Preparation of highly monodisperse W/O emulsions with hydrophobically modified SPG membranes

Experimental investigations on the hydrophobic modification of SPG membranes and the preparation of monodisperse W/O (water-in-oil) emulsions using the modified membranes were carried out. Effects of the osmotic pressure of disperse phase, the average pore size of membranes, emulsifier concentrations in continuous phase and the transmembrane pressure on the average size, size distribution and size dispersion coefficient of emulsions were systematically studied. The stability of W/O emulsions was also investigated. The results showed that SPG membranes took on excellent hydrophobicity through the modification by silane coupler reagent (octyltriethoxysilane) or by silicone resin (polymethylsilsesquioxane). Monodisperse W/O emulsions with size dispersion coefficient of about 0.25, which meant high monodispersity, were successfully prepared by using the hydrophobically modified SPG membranes with average pore sizes of 1.8, 2.0, 2.5, 4.8 and 11.1 microm. When the osmotic pressure was lower than 0.855 MPa, the average size of emulsions was gradually increased while the size dispersion coefficient delta gradually decreased with the osmotic pressure; when the osmotic pressure was higher than 0.855 MPa, both the coefficients kept unvarying. When kerosene was saturated with disperse phase in advance, the average size of emulsions became larger and the monodispersity of emulsions was slightly better than that prepared using unsaturated kerosene. The smaller the pore size of SPG membranes was, the better the monodispersity of the W/O emulsions. The average size and size dispersion coefficient delta were nearly independent on the emulsifier concentrations when the PGPR concentration was in the range from 0.5 to 5.0 wt%, whereas both of them slightly increased as the PGPR concentration was below 0.5 wt%. The effect of the transmembrane pressure on size distributions was slight. Both the average size and size dispersion coefficient delta slightly increased to some extent with the increase of the transmembrane pressure in the experimental range. The stability of the W/O emulsions was dependent on the storage time. The mean size of W/O emulsions decreased gradually with the increase of storage time at the first 35 days, and then kept constant; while the size dispersion coefficient of W/O emulsions was nearly not changed.     

Status of cross-flow membrane emulsification and outlook for industrial application

Cross-flow membrane emulsification has great potential to produce monodisperse emulsions and emulsions with shear sensitive components. However, until now, only low disperse phase fluxes were obtained. A low flux may be a limiting factor for emulsion production on a commercial scale. Therefore, the effects of membrane parameters on the disperse phase flux are estimated. Besides, the effects of these parameters on the droplet size and droplet size distribution are qualitatively described. Wetting properties, pore size and porosity mainly determine the droplet size (distribution). Membrane morphology largely determines the disperse phase flux. As an example, industrial-scale production of culinary cream was chosen to evaluate the required membrane area of different types of membranes: an SPG membrane, an -Al₂O₃ membrane and a microsieve. Due to the totally different morphologies of these membranes, the fraction of active pores is 1 for a microsieve and is very low for the other membranes. The choice of the optimal membrane did not depend on the production strategy: either to produce large quantities or to produce monodisperse emulsions, the best suitable was a microsieve with an area requirement of around 1 m². In general, the total membrane resistance should be low to obtain a large disperse phase flux. In contrast, the membrane resistance should be high to obtain monodisperse emulsions when using membranes with a high porosity.     

Preparation of monodisperse crosslinked polymelamine microcapsules by phase separation method

Monodisperse polymelamine microcapsules were prepared by phase separation method. Control of microcapsule diameter was investigated using the uniform-sized oil-in-water emulsion droplets as the capsule core. The monodisperse emulsion droplets were prepared using the Shirasu porous glass (SPG) membrane emulsification technique. The effects of the diameter of the oil droplet and concentration of sodium dodecyl sulfate (SDS), which is a typical emulsifier in SPG membrane emulsification, on microencapsulation were investigated. The microcapsules were aggregated when oil droplets with small size were microencapsulated at high SDS concentration. To reduce the SDS concentration, the creamed emulsion was used. The monodisperse polymelamine microcapsules were successfully prepared by using the creamed emulsion. The microcapsule diameter was almost similar to the diameter of the encapsulated oil droplet. The coefficient of variation values was about 10% for all microcapsules prepared in this study. Control of microcapsule diameter was achieved in the range of 5–60 μm.     

