A continuous approach to the emulsion gelation method for the production of aerogel micro-particle

Brownian motion of droplets induced by thermal noise

Brownian motion (BM) is pivotal in natural science for the stochastic motion of microscopic droplets. In this study, we investigate BM driven by thermal composition noise at submicro scales, where intermolecular diffusion and surface tension both are significant. To address BM of microscopic droplets, we develop two stochastic multiphase-field models coupled with the full Navier-Stokes equation, namely, Allen-Cahn-Navier-Stokes and Cahn-Hilliard-Navier-Stokes. Both models are validated against capillary-wave theory; the Einstein's relation for the Brownian coefficient D^{*}∼k_{B}T/r at thermodynamic equilibrium is recovered. Moreover, by adjusting the co-action of the diffusion, Marangoni effect, and viscous friction, two nonequilibrium phenomena are observed. (I) The droplet motion transits from the Brownian to Ballistic with increasing Marangoni effect which is emanated from the energy dissipation mechanism distinct from the conventional fluctuation-dissipation theorem. (II) The deterministic droplet motion is triggered by the noise induced nonuniform velocity field which leads to a novel droplet coalescence mechanism associated with the thermal noise.

Hybrid and Single-Component Flexible Aerogels for Biomedical Applications: A Review

The inherent disadvantages of traditional non-flexible aerogels, such as high fragility and moisture sensitivity, severely restrict their applications. To address these issues and make the aerogels efficient, especially for advanced medical applications, different techniques have been used to incorporate flexibility in aerogel materials. In recent years, a great boom in flexible aerogels has been observed, which has enabled them to be used in high-tech biomedical applications. The current study comprises a comprehensive review of the preparation techniques of pure polymeric-based hybrid and single-component aerogels and their use in biomedical applications. The biomedical applications of these hybrid aerogels will also be reviewed and discussed, where the flexible polymeric components in the aerogels provide the main contribution. The combination of highly controlled porosity, large internal surfaces, flexibility, and the ability to conform into 3D interconnected structures support versatile properties, which are required for numerous potential medical applications such as tissue engineering; drug delivery reservoir systems; biomedical implants like heart stents, pacemakers, and artificial heart valves; disease diagnosis; and the development of antibacterial materials. The present review also explores the different mechanical, chemical, and physical properties in numerical values, which are most wanted for the fabrication of different materials used in the biomedical fields.

Macroporous Polyimide Aerogels: A Comparison between Powder Microparticles Synthesized via Wet Gel Grinding and Emulsion Processes

It is noteworthy to mention that synthesizing the polyimide aerogel powder, which is carried out in this study, benefits from two advantages: (i) the powder particles can be used for some specific applications where the monolith is not suitable and (ii) there is a possibility to investigate how a polyimide aerogel monolith can be made through the polyimide powder to reduce its cost and cycle time. In this study, two straightforward methods, wet gel grinding and emulsion, are introduced to prepare polyimide aerogel powders using ambient pressure drying. The microscopic properties of interest, including skeletal and porous structures, microparticle size and assembly, combined with macroscopic properties such as thermal stabilities and conductivities (0.039 W/m·K), confirm that the fabricated microparticles with a size in the range of 7-20 μm and porosity in the range of 65-85% are thermally stable up to 500 °C.

Development of Regular Hydrophobic Silica Aerogel Microspheres for Efficient Oil Adsorption

The objective of this research was to develop new hydrophobic silica aerogel microspheres (HSAMs) with water glass and hexmethyldisilazane for oil adsorption. The effects of the hexmethyldisilazane concentration and drying method on the structure and organic liquid adsorption capacity were investigated. The hexmethyldisilazane concentration of the modification solution did not influence the microstructure and pore structure in a noteworthy manner, which depended more on the drying method. Vacuum drying led to more volume shrinkage of the silica gel microsphere (SGM) than supercritical CO₂ drying, thus resulting in a larger apparent density, lower pore volume, narrower pore size distribution, and more compact network. Owing to the large pore volume and pore size, the HSAMs synthesized via supercritical CO₂ drying had a larger organic liquid adsorption capacity. The adsorption capacities of the HSAMs with pore volumes of 4.04-6.44 cm³/g for colza oil, vacuum pump oil, and hexane are up to 18.3, 18.9, and 11.8 g/g, respectively, higher than for their state-of-the-art counterparts. The new sorbent preparation method is facile, cost-effective, safe, and ecofriendly, and the resulting HSAMs are exceptional in capacity, stability, and regenerability.

