We investigate the impact of ternary phase behavior on the microstructure of porous polymer particles produced by solvent extraction of polymer solution droplets by a nonsolvent. Microfluidic devices fabricated by frontal photopolymerization are employed to produce monodisperse polymer (P)/solvent (S) droplets suspended in a carrier (C) phase before inducing solvent extraction by precipitation in a nonsolvent (NS) bath. Model systems of sodium poly(styrenesulfonate) (P), water (S), hexadecane (C), and either methyl ethyl ketone (MEK) or ethyl acetate (EA) as NS are selected. Extraction across the liquid-liquid interface results in a decrease in the droplet radius and also an ingress of nonsolvent, leading to droplet phase demixing and coarsening. As the concentration of the polymer-rich phase increases, droplet shrinkage and solvent exchange slow down and eventually cease, resulting in microporous polymer particles (of radius ≃50-200 μm) with a smooth surface. The internal structure of these capsules, with pore sizes of ≃1-100 μm, is found to be controlled by polymer solution thermodynamics and the extraction pathway. The ternary phase diagrams are measured by turbidimetry, and the kinetics of phase separation is estimated by stopped-flow small-angle neutron scattering. The higher solubility of water in MEK results in faster particle-formation kinetics than in EA. Surprisingly, however, the lower polymer miscibility with EA/water results in a deeper quench inside the phase boundary and small phase sizes, thus yielding particles with small pores (of narrow distribution). The effects of droplet size, polymer content, and nonsolvent quality provide comprehensive insight into porous particle and capsule formation by phase inversion, with a range of practical applications.

Nanocomposite microcapsules with bicontinuous internal morphology release nanoparticles in directional bursts.

Monolayers of ligand-grafted nanoparticles at fluid interfaces exhibit a complex response to deformation due to an interplay of particle rearrangements within the monolayer, and molecular rearrangements of the ligand brush on the surface of the particles. We use grazing-incidence small-angle X-ray scattering (GISAXS) combined with pendant drop tensiometry to probe in situ the dynamic organization of ligand-grafted nanoparticles upon adsorption at a fluid–fluid interface, and during monolayer compression. Through the simultaneous measurements of interparticle distance, obtained from GISAXS, and of surface pressure, obtained from pendant drop tensiometry, we link the interfacial stress to the monolayer microstructure. The results indicate that, during adsorption, the nanoparticles form rafts that grow while the interparticle distance remains constant. For small-amplitude, slow compression of the monolayer, the evolution of the interparticle distance bears a signature of ligand rearrangements leading to a local decrease in thickness of the ligand brush. For large-amplitude compression, the surface pressure is found to be strongly dependent on the rate of compression. Two-dimensional Brownian dynamics simulations show that the rate-dependent features are not due to jamming of the monolayer, and suggest that they may be due to out-of-plane reorganization of the particles (for instance expulsion or buckling). The corresponding GISAXS patterns are also consistent with out-of-plane reorganization of the nanoparticles.

We report the formation of polymeric and nanocomposite capsules via droplet solvent extraction, elucidating the interplay between solvent exchange and removal, demixing and directional solidification kinetics.

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