Oil core/polymer shell microcapsules by internal phase separation from emulsion droplets. II: controlling the release profile of active molecules

Microcapsules with oil cores and solid polymer shells have been prepared by precipitation of the polymer from the internal phase of an oil-in-water emulsion. The dispersed phase consists of a polymer, a good solvent for the polymer (dichloromethane), and a poor solvent for the polymer (hexadecane). Removal of the good solvent results in phase separation of the polymer within the emulsion droplet, leading to the formation of a polymeric shell surrounding the poor solvent. A UV-active organic molecule is added to the oil phase prior to emulsification. Provided this molecule has some water solubility, the release profile of the molecule from the capsule can be determined. While the microcapsule size was kept approximately constant, the influence of a wide range of factors on the release profile has been studied. These include the type and molecular weight of the shell-forming polymer, the molecular weight of the active ingredient molecule, the shell thickness, the use of copolymers or polymer blends to form the shell, the effect of cross-linking the shell or heating the capsule to temperatures above the T(g) value of the polymer after the shell has been formed, and the effect of changes in the pH of the release solution in the case when a weak polyelectrolyte is used as the shell polymer. The differences in behavior are discussed in terms of the properties of the polymer shell, in particular the thickness, the polymer/release molecule interaction, and the free volume/porosity. Variation of these parameters allows one to control both the final release yield and the rate of release for time periods between a few hours and days.     

Synthesis of spherical microcapsules by photopolymerization in aerosols

 The preparation of polymer microcapsules of well defined size in the range of 10–50 μm with different shell thickness to core diameter ratios is described. An aerosol of monodisperse droplets of a homogeneous ternary liquid system which contained a hydrophobic component and a hydrophilic component dissolved in a high-volatile mutual solvent, was produced by dispersing with a vibrating-orifice aerosol generator. After the evaporation of the solvent in a nitrogen atmosphere the particles demix and form a two-phase droplet of core-shell type. These droplets were illuminated with UV light and polymerized to highly monodisperse microcapsules with a solid polymer shell and a liquid core. The properties of the resulting particles (size, size distribution, shell thickness, shape and surface characteristics) were investigated by scanning electron microscopy, Raman spectroscopy on single optically levitated particles, and confocal Raman micro spectroscopy. The microcapsules were highly monodisperse and have spherical shape. Received: 24 July 1996 Accepted: 29 August 1996     

Synthesis of polymer–inorganic patchy microcapsules with tunable patches

We introduce a facile and versatile approach for the formation of ball-like polymer–inorganic patchy microcapsules with a tunable shell by combining sol–gel chemistry of silica precursor and phase separation between the polymer and the precursor. Firstly, chloroform-in-water emulsion droplets containing poly(methyl methacrylate) (PMMA), silica precursor [tetraethyl orthosilicate (TEOS)] and co-surfactant sodium dioctyl sulfosuccinate (Aerosol OT or AOT) were prepared by shaking the mixture by hand. Due to the added AOT, water molecules diffuse into the chloroform droplets, and the tiny water droplets would coalesce gradually, triggering the formation of double emulsion droplets. Upon further solvent evaporation, the concentration of the polymer and the silica precursor in the oil shell of the double emulsions increases, leading to the phase separation between the polymer and the precursors (and partially formed silica through the hydrolysis and condensation of TEOS). Because of the confined geometry of the oil shell in the double emulsions, polymeric disc-like structures, stabilized by AOT, were dispersed in the silica precursors. Meanwhile, the silica precursor hydrolyzed and condensed when brought in contact with the aqueous solution, ultimately leading to the formation of a mineralized shell around the polymer domains and the hybrid patchy microcapsules. Effect of synthesis conditions, such as the amount of TEOS, AOT, and PMMA used, the pH value, and solvent evaporation rate on interfacial behavior of the solvent/water; and the morphology of the patchy microcapsules were investigated. Patchy microcapsules with tunable patch size and shape can be generated through tailoring the experimental parameters. Our study indicates that the hybrid patchy microcapsules can be formed by taking advantage of the sol–gel chemistry and the phase separation process, and the underlying generality of the synthesis procedure allows for a variety of applications, including drug storage, coatings, delivery, catalysis, and smart building blocks in self-assembling systems.     

