Formulation and mechanical properties of emulsion-based model polymer foams

Functionally Gradient Macroporous Polymers: Emulsion Templating Offers Control over Density, Pore Morphology, and Composition

Gradient macroporous polymers were produced by polymerization of emulsion templates comprising a continuous monomer phase and an internal aqueous template phase. To produce macroporous polymers with gradient composition, pore size, and foam density, we varied the template formulation, droplet size, and internal phase ratio of emulsion templates continuously and stacked those prior to polymerization. Using the outlined approach, it is possible to vary one property along the resulting macroporous polymer while retaining the other properties. The elastic moduli and crush strengths change along the gradient of the macroporous polymers; their mechanical properties are dominated by those of the weakest layers in the gradient. Macroporous polymers with gradient chemical composition and thus stiffness provide both high impact load and energy adsorption, rendering the gradient foam suitable for impact protective applications. We show that dual-dispensing and simultaneous blending of two different emulsion formulations in various ratios results in a fine, bidirectional change of the template composition, enabling the production of true gradient macroporous polymers with a high degree of design freedom.

Effect of Cosurfactant on Structure and Properties of Polymerized High Internal Phase Emulsions (PolyHIPEs)

Porous polymerized high internal phase emulsion (polyHIPE) monoliths are synthesized by using Span 80 with different cosurfactants. The results reveal that the void size can be reduced by employing cosurfactants, except for Tween 20. Furthermore, the openness of polyHIPEs changes by using different cosurfactants or by varying their concentration. To further investigate the effect of cosurfactants, we perform rheology measurements on the interface of the aqueous and oil phase. This study demonstrates the important role of interfacial elasticity in the successful preparation of polyHIPEs with different morphologies. Additionally, this study suggests that the increase in interfacial elasticity hinders the formation of interconnections between pores, known as windows. Finally, the compression test is performed to investigate the effect of the pore structure on the mechanical properties.

Basic Principles of Emulsion Templating and Its Use as an Emerging Manufacturing Method of Tissue Engineering Scaffolds

Tissue engineering (TE) aims to regenerate critical size defects, which cannot heal naturally, by using highly porous matrices called TE scaffolds made of biocompatible and biodegradable materials. There are various manufacturing techniques commonly used to fabricate TE scaffolds. However, in most cases, they do not provide materials with a highly interconnected pore design. Thus, emulsion templating is a promising and convenient route for the fabrication of matrices with up to 99% porosity and high interconnectivity. These matrices have been used for various application areas for decades. Although this polymer structuring technique is older than TE itself, the use of polymerised internal phase emulsions (PolyHIPEs) in TE is relatively new compared to other scaffold manufacturing techniques. It is likely because it requires a multidisciplinary background including materials science, chemistry and TE although producing emulsion templated scaffolds is practically simple. To date, a number of excellent reviews on emulsion templating have been published by the pioneers in this field in order to explain the chemistry behind this technique and potential areas of use of the emulsion templated structures. This particular review focusses on the key points of how emulsion templated scaffolds can be fabricated for different TE applications. Accordingly, we first explain the basics of emulsion templating and characteristics of PolyHIPE scaffolds. Then, we discuss the role of each ingredient in the emulsion and the impact of the compositional changes and process conditions on the characteristics of PolyHIPEs. Afterward, current fabrication methods of biocompatible PolyHIPE scaffolds and polymerisation routes are detailed, and the functionalisation strategies that can be used to improve the biological activity of PolyHIPE scaffolds are discussed. Finally, the applications of PolyHIPEs on soft and hard TE as well as in vitro models and drug delivery in the literature are summarised.

Ultralight Aerogels with Hierarchical Porous Structures Prepared from Cellulose Nanocrystal Stabilized Pickering High Internal Phase Emulsions

Cellulose nanocrystal (CNC)-based aerogels with extremely low density and hierarchical porous structure were constructed via a facile Pickering-emulsion-templated strategy. In this method, aminated CNCs (CNC-NH₂) were synthesized to stabilize o/w Pickering high internal phase emulsions (Pickering HIPEs). Amino groups were introduced to CNCs to decrease the net surface charges of CNCs, enhance their aggregation, and therefore achieve Pickering HIPEs stabilized by the particles of ultralow content (∼0.1 wt %). A series of CNC aerogels was then obtained by freeze drying these emulsions. The resulting aerogels were ultralight with a density that reached ca. 0.5 mg/cm³ (an order of magnitude lower than that previously reported for CNC aerogels) and an ultrahigh porosity (up to 99.969%). Contributed to the extremely low density, the thermal conductivity of the aerogels was around 0.021 W/(m·K) which is lower than that of air (0.024 W/(m·K)). This novel strategy could be applied to other materials, such as graphene and carbon nanotubes, to prepare ultralight aerogels with controllable porous structures and unique properties.

Production of High Internal Phase Emulsion with a Miniature Twin Screw Extruder

Emulsions are traditionally prepared by batched emulsifying an oil phase and aqueous phase with a magnetic/mechanical stirrer, homogenizer, or ultrasonic machine, etc. Herein, high internal phase emulsions (HIPEs) produced with a miniature twin screw extruder were first investigated. Adding an oil phase (the mixture of styrene, divinylbenzene, and span 80) and aqueous phase to the inlet of a miniature twin screw extruder, a series of white and viscous HIPEs were obtained at the outlet of the extruder. With the screw rotation speed and the surfactant content varied respectively in the ranges of 50-200 rpm and 5-20%, a series of HIPEs having uniform droplet size were produced. Polymerizing these HIPEs caused a series of polymerized HIPES, which have a well-defined open-cell structure. The method developed herein shows that it is possible to prepare emulsions with oil and water by twin screw extrusion. Also, it may also cause a continuous preparation of HIPEs when the miniature twin screw extruder was replaced by an industrial extruder.

