Morphology control of poly(vinylidene fluoride) thin film made with electrospray

Thin polymer films of poly(vinylidene fluoride) were prepared with electrospray. Effects of solvent, initial spray concentration, temperature, solution conductivity, and polymer size on the film morphology were studied with AFM. The two main factors controlling polymer film morphology are the droplet size of the spray and the viscosity of the solution at deposition. These factors determine the flow of the polymer-solvent mixture over the substrate, the density of the film, and its smoothness. The solvent is a key parameter of the entire process. It affects spray stability, polymer solubility, droplet size of the spray, and viscosity of the solution at deposition. Solvents with a low vapor pressure provide a wider window for optimization of other parameters and are therefore preferred over solvents with high vapor pressure. The viscosity at deposition is mainly controlled with the initial spray concentration, polymer size, temperature, and droplet size. The droplet size is best controlled by the conductivity of the solution and the flow rate of the spray.     

Complex aggregates of silica microspheres by the use of a polymer template

Evaporation of a droplet of silica microsphere suspension on a polystyrene and poly(methyl methacrylate) blend film with isolated holes in its surface has been exploited as a means of particles self-assembly. During the retraction of the contact line of the droplet, spontaneous dewetting combined with the strong capillary force pack the silica microspheres into the holes in the polymer surface. Complex aggregates of colloids are formed after being exposed to acetone vapor. The morphology evolution of the underlying polymer film by exposure to acetone solvent vapor is responsible for the complex aggregates of colloids formation.     

Production of uniform-sized polymer core-shell microcapsules by coaxial electrospraying

Spherical polymeric core-shell microcapsules in uniform size were produced by electrospraying with a coaxial nozzle setup. Contrary to the usual coaxial setup, the inner nozzle was slightly bent to touch the inside wall of the outer nozzle. A polymer solution for the core was introduced through the outer nozzle, and the other solution for the shell was supplied through the inner nozzle. The setup greatly increased reproduction of the same results. As a proof of the concept, core-shell microcapsules consisting of a PS or PMMA core and a PCL shell (PS@PCL, PMMA@PCL) were produced. When the volumetric feed rate of the shell-forming PCL solution was higher than that of the core-forming PS or PMMA solution the core-shell structures in uniform size were readily obtained. In contrast, irregular morphologies were observed when the feed rate of the PCL solution was slower or equal to that of the PS or PMMA solution. The size of the colloid was dependent on the relative feed ratio between the polymer solutions as well as the magnitude of applied voltage.     

Electrosprayed recovered wool keratin nanoparticles

This work reports on producing wool keratin nanoparticles through electrospraying. Wool keratin is a natural biodegradable and biocompatible protein. Keratin powder has found application in hygiene, cosmetics, filtration, tissue engineering scaffolds, and controlled drug release. Like other nano materials, the performance of keratin in submicron size range changes drastically. Electrospraying is a technique that is capable of producing nanosized, regular, and spherical particles. To prepare the electrospraying wool keratin solution, keratin was recovered from descaled wool fibers by dissolving it in mercaptoethanol first, and keratin sponge was obtained. Then, the keratin sponge was dissolved in formic acid that provided the electrospraying solution. This research involved primarily an investigation on the effect of important electrospraying conditions such as polymer concentration, feed rate, voltage, and nozzle‐collector distance on the average particle size of the electrosprayed nanoparticles. The results showed that the proper concentration of keratin in formic acid for the electrospraying keratin nanoparticle was about 0.5% (w/v). As far as electrospraying conditions are concerned, decreasing feed rate and increasing nozzle‐collector distance led to lower average particle size. Voltage did not show a practically significant effect on the average particle size. The average size of the electrosprayed keratin nanoparticles fabricated in this work lies in the range of 36–72 nm. Fourier transform infrared Fourier transform infrared (FTIR) spectra showed that electrosprayed keratin nanoparticles contain –SO₂–S– and –SO–S– linkages. Copyright © 2014 John Wiley & Sons, Ltd.     

