PolyHIPEs: Recent advances in emulsion-templated porous polymers

Porous scaffolds with the structure of an interpenetrating polymer network made by gelatin methacrylated nanoparticle-stabilized high internal phase emulsion polymerization targeted for tissue engineering

The interlacing of biopolymers and synthetic polymers is a promising strategy to fabricate hydrogel-based tissue scaffolds to biomimic a natural extracellular matrix for cell growth. Herein, open-cellular macroporous 3D scaffolds with a semi-interpenetrating network were fabricated through high internal phase emulsion templating. The scaffolds are prepared by (I) the curing of PEG diacrylate (PEGDAC) and gelatin methacrylate (GelMA) in the continuous aquatic phase of a coconut oil-in-water emulsion stabilized by GelMA nanoparticles, and (II) the removal of the internal phase. The effect of the main contributing parameters such as pH, GelMA content, and GelMA/PEGDAC weight ratio on the emulsion features was investigated systematically. Due to the isoelectric point of GelMA at around pH 6, the GelMA particle (aggregation) size decreased at both sides of pH from 1000 to 100–140 nm because of the increased number of positive and negative charges on GelMA. These GelMA nanoparticles were able to produce stable emulsions with narrowly distributed small emulsion droplets. Moreover, the stability and emulsion droplet size were enhanced and increased, respectively, with GelMA content increasing and GelMA/PEGDAC weight ratio decreasing. These trends lie in the prevented coalescence phenomenon caused by the improved viscosity and likely partially formed network by GelMA chains in the continuous phase. Hence, the following formulation was selected for scaffold preparation: φ_oil = 74%, pH = 12, GeMA = 4 wt%, and GelMA/PEGDAC = 10/8. Then, PCL in different contents was infiltrated into the scaffold to balance hydrophilicity and hydrophobicity. The cell culture assay proved that the scaffold with a pore size of 60–180 μm and containing 51.2 wt% GelMA, 10.3 wt% PEG, and PCL 27.2 wt% provided a suitable microenvironment for mouse fibroblast cell (L929) adhesion, growth, and spreading. These results show that this strategy suggests promising culture for tissue engineering applications.

The interlacing of biopolymers and synthetic polymers is a promising strategy to fabricate hydrogel-based tissue scaffolds to biomimic a natural extracellular matrix for cell growth.

Fabrication and application of a MIL-68(In)-NH2 incorporated high internal phase emulsion polymeric monolith as a solid phase extraction adsorbent in triazine herbicide residue analysis

In this work, a metal–organic framework MIL-68(In)–NH₂ incorporated high internal phase emulsion polymeric monolith (MIL-68(In)–NH₂/polyHIPE) was prepared and applied as a solid phase extraction adsorbent for the extraction and detection of trace triazine herbicides in environmental water samples by coupling with HPLC-UV detection. The fabricated material showed good adsorption for simazine, prometryn, and prometon in water samples because of π–π interactions and hydrogen bonding interactions. Under optimal conditions, the maximum adsorption capacity of simazine, prometon and prometryn was 800 μg g⁻¹, 800 μg g⁻¹ and 6.01 mg g⁻¹, respectively. The linearities were 10–800 ng mL⁻¹ for simazine, prometon and prometryn. The limits of detection were 31–97 ng L⁻¹, and the recoveries were 85.6–118.2% at four spiked levels with relative standard deviations lower than 5.0%. The method has a high sensitivity for the determination of three triazine herbicides in environmental water samples.

MIL-68(In)–NH₂ incorporated high internal phase emulsion polymeric monoliths were fabricated and applied to extract and determine triazine herbicide residues in environmental water samples.

Porous Polymers from High Internal Phase Emulsions as Scaffolds for Biological Applications

High internal phase emulsions (HIPEs), with densely packed droplets of internal phase and monomers dispersed in the continuous phase, are now an established medium for porous polymer preparation (polyHIPEs). The ability to influence the pore size and interconnectivity, together with the process scalability and a wide spectrum of possible chemistries are important advantages of polyHIPEs. In this review, the focus on the biomedical applications of polyHIPEs is emphasised, in particular the applications of polyHIPEs as scaffolds/supports for biological cell growth, proliferation and tissue (re)generation. An overview of the polyHIPE preparation methodology is given and possibilities of morphology tuning are outlined. In the continuation, polyHIPEs with different chemistries and their interaction with biological systems are described. A further focus is given to combined techniques and advanced applications.

Emulsion templating: Unexpected morphology of monodisperse macroporous polymers

HYPOTHESIS

We synthesised monodisperse macroporous polymers via polymerisation of water-in-monomer droplet emulsions and obtained non-spherical pores with layered pore walls. We hypothesise that this morphology is caused by surfactant diffusion and phase separation during polymerisation.

