Synthesis of spherical microcapsules by photopolymerization in aerosols

Formation of multilayered biopolymer microcapsules and microparticles in a multiphase microfluidic flow

This paper reports the development of a scalable continuous microfluidic-based method for the preparation of multilayered biopolymer microcapsules and microparticles, with a size range of 1 to 100 μm, in a single-layered polydimethylsiloxane-based device. This new approach has been utilised to produce polyethylene oxide (PEO)-based microparticles, layered with subsequent stage wise coatings of polylactide-based block copolymers and polyvinylpyrrolidone. The production process was shown to allow for on-chip encapsulation of protein and vitamin molecules in the biopolymer micro particles, without any further handling after collection from the device. We have studied the release profiles in the case of model molecules of distinctive molecular weights, namely, vitronectin, horse radish peroxidase, and vitamin B(12). We compared the release properties of the microparticles to those from macro-gels of the same materials prepared off-chip. The results indicated that the microparticles have definitively different molecular weight cut-off characteristics, likely due to a denser microstructure within the microparticles compared to the bulk hydrogels. This difference suggests that significant benefits may exist in the use of this method to produce layered biopolymer microparticles in achieving improved controlled release and encapsulation.

Biopolymer microparticle and nanoparticle formation within a microfluidic device

This paper reports a novel microfluidic method for the production of cross-linked alginate microparticles and nanoparticles. We describe a continuous process relying on both thermodynamic and hydrodynamic factors to form microdroplets. A rapid cross-linking reaction thereafter allows solidification of the polymer droplets either within the microfluidic device or "off-chip" to form alginate micro- and nanoparticles. Monodisperse droplets are generated by extruding an aqueous alginate solution using an axisymmetric flow-focusing design. As they flow downstream in the channel, due to water and the continuous phase being partially miscible, the water diffuses very slowly out of the polymeric droplets into the transport fluid, which causes the shrinkage of the drops and the condensation of the polymer phase. The resulting size of the solid particles depends on the polymer concentration and the ensuing balance between the kinetics of the cross-linking reaction and the volume loss due to solvent diffusion. This work details both a single-step microfluidic technique for the formation of alginate microparticles of sizes ranging from 1 to 50 microm via near-equilibrium solvent diffusion within a microfluidic device and thereafter a two-step method, which was shown to generate biopolymer nanoparticles of sizes ranging from 10 to 300 nm. These novel methodologies are extremely flexible and can be extended to the preparation of micro- and nanoparticles from a wide range of single or mixed synthetic and biologically derived polymers.

Preparation of Poly(methylmethacrylate) Microcapsules with Liquid Cores

Particles with liquid cores and solid shells have been prepared by the controlled phase separation of poly(methylmethacrylate) (PMMA) within the droplets of an oil-in-water emulsion. The oil phase of the emulsion contained poly(methylmethacrylate), a good solvent for the polymer (CH2Cl2), a poor solvent (hexadecane, decane, octanol, or tetrachloromethane), and in some cases acetone (a water soluble co-solvent) to aid emulsification. Emulsions were prepared using a Silverson high-speed stirrer, and the droplet size distributions were determined using a Coulter particle counter. Size distributions were found to be dependent on the nature of the emulsifier, the concentration of acetone in the oil phase, and the concentration of polymer in the oil phase. The good solvent was then removed under reduced pressure, causing the poly(methylmethacrylate) to phase separate within the emulsion droplets. The resultant two-phase particles were characterized by optical microscopy and scanning electron microscopy. Particle morphologies depended strongly on the nature of the non-solvent and also the emulsifier employed. Spreading coefficients were calculated from interfacial tension and contact angle measurements, and were used to account for the morphologies observed. Core/shell microcapsules were formed when hexadecane or decane was used as non-solvent, and only when polymeric emulsifiers were employed. All other combinations yielded "acorn"-shaped particles. The thickness of microcapsule walls was found to be a constant fraction of the overall capsule diameter for all microcapsule sizes and depended, as expected, on the concentration of polymer in the oil phase. Copyright 1998 Academic Press.