Solvent vapor annealing of block copolymer thin films: removal of processing history

The ordering processes of PS-b-P2VP block copolymer thin films with different processing histories were studied during solvent vapor annealing by in situ grazing incidence small-angle X-ray scattering (GISAXS). We compared cylinder-forming PS-b-P2VP thin films with 34 kg/mol molecular weight that were prepared in three different ways: spin coating, spin coating and subsequent solvent vapor annealing where the solvent vapor was removed instantaneously, and spin coating and subsequent solvent vapor annealing where the solvent vapor was removed slowly. Block copolymer thin films retained the morphology resulting from the different “processing histories” at smaller swelling ratios. This processing history was erased when the samples reached a higher swelling ratio (~1.4). After the solvent was slowly removed from the swollen film, the surface morphology was characterized by ex situ AFM. All samples showed the same morphology after solvent annealing regardless of the initial morphology, indicating the morphology of solvent annealed samples is determined by the polymer concentration in the swollen film and the solvent vapor removal rate, but not the processing history.     

Sol-Gel Route to Direct Formation of Silica Aerogel Microparticles Using Supercritical Solvents

A simple and versatile method to obtain silica aerogel particles based on the hydrolysis and subsequent condensation of silicon alkoxides in supercritical fluids is proposed. This microparticle production route reduces the number of steps of traditional microparticle sol-gel processing.A case example is explained in more detail. Spherical and fiber silica morphologies were obtained by a one step method using a sol-gel process with supercritical acetone as a solvent. Particle size was controlled by varying the relative amounts of alkoxysilane, water and acetone. The resulting materials are influenced by a large number of experimental parameters; it has been observed that a quite relevant one is the supercritical fluid venting rate. The morphology of the particles was characterized by electron microscopy (SEM and TEM) and Atomic Force Microscopy (AFM). Alternatively, a low temperature synthesis can be performed by using supercritical carbon dioxide as solvent and formic acid as condensation agent.     

Hydrolytic polycondensation of alkoxysilanes and modification of polymerization reactions

Polymers having oxide network chains are produced by hydrolytic polycondensation of metal alkoxides and alkoxysilanes. Molecular morphology and molecular size distribution of these inorganic polymers are strongly affected by certain nonchemical parameters. Included among these parameters is the molecular separation of interacting species during the polymerization. There is strong evidence that the molecular size expansion occurs by two distinct processes: initially by a gradual “growth” process, and later by “recombination” of high-molecular weight species. The later process often leads to a bi-modal molecular size distribution. The concentration of water-rich siloxane solutions leads to significant molecular size expansion by further oxide network formation. No similar polymer size growth occurs during the concentration of alcohol based solutions. This difference in the polymeric activities can be related to the difference in the terminal bond under the two different conditions.     

Controllable porous polymer particles generated by electrospraying

In this paper, an electrospraying technique was applied to prepare polycaprolactone (PCL) polymer particles with a different microstructure. The PCL particles can be controlled to have a porous microstructure by tailoring the evaporation of solvents during the electrospraying process. The effect of various concentrations on the morphology and microstructure of PCL particles was investigated. The experiment has demonstrated the versatile capability of the electrohydrodynamic atomization process for preparing polymer PCL porous particles and fibers. The thermally induced and evaporation-induced phase separations are proposed as the main mechanisms for the porous microstructure formation. The results demonstrate that the electrospraying method is a simple, innovative and cost-effective method for preparing polymer particles with controllable microstructures.     

