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A moisture-sensitive diisocyanate liquid is microencapsulated within a metal shell measuring less than 2 μm thick and 50 μm in diameter. This mild synthesis takes place through a series aqueous processing steps that occur at or near room temperature. Through a combination of emulsification, interfacial polymerization, and electroless plating, one can microencapsulate moisture- or air-sensitive chemicals within a metal seal. The liquid-filled metal microcapsules promise a number of advantages compared to conventional polymeric microencapsulation, including improved mechanical properties and improved barrier properties to gases and organic molecules.

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Microencapsulation technology has been increasingly applied toward the development of self-healing paints. Added to paint as a dry powder prior to spraying, the microcapsules store a liquid that can repair the protective barrier layer if released into a scratch. However, self-healing will not occur unless the microcapsules can withstand spray-painting, aggressive solvents in the paint, and long-term exposure to the elements. We have therefore developed a one-pot synthesis for the production of Pickering microcapsules with outstanding strength, solvent resistance, and barrier properties. Octadecyltrimethoxysilane-filled (OTS) microcapsules form via standard interfacial polycondensation, except that silica nanopowder (10-20 nm diameter) replaces the conventional surfactant or hydrocolloid emulsifier. Isophorone diisocyanate (IPDI) in the OTS core reacts with diethylenetriamine, polyethylenimine, and water to form a hard polymer shell along the interface. Compared to pure polyurea, the silica-polyurea composite improves the shelf life of the OTS by 10 times. The addition of SiO2 prevents leaching of OTS into xylenes and hexanes for up to 80 days, and the resulting microcapsules survive nebulization through a spray gun at 620 kPa in a 500 cSt fluid.

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