Membrane Emulsification Using Sol-Gel Derived Macroporous Silica Glass

A macroporous silica glass membrane with continuous cylindrical pores was prepared by a sol-gel process using phase separation. The applicability of the sol-gel derived macroporous silica to the membrane emulsification process was evaluated in comparison with a conventional SPG (Silasu Porous Glass) membrane.Aqueous colloidal silica in one side of the membrane was emulsified through the pores under an applied pressure to a toluene bath containing surfactant. With the sol-gel and SPG membranes with respective median pore diameters of 0.6 and 1.0 m, emulsions with almost the same droplet size centered around 3 m were obtained. The permeation rate of the sol-gel derived membrane was about 1.6 times faster than SPG, which reflected higher pore volume of the former one.     

Preparation of microcapsule-supported palladium catalyst using SPG (Shirasu Porous Glass) emulsification technique

<正>A new method for the preparation of microcapsule-supported palladium catalyst was described.The highly monodisperse crosslinked polystyrene microcapsules containing phosphine ligand were synthesized by the self-assembling of phase separated polymer (SaPSeP) method using diphenyl(4-vinylphenyl) phosphine and divinylbenzene as a monomer and crosslinking agent,respectively, and 2,2'-azobisisobutyronitrile(AIBN) as an initiator within the droplets of oil-in-water(O/W) emulsions,which were prepared by using the Shirasu Porous Glass(SPG) membrane emulsification technique.The prepared microcapsule-supported palladium catalyst exhibited high catalytic activity for Heck reaction and can be reused several times without loss of activity.     

单分散聚苯乙烯微球的制备及表征

应用膜乳化-液中干燥法成功制备出粒径为2～20μm的单分散聚苯乙烯(PS)微球.PS微球的粒径主要由膜孔径决定,其值约为膜孔径的2倍;PS溶液的浓度对其也有一定的影响.膜乳化过程中的压力对微球粒径的分散性有很大的影响,在一定压力范围内,粒径呈单分散.在分散相中加入致孔剂,制备出表面多孔的PS微球.采用复乳-液中干燥法制备出中空PS微球.     

Effect of membrane parameters on the size and uniformity in preparing agarose beads by premix membrane emulsification

Agarose microbeads were prepared by premix membrane emulsification with Shirasu-Porous Glass (SPG) membrane and Polyethylene (PE) membrane. The effects of membrane parameters, including pore size, pore size distribution, contact angle between membrane surface and the water phase, shape of pore opening and membrane thickness on size and uniformity of agarose beads were investigated in this study. The results showed that pore size distribution and shape of pore opening did not affect the emulsification results apparently within a wide range in premix membrane emulsification, not as the result in general emulsification. The contact angle between the water phase and the membrane surface must be large enough to obtain uniform-sized agarose beads in both direct membrane emulsification and premix membrane emulsification. The results also showed that the membrane pore size and thickness affected the size distribution of emulsion. Thicker membrane resulted in more uniform and smaller emulsion when the number of pass through membrane is controlled. There was a linear relationship between the number average diameter of agarose beads and membranes pores size in premix membrane emulsification. Agarose beads with diameters from 3.06 to 9.02 μm were prepared by controlling membranes pore size. The ratio of the number average diameter of agarose beads to membrane pore diameters was found to be 0.486.     

Novel one-pot route to monodisperse thermosensitive hollow microcapsules in a microfluidic system

We present a simple one-pot synthetic approach for the preparation of monodisperse thermo-sensitive poly(N-isopropylacrylamide) (PNIPAM) microcapsules in a microfluidic system. Based on the mechanism of shear force-driven break-off, aqueous droplets of monomer solution are continuously generated in an immiscible continuous phase containing photoinitiators. Under UV irradiation, activated initiators are diffused into the interface between the continuous phase and the aqueous droplets, which trigger polymerization of NIPAM monomers. The PNIPAM microcapsules produced are hollow microcapsules with a thin shell membrane, high monodispersity, and fast response to environmental temperature. In addition, the size of microcapsules produced can be manipulated by the flow rate of the continuous phase or aqueous phase and different concentrations of surfactant to control interfacial tension between continuous phase and aqueous phase. Furthermore, the versatility of this approach enables the preparation of monodisperse microcapsules having the capability to encapsulate various materials such as proteins and nanoparticles under mild conditions. The in situ microfluidic synthetic method provides a novel approach for the preparation of monodisperse hollow microcapsules via a one-pot route.     