EXPERIMENTS

We varied the surfactant mass fraction of the emulsions and polymerised the templates with a water-soluble initiator. From the resulting macroporous polymers we determined the shape of the pores and thickness of the layers via scanning election microscopy. The response of the monomer/surfactant mixture to polymerisation was studied by a ternary phase diagram that simulated polymerisation.

FINDINGS

The emergence of non-spherical pores with layered pore walls is indeed caused by surfactant diffusion and phase separation. During polymerisation the surfactant molecules diffuse either to the water/monomer interface or deeper into the continuous monomer phase. The first process results in non-spherical pores, while the second process generates layered pore walls.

Porous polycaprolactone and polycarbonate poly(urethane urea)s via emulsion templating: structures, properties, cell growth

Macroporous, emulsion-templated, linear poly(urethane urea) elastomers were synthesized from polyols (poly(ε-caprolactone)s or polycarbonates) and a diisocyanate. Growing cells adhered to the walls, spread, and penetrated into the porous structures.

Polydimethylsiloxane nanocomposite macroporous films prepared via Pickering high internal phase emulsions as effective dielectrics for enhancing the performance of triboelectric nanogenerators

Polydimethylsiloxane (PDMS) nanocomposite (NC) macroporous films were prepared by a Pickering high internal phase emulsion (HIPE) templating technique and used as effective dielectrics for enhancing the performance of triboelectric-nanogenerators (TENGs). HIPEs were formulated using commercial PDMS and water as the continuous and dispersed phase, respectively. The formation and solidification of PDMS-based HIPEs were possible through stabilization with silver-nanoparticles (Ag-Nps) and surfactant (Span 20) mixtures. The resulting PDMS-NC-polyHIPE films presented an interconnected 3D macroporous structure with Ag-Nps on their porous surface. The addition of different amounts of Ag-Nps (0, 4, 20, 28, 36 wt%) in HIPE formulations allowed modification of the pore size, total pore volume and dielectric properties of the tribo-materials. Results revealed that both the porosity and dielectric properties of these materials play an important role in enhancing the output performance of TENGs. Thus, the best TENG based on the PDMS-NC-polyHIPE film was achieved with 20 wt% of Ag-Nps, with voltage, current and power values of 4.88 V, 0.433 μA and 2.1 μW, respectively, which gives over 3.28-fold power enhancement compared with the reference TENG (based on a PDMS film without porosity or Ag-Nps). Therefore, the preparation of tribo-materials through a Pickering HIPE templating technique provides a novel, effective and easy way for the improvement of the TENG's performance.

Collapse and cavitation during the drying of water-saturated PDMS sponges with closed porosity

In this paper, we study the drying of water-saturated porous polydimethylsiloxane (PDMS) elastomers with closed porosity in which the evaporation of water is possible only via the diffusion across PDMS. Starting from water/PDMS emulsions, we fabricate soft macroporous samples with different pore diameter distributions and average diameters ranging from 10 to 300 μm. In these materials, the drying may lead to either a collapsed state with low porosity or the cavitation and reopening of a fraction of the pores. Using optical microscopy and porosity measurements, we showed the influence of the pore diameters and interactions on the result of drying. At pore diameters lower than 30 μm, the majority of pores remain collapsed. We attribute the permanence of the collapse of most small pores to a low probability of cavitation and to the adhesion of the pore walls. Pores with diameters larger than 100 μm reopen via cavitation of the water they contain. The behavior of pores with diameters ranging from 30 to 100 μm depends on the porosity and drying temperature. We also visualize collective cavitation upon the drying of sponges initially saturated with sodium chloride solution. In this case, the cavitation in the largest pores leads to the reopening of small pores in a neighboring zone of the sample. To our knowledge, our results present the first experimental proof of the pore-size-dependent and cooperative nature of the response of soft sponges with closed porosity to drying.

Skin-Like Stretchable Fuel Cell Based on Gold-Nanowire-Impregnated Porous Polymer Scaffolds

Skin-like energy devices can be conformally attached to the human body, which are highly desirable to power soft wearable electronics in the future. Here, a skin-like stretchable fuel cell based on ultrathin gold nanowires (AuNWs) and polymerized high internal phase emulsions (polyHIPEs) scaffolds is demonstrated. The polyHIPEs can offer a high porosity of 80% yet with an overall thickness comparable to human skin. Upon impregnation with electronic inks containing ultrathin (2 nm in diameter) and ultrahigh aspect-ratio (>10 000) gold nanowires, skin-like strain-insensitive stretchable electrodes are successfully fabricated. With such designed strain-insensitive electrodes, a stretchable fuel cell is fabricated by using AuNWs@polyHIPEs, platinum (Pt)-modified AuNWs@polyHIPEs, and ethanol as the anode, cathode, and fuel, respectively. The resulting epidermal fuel cell can be patterned and transferred onto skin as "tattoos" yet can offer a high power density of 280 µW cm^-2 and a high durability (>90% performance retention under stretching, compression, and twisting). The results presented here demonstrate that this skin-thin, porous, yet stretchable electrode is essentially multifunctional, simultaneously serving as a current collector, an electrocatalyst, and a fuel host, indicating potential applications to power future soft wearable 2.0 electronics for remote healthcare and soft robotics.

