An approach for the scalable production of macroporous polymer beads

A tubular co-flow reactor to produce macroporous polymer beads by polymerization of medium and high internal phase emulsion (M/HIPE) templates was developed. This reactor allows for improved production rates compared to tubing based microfluidic devices. Water-in-oil (W/O) M/HIPEs, containing methyl methacrylate (MMA) and ethylene glycol dimethacrylate (EGDMA) monomers in the continuous phase, were injected into a re-circulating carrier phase. The continuous phase of the emulsion droplets was UV polymerized in situ, resulting in polyM/HIPE beads. The emulsion composition was adjusted to produce poly(MMA-co-EGDMA) porous polymer beads with a protective crust and an interconnected internal pore structure. HCl loaded beads were produced by adding the active ingredient into the dispersed emulsion phase, leading to HCl encapsulation in the porous structure of the beads after polymerization. Even after exposure to ambient conditions for 24 h, 60% of the HCl remained in the beads, indicating good encapsulation efficiencies. Thus, it is possible to use such macroporous beads as delivery vehicles.

Morphology and properties of foamed high crystallinity PEEK prepared by high temperature thermally induced phase separation

Polyetheretherketone (PEEK) is a high‐performance semi‐crystalline thermoplastic polymer with outstanding mechanical properties, high thermal stability, resistance to most common solvents, and good biocompatibility. A high temperature thermally induced phase separation technique was used to produce PEEK foams with controlled foam density from PEEK in 4‐phenylphenol (4PPH) solutions. Physical and mechanical properties, foam and bulk density, surface area, and pore morphology of foamed PEEK were characterized and the role of PEEK concentration and cooling rate was investigated. Porous PEEK with densities ranging from 110 to 360 kg/m³ with elastic moduli and crush strength ranging from 13 to 125 MPa and 0.8 to 7 MPa, respectively, was produced.

High-Performance Polymer Foams by Thermally Induced Phase Separation

Macroporous, low-density polyetheretherketone, polyetherketoneketone, and polyetherimide foams are produced using a high-temperature, thermally induced phase separation method. A high-boiling-point solvent, which is suitable to dissolve at least 20 wt% of these high-performance polymers at temperatures above 250 °C, is identified. The foam morphology is controlled by the cooling procedure. The resulting polymer foams have porosities close to 80% with surface areas up to 140 m² g^-1 and elastic moduli up to 97 MPa.

Antagonistic effects between magnetite nanoparticles and a hydrophobic surfactant in highly concentrated Pickering emulsions

Herein we present a systematic study of the antagonistic interaction between magnetite nanoparticles (Fe3O4) and nonionic hydrophobic surfactant in Pickering highly concentrated emulsions. Interfacial tension measurements, phase behavior, and emulsion stability studies, combined with electron microscopy observations in polymerized systems and magnetometry, are used to support the discussion. First, stable W/O highly concentrated emulsions were obtained using partially hydrophobized magnetite nanoparticles. These emulsions experienced phase separation when surfactant is added at concentrations as low as 0.05 wt %. Such phase separation arises from the preferential affinity of the surfactant for the nanoparticle surfaces, which remarkably enhances their hydrophobicity, leading to a gradual desorption of nanoparticles from the interface. W/O emulsions were obtained at higher surfactant concentrations, but in this case, these emulsions were mainly stabilized by surfactant molecules. Therefore, stable emulsions could be prepared in two separate ranges of surfactant concentrations. After polymerization, low-density macroporous polymers were obtained, and the adsorption and aggregation of nanoparticles was analyzed by transmission electron microscopy. The progressive displacement of the nanoparticles was revealed: from the oil-water interface, in which aggregated nanoparticles were adsorbed, forming dense layers, to the continuous phase of the emulsions, where small nanoparticle aggregates were randomly dispersed. Interestingly, the results also show that the blocking temperature of the iron oxide superparamagnetic nanoparticles embedded in the macroporous polymers could be modulated by appropriate control of the concentrations of both surfactant and nanoparticles.