Preparation of Uniform Microspheres and Microcapsules by Modified Emulsification Process

Summary: Uniform microspheres and microcapsules have been prepared by developing a direct membrane emulsification technique from O/W, W/O and W/O/W emulsions in previous studies, and have been applied in bio-separation and drug delivery systems. The diameter can be controlled from several microns to above 100 microns. However, smaller microsphere with submicron size, especially from W/O/W emulsion was difficult to be prepared. In this article, a modified emulsification technique was developed to overcome the problem. That is, a pre-emulsion (W/O or W/O/W) with broad size distribution of droplets was prepared firstly by homogenization, sonification or mechanical stirring method, then the pre-emulsion was pressed through the uniform pores of a Shirasu Porous Glass (SPG) membrane to obtain relatively uniform smaller droplets, finally the droplets were solidified to form uniform microsphere or microcapsule. Uniform chitosan microsphere and poly(lactic-glycolic acid) (PLGA) microcapsule with submicron size were prepared from W/O and W/O/W emulsions, respectively. Further more, uniform polymer-magnetite microcapsule was prepared by combining this technique and a new post-precipitation process of magnetite.     

含VE微胶囊的制备及其控制释放性能研究

以天然维生素E（VE）为芯材，利用Shirasu porous glass (SPG) 膜乳化结合液中干燥法，制备了粒径单分散的聚苯乙烯（PS）微胶囊.微胶囊的粒径为膜孔径的4倍，粒径单分散系数CV小于0.2.考察了改变PS和VE的比例及微胶囊的粒径对控制释放性能的影响.     

Mechanism of formation of monodisperse polystyrene hollow particles prepared by membrane emulsification technique. Effect of hexadecane amount on the formation of hollow particles

In a previous study, it was found that monodisperse polystyrene (PSt) hollow particles can be prepared under special conditions by combining a Shirasu Porous Glass (SPG) emulsification technique and subsequent suspension polymerization process. The dispersed phase mainly containing St, hexadecane (HD), and initiator, was pressed through the uniform pores of a SPG membrane into the continuous phase to form uniform droplets. Then, the droplets were polymerized at 70°C. It was proposed that rapid phase separation between PSt and HD was a main reason responsible for the formation of hollow particle. Rapid phase separation confined the HD inside the droplets, it belonged to a non-equilibrium morphology. In this study, HD/St ratio was increased to a high value to confirm the above proposition by promoting rapid phase separation further between HD and PSt, to prevent monomer diffusion into aqueous phase, and to obtain hollow particle with a large hole.     

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.     

Preparation of monodisperse thermo-sensitive poly(N-isopropylacrylamide) hollow microcapsules

We successfully developed a novel and simple method for preparation of monodisperse thermo-sensitive poly(N-isopropylacrylamide) (PNIPAM) hollow microcapsules at the interface of water-in-oil (W/O) single emulsions at a temperature below the lower critical solution temperature (LCST) of PNIPAM. The prepared PNIPAM microcapsules are featured with hollow structures and thin membranes, high monodispersity, excellent reversible thermo-sensitivity and fast response to environmental temperature. This approach exhibits great interests in preparing monodisperse thermo-sensitive microcapsules for encapsulating bioactive materials or drugs requiring mild encapsulation conditions, because of the flexibility in choosing substances being dissolved in the aqueous phase. The preparation methodology demonstrated in this study provides a unique approach for preparing monodisperse hollow polymeric microcapsules with W/O single emulsions.     

Synthesis and characterization of crosslinked uniform polymeric microspheres containing a polyimide prepolymer by a new emulsification process

A highly crosslinked poly(styrene–divinyl benzene–trimethyolpropane trimethacrylate) microsphere containing a polyimide prepolymer (PIP) was prepared by a new emulsification method, Shirasu porous glass (SPG) membrane emulsification, and a subsequent radical suspension polymerization. That is, a mixture of styrene, divinyl benzene, trimethyol propane trimethacrylate (TMPTMA), and PIP containing an initiator was permeated through the uniform pores of the SPG membrane into a continuous phase containing a stabilizer to form uniform droplets. Then, the suspension polymerization was carried out at 65 °C for 24 h. The trifunctional crosslinker TMPTMA was added to enhance the destructive strength of the microsphere, and PIP was incorporated into the microsphere to provide an adhesion force by a known self‐curing reaction at 220 °C. The effects of the feed amounts of TMPTMA and PIP on the monomer conversion, size distribution, and destructive strength of the microsphere were investigated. The monomer conversion increased with an increase in TMPTMA. The particle size distribution became narrower as the TMPTMA feed amount increased, but it became broader with an increase in PIP. The destructive strength increased with increases in TMPTMA and PIP. After a heat treatment at 220 °C, the destructive strength decreased because of the heat degradation of the polymer. The addition of TMPTMA suppressed the heat degradation, and PIP could undergo self‐curing at 220 °C. The obtained highly crosslinked uniform microsphere containing PIP has potential applications in liquid‐crystal displays. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 2588–2598, 2003     