Auto-Continuous Synthesis of Robust and Hydrophobic Silica Aerogel Microspheres from Low-Cost Aqueous Sodium Silicate for Fast Dynamic Organics Removal

An efficient auto-continuous globing process was developed with a self-built apparatus to synthesize pure silica aerogel microspheres (PSAMs) using sodium silicate as a precursor and water as a solvent. A hydrophobic silica aerogel microsphere (HSAM) was obtained by methyl grafting. A reinforced silica aerogel microsphere (RSAM) was prepared by polymer cross-linking on the framework of the silica gel. The pH value of the reaction system and the temperature of the coagulating bath were critical to form perfect SAMs with a diameter of 3.0 ± 0.2 mm. The grafted methyl groups are thermally stable up to 400 °C. Polymer cross-linking increased the strength significantly, owing to the polymer coating on the framework of silica aerogel. The pore volumes of HSAM (6.44 cm³/g) and RSAM (3.17 cm³/g) were much higher than their state-of-the-art counterparts. Their specific surface areas were also at a high level. The HSAM and RSAM showed high organic sorption capacities, i.e., 17.9 g/g of pump oil, 11.8 g/g of hexane, and 22.2 mg/g of 10 mg/L methyl orange. The novel preparation method was facile, cost-effective, safe, and eco-friendly, and the resulting SAM sorbents were exceptional in capacity, dynamics, regenerability, and stability.

Processing of aerogels and their applications toward CO2 adsorption and electrochemical reduction: a review

Aerogels are a unique class of nanoporous ultralight materials exhibiting wide range of textural characteristic properties and tunable porosities. Due to their remarkable features such as low density, high surface area, low refractive index, small thermal conductivity, low dielectric constant and low sound velocity, they exhibit a wide range of applications in different areas such as electronics, thermal and acoustic insulation, chemistry, biomedicine and optics. The special advantages of these materials are that they can be produced in different forms such as monoliths/granular, bead/microspheres, thin films or sheets and as blankets. Aerogels are found to be potential materials for the removal of CO₂ through adsorption or electrochemical reduction. There is a plethora of research on different kinds of aerogels used for CO₂ adsorption process. Research has been going on toward the development of aerogel-based electrocatalyst, which can be used for valorization of CO₂ through electrochemical reduction methods. Although most of the review papers have covered applications of aerogels in CO₂ capture, very few discuss the processing of aerogels, more so on their applications in CO₂ valorization. In this review, we have collated literature of different forms of aerogels currently available and the steps involved in their fabrication process. In addition, we have covered applications of aerogels in CO₂ capture. Furthermore, we focussed on the basic principles involved in the development of an aerogel electrocatalyst as well as recent developments of aerogels in electrochemical CO₂ reduction.

Effect of Process Conditions on the Properties of Resorcinol-Formaldehyde Aerogel Microparticles Produced via Emulsion-Gelation Method

Organic aerogels in the form of powder, microgranules and microsized particles receive considerable attention due to their easy fabrication, low process time and costs compared to their monolithic form. Here, we developed resorcinol-formaldehyde (RF) aerogel microparticles by using an emulsion-gelation method. The main objective of this study is to investigate the influence of curing time, stirring rate, RF sol:oil ratio and initial pH of the sol in order to control the size and properties of the microparticles produced. The emulsion-gelation of RF sol prepared with sodium carbonate catalyst in an oil phase at 60 °C was explored. RF microparticles were washed with ethanol to remove the oil phase followed by supercritical and ambient pressure drying. The properties of the dried RF microparticles were analyzed using FT-IR, N₂ adsorption isotherm, gas pycnometry, wide angle X-ray scattering and scanning electron microscope. RF microparticles with high surface area up to 543 m²/g and large pore volume of 1.75 cm³/g with particle sizes ranging from 50–425 µm were obtained.

Pulmonary drug delivery with aerogels: engineering of alginate and alginate-hyaluronic acid microspheres

In this study, the aerogel technology was used to prepare pulmonary drug carriers consisting of alginate and alginate-hyaluronic acid by an emulsion gelation technique and supercritical CO₂ drying. During the preparation process, the emulsification rate and inner phase viscosity were varied to control the diameter of aerogel microspheres. Results showed that the aerogel microspheres were highly porous (porosity > 98%) with low densities in the range between 0.0087 and 0.0634 g/cm³ as well as high surface areas between 354 and 759 m²/g. The obtained microspheres showed aerodynamic diameter below 5 µm making them suitable for pulmonary drug delivery. An in vitro drug release study with the model drug sodium naproxen was conducted and a non-Fickian drug release mechanism was observed, with no significant difference between the release profiles of alginate and alginate-hyaluronic acid microspheres. During the emulsion gelation step, the feasibility of using the capillary number to estimate the largest stable droplet size in the emulsions was also studied and it was found that using this number, the droplet size in the emulsions may well be predicted.