Emulsion-templated macroporous polymer/polymer composites with switchable stiffness

Emulsion templates containing monomers in both emulsion phases were used to manufacture polystyrene-co-divinylbenzene based polymerized high internal phase emulsions (polyHIPEs) which have been reinforced by poly(methacrylic acid) (polyMAA) and poly(dimethyl aminoethyl methacrylate) (polyDMAEMA). The morphology of the hydrogel-filled polyHIPEs is affected by the hydrogels synthesized in the aqueous emulsion phase. The pore structure of polyMAA-filled polyHIPEs is highly interconnected indicating the formation of a methacrylic acid-co-styrene copolymer at the oil/water interface of the emulsion templates during synthesis. However, polyDMAEMA-filled polyHIPEs are predominately closed celled and the pore walls are covered by grafted hydrogel. The ability of the hydrogel-filled polyHIPEs to absorb water decreased with increasing crosslinking density of the hydrogels. The dry hydrogel reinforced the polyHIPE scaffolds possessed higher elastic moduli and crush strengths than the control polyHIPEs. The reinforcing ability of the dry hydrogels was further enhanced by increasing their degree of crosslinking. However, the reinforcement could be “switched off” simply by hydrating the hydrogels. The switchable mechanical properties of the hydrogel-filled polyHIPEs could potentially be utilized in smart humidity sensor technology.

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.

Macroporous polymers obtained in highly concentrated emulsions stabilized solely with magnetic nanoparticles

Magnetic macroporous polymers have been successfully prepared using Pickering high internal phase ratio emulsions (HIPEs) as templates. To stabilize the HIPEs, two types of oleic acid-modified iron oxide nanoparticles (NPs) were used as emulsifiers. The results revealed that partially hydrophobic NPs could stabilize W/O HIPEs with an internal phase above 90%. Depending upon the oleic acid content, the nanoparticles showed either an arrangement at the oil-water interface or a partial dispersion into the oil phase. Such different abilities to migrate to the interface had significant effects on the maximum internal phase fraction achievable and the droplet size distribution of the emulsions. Highly macroporous composite polymers were obtained by polymerization in the external phase of these emulsions. The density, porosity, pore morphology and magnetic properties were characterized as a function of the oleic acid content, concentration of NPs, and internal phase volume of the initial HIPEs. SEM imaging indicated that a close-cell structure was obtained. Furthermore, the composite materials showed superparamagnetic behavior and a relatively high magnetic moment.

High-porosity macroporous polymers sythesized from titania-particle-stabilized medium and high internal phase emulsions

Particle-stabilized high internal phase emulsions have been used to synthesize tough and very high porosity macroporus polymers with a closed-cell pore structure. In this study, we show that Pickering water-in-oil emulsion templates with up to an 85 vol % internal phase can be stabilized by only 1 wt % of titania particles with their surfaces suitably modified by the adsorption of 3.5 +/- 0.5 wt % oleic acid. The pore structure and mechanical properties of the resulting macroporous polymers were tailored by altering the internal phase volume ratio of the emulsion template and the titania particle concentration used to stabilize the emulsion templates. The pore size and pore size distributions increase with increasing internal phase volume of the emulsion template as well as decreasing titania particle concentration used to stabilize the emulsion template. The mechanical properties, namely, Young's modulus and the crush strength of the macroporous polymers, increased with decreasing porosity and increasing foam density. The toughest macroporous polymer had the lowest porosity but also the smallest pore size and narrowest pore size distribution.

High internal phase emulsion templates solely stabilised by functionalised titania nanoparticles

Porous polymer foams (poly-Pickering-HIPEs) have been synthesised from stable high internal phase emulsion templates solely stabilised by low concentrations of functionalised titania nanoparticles.

Particle-stabilized surfactant-free medium internal phase emulsions as templates for porous nanocomposite materials: poly-Pickering-Foams

We report on the successful use of particle-stabilized Medium Internal Phase Emulsion (MIPE) templates for the synthesis of porous polymer foams. In this case, carbon nanotubes (CNTs) were used to stabilize the minority phase as the continuous phase, through adsorption at the interface. The addition of the CNTs not only provides processing advantages (no need for traditional non-ionic molecular surfactants) but also enhances the mechanical and electrical properties of the final polyFoams. This approach allows the manufacture of both closed- and open-celled porous polymer foams in a one-pot process with porosities up to 66%.

A new route to carbon black filled polyHIPEs

A series of carbon black filled polyHIPEs was synthesised following a new preparation protocol. 1 wt% carbon black was dispersed in the monomer mixture. In order to enhance the stability of the suspension, polymer grafting of carbon black was performed by initiating the polymerisation prior to emulsifying the formulation. All of the carbon black filled polymer foams synthesised the new preparation protocol have the characteristics usually observed for polyHIPEs. Carbon black particles are incorporated into the pore walls without affecting the pore structure of the polyHIPEs. The new preparation protocol positively influenced the properties of the resulting polyHIPEs namely the pore interconnectivity is increased and a water permeability of up to 2.3 D is achieved.