Block Copolymer Capsules with Structure‐Dependent Release Behavior

Although high‐boiling non‐solvent induced macrophase separation in emulsion droplets has been widely applied for the fabrication of polymeric capsules, precise control of their structures remains a great challenge. Herein, block copolymer capsules with tunable shell structures were fabricated by employing a non‐solvent as a liquid template in emulsion droplets. The properties of the non‐solvents dictate the phase separation sequence in the droplets and the capsule formation mechanism. Two different pathways for capsule formation were observed, and could be applied to predict the shell structure. The structured capsules could be transformed into mesoporous capsules, which demonstrated an intriguing structure‐dependent release behavior. Capsules with spherical shell structures displayed the best permeability, while those with lamellar shell structures showed the slowest release, but with a stepwise profile. After loading with an anticancer drug, different capsules induced different apoptosis ratios in cancer cell studies.     

Biocompatible microcapsules with a water core templated from single emulsions

We use single emulsions as templates to fabricate monodisperse biocompatible microcapsules with a water core. These microcapsules are fabricated using FDA-approved polymer and non-toxic solvents and are of great use in drugs, cosmetics and foods.     

Preparation of insulin-loaded PLA/PLGA microcapsules by a novel membrane emulsification method and its release in vitro

Uniform-sized biodegradable PLA/PLGA microcapsules loading recombinant human insulin (rhI) were successfully prepared by combining a Shirasu Porous Glass (SPG) membrane emulsification technique and a double emulsion-evaporation method. An aqueous phase containing rhI was used as the inner water phase (w1), and PLA/PLGA and Arlacel 83 were dissolved in a mixture solvent of dichloromethane (DCM) and toluene, which was used as the oil phase (o). These two solutions were emulsified by a homogenizer to form a w1/o primary emulsion. The primary emulsion was permeated through the uniform pores of a SPG membrane into an outer water phase by the pressure of nitrogen gas to form the uniform w1/o/w2 droplets. The solid polymer microcapsules were obtained by simply evaporating solvent from droplets. Various factors of the preparation process influencing the drug encapsulation efficiency and the drug cumulative release were investigated systemically. The results indicated that the drug encapsulation efficiency and the cumulative release were affected by the PLA/PLGA ratio, NaCl concentration in outer water phase, the inner water phase volume, rhI-loading amount, pH-value in outer water phase and the size of microcapsules. By optimizing the preparation process, the drug encapsulation efficiency was high up to 91.82%. The unique advantage of preparing drug-loaded microcapsules by membrane emulsification technique is that the size of microcapsules can be controlled accurately, and thus the drug cumulative release profile can be adjusted just by changing the size of microcapsules. Moreover, much higher encapsulation efficiency can be obtained when compared with the conventional mechanical stirring method.     

Versatile Preparation of Nonspherical Multiple Hydrogel Core PAM/PEG Emulsions and Hierarchical Hydrogel Microarchitectures

The preparation of nonspherical materials composed of separated multicomponents by droplet‐based microfluidics remains a challenge. Based on polymerization‐induced phase separation and droplet coalescence in microfluidics, we prepared emulsions of variously shaped PAM/PEG core/shell droplets and hydrogels composed of two separated components, which show flexible and transformable hierarchical structures and microarchitectures. We find that AM/PEG aqueous droplets form a core/shell structure after polymerization resulting from phase separation. Thus multicore/shell droplets are easily produced by coalescence of core/shell structures. By changing the polymerization temperature and the flow rate, the morphology of the multicore droplets and the hydrogel can be easily adjusted. The hydrogels exhibit apparent anisotropy and different protein release rates depending on their structures. The preparation technique is simple and versatile and the resulting hydrogels have potential applications in many fields.     

Effect of interfacial free energy on the formation of polymer microcapsules by emulsification/freeze-drying

Hollow polymer microparticles with a single opening on the surface were formed by freeze-drying aqueous polymer colloids swollen with solvent. The results show that the particle morphology is due to phase separation in the polymer emulsion droplets upon freezing in liquid nitrogen, and that morphological changes are driven largely by lowering interfacial free energy. The effects of added surfactant, volume fraction of solvent, type of solvent, and processing conditions on the particle morphology were examined and compared to theoretical predictions. The dried hollow particles were resuspended in a dispersing media and exposed to a second swelling solvent to close the surface opening and form microcapsules. The interfacial free energy difference between the inside and outside surfaces is the driving force for closing the hole on the surface. The emulsification/freeze-drying technique can be used to encapsulate hydrophilic additives in the core of the microcapsules, demonstrating the potential of the technique in controlled-release applications.     