MORPHOLOGICAL OBSERVATION OF SINGLE-CHAIN POLY (METHYL METHACRYLATE) PARTICLES*

Tapping mode atomic force microscope has been applied to observe single-chain PMMAparticles which were stored for six months at room temperature after sprayed from verydilute solutions in good solvents, good/poor mixed solvents, and a theta solvent. Monodis-perse PMMA standards of molecular weights ranging from 7.90×10~4 to 1.3×10~6 wereused to investigate the effect of molecular weight oh the size of the single-chain PMMAparticles. These single-chain particles showed close to spherical shapes. The morphologyof single-chain PMMA particles of a given molecular weight was found to be identical inspite of different solvents used for solution spraying. Molecular weigh dependence of theparticle dimension was also found. The diameters of single-chain PMMA particles aftercorrection of tlp-geometry effect were compared to the values estimated from molecularweight and density.     

The effect of formulation variables on the characteristics of insulin-loaded poly(lactic-co-glycolic acid) microspheres prepared by a single phase oil in oil solvent evaporation method

Biodegradable polymeric microspheres are ideal vehicles for controlled delivery applications of drugs, peptides and proteins. Amongst them, poly(lactic-co-glycolic acid) (PLGA) has generated enormous interest due to their favorable properties and also has been approved by FDA for drug delivery. Insulin-loaded PLGA microparticles were prepared by our developed single phase oil in oil (o/o) emulsion solvent evaporation technique. Insulin, a model protein, was successfully loaded into microparticles by changing experimental variables such as polymer molecular weight, polymer concentration, surfactant concentration and stirring speed in order to optimize process variables on drug encapsulation efficiency, release rates, size and size distribution. A 2⁴ full factorial design was employed to evaluate systematically the combined effect of variables on responses. Scanning electron microscope (SEM) confirmed spherical shapes, smooth surface morphology and microsphere structure without aggregation. FTIR and DSC results showed drug–polymer interaction. The encapsulation efficiency of insulin was mainly influenced by surfactant concentration. Moreover, polymer concentration and polymer molecular weight affected burst release of drug and size characteristics of microspheres, respectively. It was concluded that using PLGA with higher molecular weight, high surfactant and polymer concentrations led to a more appropriate encapsulation efficiency of insulin with low burst effect and desirable release pattern.     

Electrohydrodynamic atomization for biodegradable polymeric particle production

Electrohydrodynamic atomization (EHDA) has many applications such as electrospray ionization in mass spectroscopy, electrospray deposition of thin films, pharmaceutical productions, and polymeric particle fabrications for drug encapsulation. In the present study, EHDA was employed to produce biodegradable polymeric micro- and nanoparticles. The effects of processing parameters such as polymer concentration, flow rate, surfactants, organic salt, and setup configurations on the size and morphology of polymeric particles were investigated systematically. By changing the various processing parameters, controllable particle shape and size can be achieved. PLGA nanoparticles with size of around 250 nm can be obtained by using organic salts to increase the conductivity of the spraying solution even at a relatively high flow rate. A higher flow rate has the advantage of producing a stable cone spray and can be easily reproduced. Solid and porous particles can be fabricated using different experimental setups to control the organic solvent evaporation rate. Also, paclitaxel, a model antineoplastic drug, was encapsulated in polymeric particles which can be employed for controlled release applications. In short, EHDA is a promising technique to fabricate polymeric micro- or nanoparticles which can be used in drug delivery systems.     

Molecular Dynamic Simulation of Side-Chain Liquid Crystalline Elastomer

Summary: Molecular dynamic simulation of side chain liquid crystalline elastomer has been carried out. As an initial state a flexible polymer network in a low molecular liquid-crystal (LC) solvent was used. The LC solvent comprises of anisotropic rod-like semiflexible linear molecules (mesogens) composed of particles bonded into the chain by FENE potential. Rigidity of LC molecules was induced by a bending potential. All interactions between nonbonded particles are described by a repulsive Lennard-Jones potential. For the systems with different values of density and order parameter obtained after sufficiently long trajectory the attachment of ends of mesogens to the polymer network was simulated. The kinetic of the process of mesogens attachment to network was studied as well as morphology of attachment. The structural and dynamical behaviour of side chain LC elastomer was studied and compared with systems of polymer network in low molecular LC solvent.     