Recent advances in separation applications of polymerized high internal phase emulsions

Polymerized high internal phase emulsions as highly porous adsorption materials have received increasing attention and wide applications in separation science in recent years due to their remarkable merits such as highly interconnected porosity, high permeability, good thermal and chemical stability, and tailorable chemistry. In this review, we attempt to introduce some strategies to utilize polymerized high internal phase emulsions for separation science, and highlight the recent advances made in the applications of polymerized high internal phase emulsions for diverse separation of small organic molecules, carbon dioxide, metal ions, proteins, and other interesting targets. Potential challenges and future perspectives for polymerized high internal phase emulsion research in the field of separation science are also speculated at the end of this review.

Hierarchically Engineered Nanocarbon Florets as Bifunctional Electrode Materials for Adsorptive and Intercalative Energy Storage

Three-dimensional dendritic nanostructured carbon florets (NCFs) with tailored porosity are demonstrated as electrochemically versatile electrodes for both adsorptive and intercalative energy storage pathways. Achieved through a single-step template-driven approach, the NCFs exhibit turbostratic graphitic lamellae in a floral assembly leading to high specific surface area and multi-modal pore distribution (920 m²/g). The synergism in structural and chemical frameworks, along with open-ended morphology, enables bifunctionality of hard carbon NCFs as symmetric adsorptive electrodes for supercapacitors (SCs) and intercalation anodes for hybrid potassium-ion capacitors (KICs). Flexible, all-solid-state SCs through facile integration of NCF with the ionic-liquid-imbibed porous polymeric matrix achieve high-energy density (20 W h/kg) and power density (32.7 kW/kg) without compromising on mechanical flexibility and cyclability (94% after 20k cycles). Furthermore, NCF as an anode in a full-cell hybrid KIC (activated carbon as cathode) delivers excellent electrochemical performance with maximum energy and power densities of 57 W h/kg and 12.5 kW/kg, respectively, when cycled in a potential window of 1.0-4.0 V. The exceptional bifunctional performance of NCF highlights the possibility of utilizing such engineered nanocarbons for high-performance energy storage devices.

Basic Principles of Emulsion Templating and Its Use as an Emerging Manufacturing Method of Tissue Engineering Scaffolds

Tissue engineering (TE) aims to regenerate critical size defects, which cannot heal naturally, by using highly porous matrices called TE scaffolds made of biocompatible and biodegradable materials. There are various manufacturing techniques commonly used to fabricate TE scaffolds. However, in most cases, they do not provide materials with a highly interconnected pore design. Thus, emulsion templating is a promising and convenient route for the fabrication of matrices with up to 99% porosity and high interconnectivity. These matrices have been used for various application areas for decades. Although this polymer structuring technique is older than TE itself, the use of polymerised internal phase emulsions (PolyHIPEs) in TE is relatively new compared to other scaffold manufacturing techniques. It is likely because it requires a multidisciplinary background including materials science, chemistry and TE although producing emulsion templated scaffolds is practically simple. To date, a number of excellent reviews on emulsion templating have been published by the pioneers in this field in order to explain the chemistry behind this technique and potential areas of use of the emulsion templated structures. This particular review focusses on the key points of how emulsion templated scaffolds can be fabricated for different TE applications. Accordingly, we first explain the basics of emulsion templating and characteristics of PolyHIPE scaffolds. Then, we discuss the role of each ingredient in the emulsion and the impact of the compositional changes and process conditions on the characteristics of PolyHIPEs. Afterward, current fabrication methods of biocompatible PolyHIPE scaffolds and polymerisation routes are detailed, and the functionalisation strategies that can be used to improve the biological activity of PolyHIPE scaffolds are discussed. Finally, the applications of PolyHIPEs on soft and hard TE as well as in vitro models and drug delivery in the literature are summarised.