Microfluidics assisted synthesis of well-defined spherical polymeric microcapsules and their utilization as potential encapsulants

In this article, the development of a novel technique to fabricate spherical polymeric microcapsules by utilizing microfluidic technology is presented. Atom transfer radical polymerization (ATRP) was employed to synthesize well-defined amphiphilic block copolymers. An organic polymer solution was constrained to adopt the spherical droplets in a continuous water phase at a T-junction microchannel, and the generation of the droplets was studied quantitatively. The flow conditions of two immiscible solutions were adjusted for the successful generation of the polymer droplets. The morphology of the microcapsules was examined. The efficiency of these polymer microcapsules as containers for the storage and controlled release of loaded molecules was evaluated by encapsulating the microcapsules with Congo-red dye and investigating the release performance using temperature controlled UV-VIS spectroscopy.     

Electrosprayed core-shell nanoparticles of PVP and shellac for furnishing biphasic controlled release of ferulic acid

Coaxial electrospraying was explored to organize polymer excipients in a core-shell manner for providing biphasic controlled release of active ingredient. With ferulic acid (FA) as a model drug, and shellac and polyvinylpyrrolidone (PVP) as the core and shell polymeric matrices, core-shell nanoparticles were successfully fabricated. A series of tests were carried out to characterize the prepared core-shell nanoparticles and also the nanoparticles prepared using a single fluid electrospraying of the shell or core fluids alone. The core-shell nanoparticles had an average diameter of 530?±?80 nm with clear core-shell structure. The contained FA was converted to an amorphous state both in the core and the shell parts due to the favorable hydrogen bonding between the components. In vitro dissolution tests demonstrated that the core-shell nanoparticles were able to provide the desired biphasic drug-controlled release profiles. Coaxial electrospraying is a useful tool for the development of novel nanodrug delivery systems from polymers.     

Preparation of a unique microporous structure via two step phase separation in the course of drying a ternary polymer solution

A unique porous polymeric film was prepared by drying a ternary polymer solution: a polystyrene (PS), polyethylene glycol (PEG), and toluene solution. Highly ordered micropores, ranging from 5 to 12 mum in diameter, were formed on the film surface, and the rim of each micropore was surrounded by a ring of PEG. The effects of the weight ratio of the polymer blend and molecular weight of the polymer (PEG) on the porous structure were investigated. Based on in situ visual observation and light scattering measurements, the formation mechanism of the porous structure was speculated to be a two step phase separation: the phase separation into PEG-rich and PEG-poor (i.e., PS-rich) phases occurred first at the surface area of the ternary solutions, where polymers were condensed due to solvent evaporation. The PEG-rich phase became droplets and had an ordered structure on the surface. The PEG-poor phase became a matrix where PS and solvent coexisted as a single phase solution. Secondary phase separation then followed in the PEG droplets, which was induced by further solvent evaporation, and formed into solvent-rich and PEG-rich domains within the droplets. Solvent evaporation and secondary phase separation created a cavity structure in each PEG droplet structured on the film surface.     

Three-phase interactions and interfacial transport phenomena in coacervate/oil/water systems

Complex coacervation is an associative liquid/liquid phase separation resulting in the formation of two liquid phases: a polymer-rich coacervate phase and a dilute continuous solvent phase. In the presence of a third liquid phase in the form of disperse oil droplets, the coacervate phase tends to wet the oil/water interface. This affinity has long been known and used for the formation of core/shell capsules. However, while encapsulation by simple or complex coacervation has been used empirically for decades, there is a lack of a thorough understanding of the three-phase wetting phenomena that control the formation of encapsulated, compound droplets and the role of the viscoelasticity of the biopolymers involved. In this contribution, we review and discuss the interplay of wetting phenomena and fluid viscoelasticity in coacervate/oil/water systems from the perspective of colloid chemistry and fluid dynamics, focusing on aspects of rheology, interfacial tension measurements at the coacervate/solvent interface, and on the formation and fragmentation of three-phase compound drops.     