Microchannel emulsification using gelatin and surfactant-free coacervate microencapsulation

In this study, we investigated the use of microchannel (MC) emulsifications in producing monodisperse gelatin/acacia complex coacervate microcapsules of soybean oil. This is considered to be a novel method for preparing monodisperse O/W and W/O emulsions. Generally, surfactants are necessary for MC emulsification, but they can also inhibit the coacervation process. In this study, we investigated a surfactant-free system. First, MC emulsification using gelatin was compared with that using decaglycerol monolaurate. The results demonstrated the potential use of gelatin for MC emulsification. MC emulsification experiments conducted over a range of conditions revealed that the pH of the continuous phase should be maintained above the isoelectric point of the gelatin. A high concentration of gelatin was found to inhibit the production of irregular-sized droplets. Low-bloom gelatin was found to be suitable for obtaining monodisperse emulsions. Finally, surfactant-free monodisperse droplets prepared by MC emulsification were microencapsulated with coacervate. The microcapsules produced by this technique were observed with a confocal laser scanning microscope. Average diameters of the inner cores and outer shells were 37.8 and 51.5 microm; their relative standard deviations were 4.9 and 8.4%.     

Fabrication of nano-scale liposomes containing doxorubicin using Shirasu porous glass membrane

Nano-scale liposomes were successfully produced using a Shirasu porous glass (SPG) membrane emulsification technique. Primary liposomes prepared by a film-hydration method were treated using SPG membranes with different pore sizes (2.0, 1.0, 0.7, 0.5, and 0.2 μm) for control over the liposome size. The liposome sizes were evaluated using a dynamic light scattering method and their morphologies were observed by optical microscopy and transmission electron microscopy. As the passage number of liposomes through SPG membrane increased, the size and its distribution of the liposomes gradually decreased. A smaller pore size of the SPG membrane and a higher applied pressure resulted in liposomes with a smaller size. After the preparation of nano-scale liposomes containing ammonium sulfate (AS), doxorubicin (DOX) was encapsulated in the liposomes by a remote loading method, where AS served as a precipitant for DOX. The encapsulation efficiency of the DOX was maximized up to 94% when the concentrations of AS and DOX were 250 and 0.045 mM, respectively. We have obtained the release profiles of the liposomes with different sizes. As shown below, liposomes with smaller size exhibited a faster release profile of drug due to the large surface area. These nano-scale liposomes encapsulating an anti-cancer drug can potentially be employed as drug delivery vehicles for intravenous injection.     

Microbubble formation using asymmetric Shirasu porous glass (SPG) membranes and porous ceramic membranes—A comparative study

We have recently proposed a new method for generating uniformly sized microbubbles from Shirasu porous glass (SPG) membranes with a narrow pore size distribution. In this study, to obtain a high gas permeation rate through SPG membranes in microbubble formation process, asymmetric SPG membranes were used. At the transmembrane/bubble point pressure ratio of less than 1.50, uniformly sized microbubbles with a bubble/pore diameter ratio of approximately 9 were generated from an asymmetric SPG membrane with a mean pore diameter of 1.58 μm and a skin-layer thickness of 12 ± 2 μm at a gaseous-phase flux of 2.1–24.6 m³ m⁻² h⁻¹, which was much higher than that through a symmetric SPG membrane with the same pore diameter. This is mainly due to the much smaller membrane resistance of the asymmetric SPG membrane. Only 0.27–0.43% of the pores of the asymmetric SPG membrane was active under the same conditions. The proportion of active pores increased with a decrease in the thickness of skin layer. In contrast to the microbubble formation from asymmetric SPG membranes, polydispersed larger bubbles were generated from asymmetric porous ceramic membranes used in this study, due to the surface defects on the skin layer. The surface defects were observed by the scanning electron microscopy and detected by the bubble point method.     