Effects of graphene surface energy on the structure and mechanical properties of phenolic foams

Graphene nanoplates (GNPs) and graphene oxide (GO) were used to investigate the effects of surface free energy (SFE) of nanoparticles on the cellular structure and mechanical properties of phenolic nanocomposite foams. The results showed that the SFE of nanoparticles is a key parameter in determining the interfacial action between fillers and matrix before foaming, which in turn determines the energy barrier of bubble nucleation during foaming process. It indicated that the higher interfacial energy of GO brought out the lower Gibbs free energy and smaller driving force for heterogeneous nucleation, leading to smaller cell size with more uniform distribution. According to the effect of SFE in foaming process, different mass fractions of GNPs and GO were used in phenolic foams to investigate the effects of heterogeneous nucleating agent on cell nucleation. As a result, phenolic foam with 0.6 wt% graphene oxide (GO-0.6/PF) exhibited the optimized mechanical properties and cell microstructure.

Modeling compressive behavior of open-cell polymerized high internal phase emulsions: effects of density and morphology

The compressive behavior of poly(HIPE) foams was studied using the developed micromechanics based computational model. The model allowed identifying the morphological parameters governing the foam compressive behavior. These parameters comprise: (i) foam density, (ii) Sauter mean diameter of voids calculated from the morphological analysis of the polydispersed microstructure of poly(HIPE), and (iii) polymer/strut characteristic size identified as the height of the curvilinear triangular cross-section. The model prediction compared closely with the experiments and considered both the linear and plateau regions of the compressive poly(HIPE) behavior. The computational model allows the prediction of structure-property relationships for poly(HIPE) foams with various relative densities and open cell microstructure using the input parameters obtained from the morphology characterization of the poly(HIPE). The simulations provide a pathway for understanding how tuning the manufacturing process can enable the optimal foam morphology for targeted mechanical properties.

Tuning the sound speed in macroporous polymers with a hard or soft matrix

In this paper, we investigate the factors affecting the sound speed in air-filled macroporous polymer materials at ultrasound frequencies. Due to the presence of large proportion of gas, these porous materials present high compressibility and, as a consequence, low sound speed which may fall down to values as low as 40 m s^-1. Using an emulsion-templating method, we synthesize macroporous samples with similar porous structures but with three different matrices, i.e. a hard poly(styrene-divinylbenzene (DVB)) matrix, a soft epoxy-modified polydimethylsiloxane (PDMS) matrix and a very soft polyaddition PDMS matrix. We characterize the matrix mechanical properties by measuring both the bulk modulus K₀ and the shear modulus G₀. Next, we compare the sound speed measured in porous samples with porosity varying from 0 to 50%. We show that, in agreement with theoretical predictions, the sound speed is mainly controlled by two parameters, the porosity value and the K₀/G₀ ratio of the polymer matrix. These parameters may be used to control the sound propagation in porous polymers, which opens the way to the realization of gradient-index materials.

Diving into the Finestructure of Macroporous Polymer Foams Synthesized via Emulsion Templating: A Phase Diagram Study

During our studies on emulsion-templated monodisperse polymer foams we found significant differences in the finestructure if the locus of initiation is changed. This motivated us to study the phase behavior of the liquid template. Our studies indicate that the template consists of droplets of three different length scales: The water droplets generated via microfluidics (∼70 μm) are surrounded by a continuous phase in which a w/o emulsion (≤100 nm) coexists with a w/o microemulsion (∼5 nm). We speculate that the w/o-emulsion droplets act as seeds for the porous finestructure observed in AIBN-initiated polymer foams. We have experimental evidence that the w/o emulsion inverts to an o/w emulsion with progressing polymerization. This explains the granular texture observed in KPS-initiated polymer foams. The control of the finestructure is important in the preparation of tailor-made polymer foams because it directly impacts the material's density and thus, in turn, its mechanical stability.

Soft porous silicone rubbers as key elements for the realization of acoustic metamaterials

In this work, macroporous materials made of polydimethylsiloxane, a soft silicone rubber, are prepared using UV polymerization with an emulsion-templating procedure. The porosity of the final materials can be precisely controlled by adjusting the volume of the dispersed phase. We show that the porous structure of the materials is the template of the droplets of the initial emulsions. Mechanical tests show that the materials Young's moduli decrease with the porosity of the materials. Acoustic measurements indicate that, in such a porous elastomeric matrix, the sound speed also decreases dramatically as soon as the porosity increases to attain values of as low as 80 m/s. The results are compared to earlier ones on silica aerogels and are interpreted within the framework of a simple theoretical approach. We show that the very low sound speed value is a consequence of the low value of the polymer shear modulus. This explains why such porous soft silicone rubbers are so efficient at playing the role of slow-soft resonators in acoustic metamaterials. Moreover, the fast rate of polymerization of such UV-curable fluid allows for a facile shaping of the final material as beads or rods in microfluidic devices.1.