Polymeric micelles with tunable channels

This article describes a novel type of polymeric micelles with tunable channels (PMTC), which are usually composed of a common core and a mixed shell of two different kinds of polymer chains with at least one of them being stimuli-responsive. Phase separation of the mixed shell upon stimuli results in channels between the micelle core and the outer milieu for controlling mass exchange. Channel-modulated drug release and catalysis based on PMTC are discussed. The PMTC have peculiar merits including facile manipulation of drug release rate and catalytic velocity, remarkable restraint of burst drug release, and efficient prevention of degradation of the micelle core due to their unique structure. Finally, prospects and challenges of PMTC are reviewed.     

Photocleavable microcapsules built from photoreactive nanospheres

We show how photo-cross-linking of nanoparticles within the micrometer-sized thin oil shell of water-oil-water emulsion droplets leads to a new species of optically addressable microcontainers. The inner water droplet of these emulsions may contain drugs, dyes, or other water-soluble components, leading to filled containers. The thickness, mechanical stability, and light resistance of the container walls can be controlled in a simple way by the amount and adjustable photoreactivity of the nanoparticles. Importantly, the chemical bonds between the nanoparticles constituting the microcapsule shell can be cleaved photochemically by irradiation with UV light. This optically controlled destruction of our microcontainers opens up a pathway to controlled release of the enclosed components, as will be illustrated by the example of enclosed cyclodextrin molecules.     

Multicore-shell PNIPAm-co-PEGMa microcapsules for cell encapsulation

The overall goal of this study was to fabricate multifunctional core-shell microcapsules with biological cells encapsulated within the polymer shell. Biocompatible temperature responsive microcapsules comprised of silicone oil droplets (multicores) and yeast cells embedded in a polymer matrix (shell) were prepared using a novel microarray approach. The cross-linked polymer shell and silicone multicores were formed in situ via photopolymerization of either poly(N-isopropylacryamide)(PNIPAm) or PNIPAm, copolymerized with poly(ethylene glycol monomethyl ether monomethacrylate) (PEGMa) within the droplets of an oil-in-water-in-oil double emulsion. An optimized recipe yielded a multicore-shell morphology, which was characterized by optical and laser scanning confocal microscopy (LSCM) and theoretically confirmed by spreading coefficient calculations. Spreading coefficients were calculated from interfacial tension and contact angle measurements as well as from the determination of the Hamaker constants and the pair potential energies. The effects of the presence of PEGMa, its molecular weight (M(n) 300 and 1100 g/mol), and concentration (10, 20, and 30 wt %) were also investigated, and they were found not to significantly alter the morphology of the microcapsules. They were found, however, to significantly improve the viability of the yeast cells, which were encapsulated within PNIPAm-based microcapsules by direct incorporation into the monomer solutions, prior to polymerization. Under LSCM, the fluorescence staining for live and dead cells showed a 30% viability of yeast cells entrapped within the PNIPAm matrix after 45 min of photopolymerization, but an improvement to 60% viability in the presence of PEGMa. The thermoresponsive behavior of the microcapsules allows the silicone oil cores to be irreversibly ejected, and so the role of the silicone oil is 2-fold. It facilitates multifunctionality in the microcapsule by first being used as a template to obtain the desired core-shell morphology, and second it can act as an encapsulant for oil-soluble drugs. It was shown that the encapsulated oil droplets were expelled above the volume phase transition temperature of the polymer, while the collapsed microcapsule remained intact. When these microcapsules were reswollen with an aqueous solution, it was observed that the hollow compartments refilled. In principle, these hollow-core microcapsules could then be filled with water-soluble drugs that could be delivered in vivo in response to temperature.     

A general strategy for one-step fabrication of biocompatible microcapsules with controlled active release

Fabrication of biocompatible core-shell microcapsules in a controllable and scalable manner remains an important but challenging task.Here,we develop a one-step microfluidic approach for the highthroughput production of biocompatible microcapsules,which utilizes single emulsions as templates and controls the precipitation of biocompatible polymer at the water/oil interface.The facile method enables the loading of various oils in the core and the enhancement of polymer shell strength by polyelectrolyte coating.The resulting microcapsules have the advantages of controllability,scalability,biocompatibility,high encapsulation efficiency and high loading capacity.The core-shell microcapsules are ideal delivery vehicles for programmable active release and various controlled release mechanisms are demonstrated,including burst release by vigorous shaking,pH-triggered release for targeted intestinal release and sustained release of perfume over a long period of time.The utility of our technique paves the way for practical applications of core-shell microcapsules.     