Novel cationic pH-responsive poly(N,N-dimethylaminoethyl methacrylate) microcapsules prepared by a microfluidic technique

Novel monodisperse cationic pH-responsive microcapsules are successfully prepared using oil-in-water-in-oil double emulsions as templates by a microfluidic technique in this study. With the use of a double photo-initiation system and the adjustment of pH value of the monomer solution, cross-linked poly(N,N-dimethylaminoethyl methacrylate) (PDM) microcapsules with good sphericity and monodispersity can be effectively fabricated. The obtained microcapsule membranes swell at low pH due to the protonation of N(CH(3))(2) groups in the cross-linked PDM networks. The effects of various preparation parameters, such as pH of the aqueous monomer fluid, concentration of cross-linker, concentration of monomer N,N-dimethylaminoethyl methacrylate (DM) and addition of copolymeric monomer acrylamide (AAm), on the pH-responsive swelling characteristics of PDM microcapsules are systematically studied. The results show that, when the PDM microcapsules are prepared at high pH and with low cross-linking density and low DM monomer concentration, they exhibit high pH-responsive swelling ratios. The addition of AAm in the preparation decreases the swelling ratios of PDM microcapsules. The external temperature has hardly any influence on the swelling ratios of PDM microcapsules when the external pH is less than 7.4. The prepared PDM microcapsules with both biocompatibility and cationic pH-responsive properties are of great potential as drug delivery carriers for tumor therapy. Moreover, the fabrication methodology and results in this study provide valuable guidance for preparation of core-shell microcapsules via free radical polymerization based on synergistic effects of interfacial initiation and initiation in a confined space.     

Manufacture of large uniform droplets using rotating membrane emulsification

A new rotating membrane emulsification system using a stainless steel membrane with 100 microm laser drilled pores was used to produce oil/water emulsions consisting of 2 wt% Tween 20 as emulsifier, paraffin wax as dispersed oil phase and 0.01-0.25 wt% Carbomer (Carbopol ETD 2050) as stabilizer. The membrane tube, 1 cm in diameter, was rotated inside a stationary glass cylinder, diameter of 3 cm, at a constant speed in the range 50-1500 rpm. The oil phase was introduced inside the membrane tube and permeated through the porous wall moving radially into the continuous phase in the form of individual droplets. Increasing the membrane rotational speed increased the wall shear stress which resulted in a smaller average droplet diameter being produced. For a constant rotational speed, the average droplet diameter increased as the stabilizer content in the continuous phase was lowered. The optimal conditions for producing uniform emulsion droplets were a Carbomer content of 0.1-0.25 wt% and a membrane rotational speed of 350 rpm, under which the average droplet diameter was 105-107 microm and very narrow coefficients of variation of 4.8-4.9%. A model describing the operation is presented and it is concluded that the methodology holds potential as a manufacturing protocol for both coarse and fine droplets and capsules.     

Emulsification using micro porous glass (MPG): surface behaviour of milk proteins

To investigate the emulsifying properties and adsorption behaviour of high molecular amphiphilic substances such as proteins, it is important to maintain the native status of the used samples. The new method of micro porous glass (MPG) emulsification could offer an opportunity to do this because of the low shear forces. The oil-in-water emulsions were produced by dispersing the hydrophobic phase (liquid butter fat or sunflower oil) through the MPG of different average pore diameters (d_p=0.2 or 0.5 μm) into the flowing continuous phase containing the milk proteins (from reconstituted skim milk and buttermilk). The emulsions were characterised by particle size distribution, creaming behaviour and protein adsorption at the hydrophobic phase. The particle size distribution of protein-stabilised MPG emulsions is determined by the pore size of MPG, the velocity of continuous phase (or wall shear stress σ_w) and the transmembrane pressure. A high velocity of =2 m s⁻¹ (σ_w=13.4 Pa) and low pressure (pressure of disperse phase slightly exceeded the critical pressure Δp_TM=4.5 bar of 0.2 μm-MPG) led to the smallest droplet diameter. As a consequence of average droplet diameters of d₄₃>3.5 μm creaming was observed without centrifugation in all MPG emulsions after 24 h, but no coalescence of the oil droplets occurred. The study of protein adsorption showed that the MPG emulsification at low shear forces resulted in lower protein load values (2.5±0.5 mg m⁻²) than pressure emulsification (11.5±1.0 mg m⁻²). In addition, the various emulsification conditions (MPG or pressure homogenization) led to differences in the relative proportions of casein fractions, whey proteins and milk fat globule membranes (MFGM) at the fat globule surfaces.