Monodisperse red blood cell-like particles via consolidation of charged droplets

Recently, researchers have tried to produce non-spherical and anisotropic particles to be used in the next generation of multi-functional materials. Of key interest is the red blood cell-like particle. The torus structure was produced under the relatively fast consolidation of monodisperse droplets, and its parameters were found to be tunable by temperature as well as solvent type and concentration. The observation of consolidation demonstrated that the polymers were accumulated and solidified in the torus structure, naturally, whereas there was the critical droplet size to induce the asymmetry diffusivities. The torus structures could be simply tuned by the flow rate and concentration. The coaxial nozzle system produced the core/shell torus particles. These results state that the consolidation mechanism can hold important clues to enhance the range of tuning capabilities.     

Electrospray deposition, model, and experiment: toward general control of film morphology

Poly(vinylidene fluoride) film formation with electrospray deposition has been studied with support of a droplet evaporation model. The input parameters of the model consist basically of the solvent, the solute concentration, the flow rate, and the solution conductivity. The model provides the droplet size, the solute concentration, the droplet velocity, and the shear stress of the droplet at impact as a function of the distance between the nozzle and the substrate. With some additional experimental information such as the size change of the film with spray distance and the viscosity of the solution, the growth rate of the film and the shear rate of the droplet at impact can be determined. Growth rate is shown to define distinct regimes of film formation. In those regimes, only a single factor or a limited number of factors controls the film morphology. The most important factors include the shear rate and the surface energy. It is found that at a specific range of growth rates only the shear rate determines the morphology of the polymer film. Growth rate, as the defining quantity of film morphology, is not limited to polymer solutions. Therefore, the growth rate, in combination with the control factors mentioned above, functions as a general framework through which understanding and control of film formation with electrospray deposition can be improved.     

Microencapsulation of bovine hemoglobin with high bio-activity and high entrapment efficiency using a W/O/W double emulsion technique

This study focused on the influences of solvent removal method and wall polymer composition on microspheres characteristics in W/O/W double emulsion procedure. Monomethoxypoly(ethylene glycol)-b-poly- -lactide (PELA) microspheres containing bovine hemoglobin (BHb, a model protein) were prepared by four solvent removal methods, including solvent-evaporation at atmosphere, at reduced pressure, solvent-extraction and solvent-diffusion methods, where the last method used ethyl acetate (EA) as organic solvent and the others used methylene chloride (MC). The bio-activity of encapsulated BHb, encapsulation efficiency, particle size and surface morphology of microspheres were evaluated in relation to the influences of solvent removal method and PELA composition. BHb encapsulated by the W/O/W double emulsion–solvent diffusion method with EA as organic solvent displayed a bio-activity near to that of native BHb. The efficiency of BHb entrapment achieved by this method was much higher than those by other methods (ca. 90% versus 30%). When using this process, the copolymers with MPEG 2000 block (molecular weight of PEG block: 2000 g/mol) yielded much higher efficiencies of BHb entrapment than those with MPEG 5000 block (90% versus 36%). Copolymer composition had less impact on microsphere size, but had a pronounced effect on surface morphology of microspheres. This study suggests that the W/O/W double emulsion–solvent diffusion method with EA as organic solvent is an effective process to prepare microspheres containing therapeutic proteins, and that the PELA copolymers containing MPEG 2000 block are promising wall material for biodegradable microsphere protein delivery system.     

Fabrication of tragacanth and water soluble tragacanth nanoparticles through electrospraying

