplastic polyurethane (TPU) chemistry and concentration on the cellular structure of nanocellular polymers based on poly(methyl-methacrylate) (PMMA) are presented. Three grades of TPU with different fractions of hard segments (HS) (60%, 70%, and 80%) have been synthesized by the prepolymer method. Nanocellular polymers based on PMMA have been produced by gas dissolution foaming using TPU as a nucleating agent in different contents (0.5 wt%, 2 wt%, and 5 wt%). TPU characterization shows that as the content of HS increases, the density, hardness, and molecular weight of the TPU are higher. PMMA/TPU cellular materials show a gradient cell size distribution from the edge of the sample towards the nanocellular core. In the core region, the addition of TPU has a strong nucleating effect in PMMA. Core structure depends on the HS content and the TPU content. As the HS or TPU content increases, the cell nucleation density increases, and the cell size is reduced. Then, the use of TPUs with different characteristics allows controlling the cellular structure. Nanocellular polymers have been obtained with a core relative density between 0.15 and 0.20 and cell sizes between 220 and 640 nm.

Oxygen-Selective Diffusion-Bubbling Membranes with Core-Shell Structure: Bubble Dynamics and Unsteady Effects

Oxygen is the second-largest-volume industrial gas that is mainly produced using cryogenic air separation. However, the state-of-the-art cryogenic technology thermodynamic efficiency has approached a theoretical limit as near as is practicable. Therefore, there is stimulus to develop an alternative technology for efficient oxygen separation from air. Mixed ionic electronic-conducting (MIEC) ceramic membrane-based oxygen separation technology could become this alternative, but commercialization aspects, including cost, have revealed inadequacies in ceramic membrane materials. Currently, diffusion-bubbling molten oxide membrane-based oxygen separation technology is being developed. It is a potentially disruptive technology that would propose an improvement in oxygen purity and a reduction in capital costs. Bubbles play an important role in ensuring the oxygen mass transfer in diffusion-bubbling membranes. However, there is not sufficient understanding of the bubble dynamics. This understanding is important to be able to control transport properties of these membranes and assess their potential for technological application. The aim of this feature article is to highlight the progress made in developing this understanding and specify the directions for future research.

Mechanism of Heterogeneous Bubble Nucleation in Polymer Blend Foaming

A three-dimensional heterogeneous bubble nucleation model is constructed to provide a reasonable explanation at the molecular level for the foaming mechanism of polypropylene (PP) and polystyrene (PS) blends. CO₂ solubilities and supersaturation rations are quantitatively calculated to help interpret the contribution of each phase of the blend in the CO₂ dissolution stage. The spatial density profiles of polymer/CO₂ binary melt around different polymer chains are presented to give an intuitive perspective to the thermodynamic driving force. The predicted interfacial tension and contact angles of critical bubbles provide valid evidence to distinguish the wettability of CO₂ in different regions. The values of predicted free-energy barriers, critical radii, and nucleation number densities imply that bubbles that nucleate in the PP and PS blend interfacial region attached to the PS-rich phase achieve the smallest size and largest number density. The reliability of the theoretical model has been tested by partial available experimental data.

Ultrafast Flame-Induced Pyrolysis of Poly(dimethylsiloxane) Foam Materials toward Exceptional Superhydrophobic Surfaces and Reliable Mechanical Robustness

Superhydrophobic surfaces are imperative in flexible polymer foams for diverse applications; however, traditional surface coatings on soft skeletons are often fragile and can hardly endure severe deformation, making them unstable and highly susceptible to cyclic loadings. Therefore, it remains a great challenge to balance their mutual exclusiveness of mechanical robustness and surface water repellency on flexible substrates. Herein, we describe how robust superhydrophobic surfaces on soft poly(dimethylsiloxane) (PDMS) foams can be achieved using an extremely simple, ultrafast, and environmentally friendly flame scanning strategy. The ultrafast flame treatment (1-3 s) of PDMS foams produces microwavy and nanosilica rough structures bonded on the soft skeletons, forming robust superhydrophobic surfaces (i.e., water contact angles (WCAs) > 155° and water sliding angles (WSAs) < 5°). The rough surface can be effectively tailored by simply altering the flame scanning speed (2.5-15.0 cm/s) to adjust the thermal pyrolysis of the PDMS molecules. The optimized surfaces display reliable mechanical robustness and excellent water repellency even after 100 cycles of compression of 60% strain, stretching of 100% strain, and bending of 90° and hostile environmental conditions (including acid/salt/alkali conditions, high/low temperatures, UV aging, and harsh cyclic abrasion). Moreover, such flame-induced superhydrophobic surfaces are easily peeled off from ice and can be healable even after severe abrasion cycles. Clearly, the flame scanning strategy provides a facile and versatile approach for fabricating mechanically robust and surface superhydrophobic PDMS foam materials for applications in complex conditions.