Core‐shell structure microcapsules with dual pH‐responsive drug release function

We report dual pH‐responsive microcapsules manufactured by combining electrostatic droplets (ESD) and microfluidic droplets (MFD) techniques to produce monodisperse core (alginate)‐shell (chitosan) structure with dual pH‐responsive drug release function. The fabricated core‐shell microcapsules were size controllable by tuning the synthesis parameters of the ESD and MFD systems, and were responsive in both acidic and alkaline environment, We used two model drugs (ampicillin loaded in the chitosan shell and diclofenac loaded in the alginate core) for drug delivery study. The results show that core‐shell structure microcapsules have better drug release efficiency than respective core or shell particles. A biocompatibility test showed that the core‐shell structure microcapsules presented positive cell viability (above 80%) when evaluated by the 3‐(4,5‐dimethylthiazol‐2‐yl)‐2,5‐diphenyltetrazolium bromide (MTT) assay. The results indicate that the synthesized core‐shell microcapsules were a potential candidate of dual‐drug carriers.     

Porous microcapsule formation with microsieve emulsification

A simple route is presented to prepare core-shell Eudragit microcapsules through a solvent extraction method with the use of microsieve emulsification. Droplets from a solution of Eudragit FS 30D (a commercial copolymer of poly(methyl acrylate-co-methyl methacrylate-co-methacrylic acid) 7:3:1) and hexadecane in dichloromethane are dispersed into water, using a micro-engineered membrane with well-defined pores, in a cross-flow setting. The dichloromethane is extracted from the droplets, which induces demixing in the droplets, leading to a hexadecane-rich core, and an Eudragit-rich shell. The obtained microcapsules have a narrow size distribution due to the microsieve emulsification process. The capsules have a porous shell as shown by SEM and AFM measurements. Their porosity and pore size is dependent on the ratios of Eudragit and hexadecane in the dispersed phase. At pH 7.1 and above Eudragit (FS 30D) dissolves in water; this pH change is used to release the contents of the microcapsule.     

Cagelike polymer microspheres with hollow core/porous shell structures

Submicron‐scaled cagelike polymer microspheres with hollow core/porous shell were synthesized by self‐assembling of sulfonated polystyrene (PS) latex particles at monomer droplets interface. The swelling of the PS latex particles by the oil phase provided a driving force to develop the hollow core. The latex particles also served as porogen that would disengage automatically during polymerization. Influential factors that control the morphology of the microspheres, including the reserving time of emulsions, polymerization rate, and the Hildebrand solubility parameter and polarity of the oil phase, were studied. A variety of monomers were polymerized into microspheres with hollow core/porous shell structure and microspheres with different diameters and pore sizes were obtained. The polymer microspheres were characterized by scanning electron microscopy, transmission electron microscopy, optical microscopy, and Fourier transform infrared spectroscopy. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 933–941, 2007     

Formation of Pickering emulsions stabilized via interaction between nanoparticles dispersed in aqueous phase and polymer end groups dissolved in oil phase

The influence of end groups of a polymer dissolved in an oil phase on the formation of a Pickering-type hydroxyapatite (HAp) nanoparticle-stabilized emulsion and on the morphology of HAp nanoparticle-coated microspheres prepared by evaporating solvent from the emulsion was investigated. Polystyrene (PS) molecules with varying end groups and molecular weights were used as model polymers. Although HAp nanoparticles alone could not function as a particulate emulsifier for stabilizing dichloromethane (oil) droplets, oil droplets could be stabilized with the aid of carboxyl end groups of the polymers dissolved in the oil phase. Lower-molecular-weight PS molecules containing carboxyl end groups formed small droplets and deflated microspheres, due to the higher concentration of carboxyl groups on the droplet/microsphere surface and hence stronger adsorption of the nanoparticles at the water/oil interface. In addition, Pickering-type suspension polymerization of styrene droplets stabilized by PS molecules containing carboxyl end groups successfully led to the formation of spherical HAp-coated microspheres.