This work reports the fabrication of tragacanth and water soluble tragacanth (WST) through electrospraying technique. Tragacanth is a biocompatible and biodegradable carbohydrate with a wide range of applications. Suspensions of tragacanth in water and water‐ethanol (70:30) were electrosprayed successfully. Moreover, deesterified tragacanth (WST), which is highly water soluble, was also successfully electrosprayed. The results showed that electrospraying technique is capable of producing tragacanth nanoparticles with an average size in the range of 30 to 50 nm, depending on the electrospraying conditions. Water soluble tragacanth gave rise to even smaller nanoparticles. It was also found that lowering feed rate, increasing nozzle‐ collector distance, and increasing voltage decrease the average size of the electrosprayed tragacanth nanoparticles. The molecular weight of tragacanth and WST was measured to be 610 and 301 KDa, respectively. The electrosprayed tragacanth and WST nanoparticles showed moisture regain of 50% and 75%, respectively. These values are much higher than that of their normal powder form. Fourier transform infrared proved the absence of ester groups in the WST as a result of deesterification. X‐ray diffraction studies showed an amorphous microstructure for both tragacanth and WST before electrospraying. After electrospraying, the amorphous structure of the 2 showed some orientation.     

Fabrication of Micron Level Particles of Amoxicillin by Rapid Expansion of Supercritical Solution

In this study, the rapid expansion of supercritical solution (RESS) process was used to precipitate fine solid particles of amoxiccilin where supercritical carbon dioxide was used as a solvent. The process has been done by changing the RESS parameters, including extraction pressure (150–210 bar), extraction temperature (313–333 K), nozzle length (2–15 mm), effective nozzle diameter (450–1700 µm), and spraying distance (1–10 cm), to investigate the effect of these parameters on the size and morphology of the precipitated amoxicillin particles. The characterization (size and morphology) of the particles was examined using scanning electron microscopy (SEM). Based on the different experimental conditions, the mean particle size of the fabricated particles were between 1.08 and 5.72 µm, while the intact particles of amoxicillin were about 41.46 µm. Also, no regular changes in the morphology of the processed particles were observed.     

Synthesis and characterization of monodisperse porous polymer particles

Monodisperse porous polymer particles in the size range of 10 μm in diameter were prepared via seeded emulsion polymerization. Linear polymer (polystyrene seed) or a mixture of linear polymer and solvent or nonsolvent were used as inert diluents. The pore diameters of these porous polymer particles were on the order of 1000 Å with pore volumes up to 0.9 mL/g and specific surface areas up to 200 m²/g. The physical features of the porous polymer particles depended on the diluent type and the crosslinker content, as well as the molecular weight of polymer seed particles. By varying the molecular weight of the linear polymer, monodisperse porous polymer particles with different pore size distribution could be synthesized. Polymer seed with a low degree of crosslinking instead of linear polymer could also be used to prepare monodisperse porous polymer particles with smaller pore volume and pore size.     

Molecular coils and their deformation

The study of stress-effects on chain conformation has always been a fruitful - and sometimes highly controversial - issue in macromolecular science. In this paper chain scission in transient elongational flow is investigated. Particular attention is given to the possible nature of stress transfer from the deforming highly dilute polymer solution to the embedded molecular (PS) chain. The dependencies of the measured degradation efficiency on molecular weight, solvent viscosity, nozzle geometry and flow rate exclude the classical mechanism of chain loading through strain-rate dependent viscous friction. On the basis of their findings the authors propose a model where the loading of hairpin-like segments in almost static friction works against the internal relaxation of these structures.     

Electrosprayed maize starch and its constituents (amylose and amylopectin) nanoparticles

Starch consists of amylose and amylopectin. Properties such as being natural and highly hygroscopic as well as biodegradability have opened a considerable range of applications for amylose, amylopectin and starch. The performance of particles is highly dependent on their size which in turn determines the specific surface area. This work studies the application of electrospraying to fabricate maize starch and its constituents: amylose and amylopectin nanoparticles. This study showed that electrospraying technique is capable of producing amylose, amylopectin and starch nanopowder with an average particle size around 100 nm. FTIR analysis showed no reaction or interaction occurring in amylose, amylopectin and starch nanoparticle compared with their natural form. Basically, lower concentration, lower viscosity and lower surface tension of the electrospraying solution as well as higher nozzle–collector distance, higher voltage and lower feed rate lead to smaller nanoparticle size. Copyright © 2015 John Wiley & Sons, Ltd.