Shape Memory Poly(β-hydroxythioether) Foams for Oil Remediation in Aquatic Environments

Shape memory poly(β-hydroxythioether) foams were produced using organobase catalyzed reactions between epoxide and thiol monomers, allowing for the rapid formation of porous media within approximately 5 min, confirmed using both rheology and physical foam blowing. The porous materials possess ultralow densities (0.022 g × cm^-3) and gel fractions of approximately 93%. Thermomechanical characterizations of the materials revealed glass transition temperatures tunable from approximately 50 to 100 °C, elastic moduli of approximately 2 kPa, and complete strain recovery upon heating of the sample above its glass transition temperature. The foams were characterized for their ability to take up oil from an aqueous multilayered ideal environment, revealing more than 2000% mass of oil (relative to the foam mass) could be collected. Importantly, while post-fabrication functionalization was possible with isocyanate chemistry followed by addition of hexadecanethiol or 3,3-bis(hexadecylthio)propan-1-ol, the oil collection efficiency of the system was not significantly enhanced, indicating that these materials, as porous media, possess unique attributes that make them appealing for environmental remediation without the need for costly modifications or manipulations.

Designer Core-Shell Nanoparticles as Polymer Foam Cell Nucleating Agents: The Impact of Molecularly Engineered Interfaces

The interface between nucleating agents and polymers plays a pivotal role in heterogeneous cell nucleation in polymer foaming. We describe how interfacial engineering of nucleating particles by polymer shells impacts cell nucleation efficiency in CO2 blown polymer foams. Core-shell nanoparticles (NPs) with a 80 nm silica core and various polymer shells including polystyrene (PS), poly(dimethylsiloxane) (PDMS), poly(methyl methacrylate) (PMMA), and poly(acrylonitrile) (PAN) are prepared and used as heterogeneous nucleation agents to obtain CO2 blown PMMA and PS micro- and nanocellular foams. Fourier transform infrared spectroscopy, thermogravimetric analysis, and transmission electron microscopy are employed to confirm the successful synthesis of core-shell NPs. The cell size and cell density are determined by scanning electron microscopy. Silica NPs grafted with a thin PDMS shell layer exhibit the highest nucleation efficiency values, followed by PAN. The nucleation efficiency of PS- and PMMA-grafted NPs are comparable with the untreated particles and are significantly lower when compared to PDMS and PAN shells. Molecular dynamics simulations (MDS) are employed to better understand CO2 absorption and nucleation, in particular to study the impact of interfacial properties and CO2-philicity. The MDS results show that the incompatibility between particle shell layers and the polymer matrix results in immiscibility at the interface area, which leads to a local accumulation of CO2 at the interfaces. Elevated CO2 concentrations at the interfaces combined with the high interfacial tension (caused by the immiscibility) induce an energetically favorable cell nucleation process. These findings emphasize the importance of interfacial effects on cell nucleation and provide guidance for designing new, highly efficient nucleation agents in nanocellular polymer foaming.

Light-intensity switch enabled nonsynchronous growth of fluorinated raspberry-like nanoparticles

Raspberry-like (RB) nanoparticles hold potential for diverse applications due to their hierarchical morphology. Here we developed a novel tandem synthetic approach of nonsynchronous growth based on photo-mediated reversible-deactivation radical polymerization, enabling simple, efficient and bottom-up synthesis of RB nanoparticles of uniform sizes at quantitative conversions of fluorinated monomers. Chain transfer agents of different chain lengths, concentrations and chemical compositions were varied to tune the diameter of RB particles. Importantly, fluorinated RB nanoparticles obtained with this method allow facile post modifications via both covalent bond formation and intermolecular physical interactions without disrupting the RB morphology. The facile nature of this method and versatility of the obtained fluorinated RB materials open new opportunities for the development of functional materials using nanoparticles.