Fabrication of hierarchically porous superhydrophilic polycaprolactone monolith based on nonsolvent-thermally induced phase separation

Monoliths with a continuous porous structure are of great interest due to high transfer efficiency and large surface area in environmental and tissue engineering fields. This study demonstrated a facile method to prepare PCL monoliths with hierarchically porous structure by nonsolvent-thermally induced phase separation. A suitable mixed solvent mixture using ethanol as nonsolvent reduced the amount of dioxane and provided PCL monoliths with three levels of structures. The monolith structure was easily controlled by changing the fabrication parameters, such as the nonsolvent, the temperature of phase separation, the concentration of the PCL. Finally, the superhydrophilic monolith was easily obtained by polydopamine surface modification. The easy way of fabrication of a hierarchically porous PCL monolith with superhydrophilicity will find applications such as in tissue engineering and purification.

Tailoring the morphology of poly(high internal phase emulsions) synthesized by using deep eutectic solvents

High internal phase emulsions (HIPEs) are among complex biphasic fluids that expand on the traditional emulsion compositions, for instance, for the preparation of macroporous polymers by emulsion templating. The use of deep eutectic solvents (DESs) as the nonaqueous internal phase of HIPEs allows expanding the conditions at which polymerizations are typically carried out in aqueous HIPEs. Herein, the properties of polystyrene macroporous polymers were studied by polymerizing DES-in-oil HIPEs using choline chloride-based DESs as the internal phase. The effect of DESs’ composition – with amide, alcohol, and carboxylic acid as hydrogen bond donors – and the homogenization method used for the HIPE preparation – vortexing versus high-speed homogenizer – was studied. The stability and droplet size of HIPE precursor, as well as the macroporous structure and the mechanical properties of the synthesized polyHIPEs, are discussed.

Ultralight Aerogels with Hierarchical Porous Structures Prepared from Cellulose Nanocrystal Stabilized Pickering High Internal Phase Emulsions

Cellulose nanocrystal (CNC)-based aerogels with extremely low density and hierarchical porous structure were constructed via a facile Pickering-emulsion-templated strategy. In this method, aminated CNCs (CNC-NH₂) were synthesized to stabilize o/w Pickering high internal phase emulsions (Pickering HIPEs). Amino groups were introduced to CNCs to decrease the net surface charges of CNCs, enhance their aggregation, and therefore achieve Pickering HIPEs stabilized by the particles of ultralow content (∼0.1 wt %). A series of CNC aerogels was then obtained by freeze drying these emulsions. The resulting aerogels were ultralight with a density that reached ca. 0.5 mg/cm³ (an order of magnitude lower than that previously reported for CNC aerogels) and an ultrahigh porosity (up to 99.969%). Contributed to the extremely low density, the thermal conductivity of the aerogels was around 0.021 W/(m·K) which is lower than that of air (0.024 W/(m·K)). This novel strategy could be applied to other materials, such as graphene and carbon nanotubes, to prepare ultralight aerogels with controllable porous structures and unique properties.

A Sacrificial Route for Soft Porous Polymers Synthesized via Frontal Photo-Polymerization

Within the very large range of porous polymers and a related immense scope of applications, we investigate here a specific route to design soft porous polymers with controlled porosity: we use aqueous-based formulations of oligomers with mineral particles which are solidified into a hydrogel upon photo-polymerization; the embedded particles are then chemically etched and the hydrogel is dried to end up with a soft porous polymeric scaffold with micron-scale porosity. Morphological and physical features of the porous polymers are measured and we demonstrate that the porosity of the final material is primarily determined by the amount of initially dispersed sacrificial particles. In addition, the liquid formulations we use to start with are convenient for a variety of material forming techniques such as microfluidics, embossing, etc., which lead to many different morphologies (monoliths, spherical particles, patterned substrates) based on the same initial material.

Zeolite Nanocrystals Embedded in Microcellular Carbon Foam as a High-Performance CO2 Capture Adsorbent with Energy-Saving Regeneration Properties

Here, the facile synthesis of four-length-scaled (ultramicro-micro-meso-macroporous) hierarchically structured porous carbon nanocomposite by an emulsion-template strategy is reported. This previously unreported combination of zeolite nanocrystals embedded in the walls of microcellular carbon foams gives unique textural and structural properties, which result in their excellent ability to selectively capture CO₂ owing to the presence of ultra-micropores. The zeolite-microcellular carbon foam synergism delivers an adsorbent with a significantly enhanced CO₂ capture capacity of up to 5 mmol g^-1 , CO₂ /N₂ selectivity of up to 80, and an outstanding multi-cycle capture performance under humid conditions (70 % performance retention after 30 regeneration cycles). More impressively, the electrically conductive carbon framework enables Joule heating and cooling, and thus fast and energy-efficient regeneration is possible, with an estimated energy consumption of only about 12 kWh.