Aerogels in drug delivery: From design to application

Aerogels are the lightest processed solid materials on Earth and with the largest empty volume fraction in their structure. Composition versatility, modularity, and feasibility of industrial scale manufacturing are behind the fast emergence of aerogels in the drug delivery field. Compared to other 3D materials, the high porosity (interconnected mesopores) and high specific surface area of aerogels may allow faster loading of small-molecule drugs, less constrained access to inner regions of the matrix, and more efficient interactions of the biological milieu with the polymer matrix. Processing in supercritical CO₂ medium for both aerogel production (drying) and drug loading (impregnation) has remarkable advantages such as absence of an oxidizing environment, clean manufacture, and easiness for the scale-up under good manufacturing practices. The aerogel solid skeleton dictates the chemical affinity to the different drugs, which in turn determines the loading efficiency and the release pattern. Aerogels can be used to increase the solubility of BCS Class II and IV drugs because the drug can be deposited in amorphous state onto the large surface area of the skeleton, which facilitates a rapid contact with the body fluids, dissolution, and release. Conversely, tuning the aerogel structure by functionalization with drug-binding moieties or stimuli-responsive components, application of coatings and incorporation of drug-loaded aerogels into other matrices may enable site-specific, stimuli-responsive, or prolonged drug release. The present review deals with last decade advances in aerogels for drug delivery. An special focus is paid first on the loading efficiency of active ingredients and release kinetics under biorelevant conditions. Subsequent sections deal with aerogels intended to address specific therapeutic demands. In addition to oral delivery, the physical properties of the aerogels appear to be very advantageous for mucosal administration routes, such as pulmonary, nasal, or transdermal. A specific section devoted to recent achievements in gene therapy and theranostics is also included. In the last section, scale up strategies and life cycle assessment are comprehensively addressed.

Preparation of aerogel beads and microspheres based on chitosan and cellulose for drug delivery: A review

Spherical aerogels are not easily broken during use and are easier to transport and store which can be used as templates for drug delivery. This review summarizes the possible approaches for the preparation of aerogel beads and microspheres based on chitosan and cellulose, an overview to the methods of manufacturing droplets is presented, afterwards, the transition mechanisms from sol to a spherical gel are reviewed in detail followed by different drying processes to obtain spherical aerogels with porous structures. Additionally, a specific focus is given to aerogel beads and microspheres to be regarded as drug delivery carriers. Furthermore, a core/shell architecture of aerogel beads and microspheres for controlled drug release is described and subjected to inspire readers to create novel drug release system. Finally, the conclusions and outlooks of aerogel beads and microspheres for drug delivery are summarized.

Biorefinery Approach for Aerogels

According to the International Energy Agency, biorefinery is "the sustainable processing of biomass into a spectrum of marketable bio-based products (chemicals, materials) and bioenergy (fuels, power, heat)". In this review, we survey how the biorefinery approach can be applied to highly porous and nanostructured materials, namely aerogels. Historically, aerogels were first developed using inorganic matter. Subsequently, synthetic polymers were also employed. At the beginning of the 21st century, new aerogels were created based on biomass. Which sources of biomass can be used to make aerogels and how? This review answers these questions, paying special attention to bio-aerogels' environmental and biomedical applications. The article is a result of fruitful exchanges in the frame of the European project COST Action "CA 18125 AERoGELS: Advanced Engineering and Research of aeroGels for Environment and Life Sciences".

Atomic Layer Deposition onto Thermoplastic Polymeric Nanofibrous Aerogel Templates for Tailored Surface Properties

Poly(vinyl alcohol-co-ethylene) (EVOH) nanofibrous aerogel (NFA) templates were fabricated through vacuum freeze-drying from EVOH nanofibrous suspensions. Aluminum oxide (Al₂O₃) layers were deposited onto highly porous templates to form organic-inorganic hybrid aerogels by the atomic layer deposition (ALD) technique. Chemical and physical measurements showed that mechanical properties were improved through ALD. In addition, the surface chemistry of ALD modified aerogels showed a fascinating cyclic change based on the number of ALD deposition cycles. A transition from hydrophilicity to hydrophobicity was observed after a few cycles of ALD coating; however, additional deposition cycles changed the wettability characteristics back to hydrophilicity. This hydrophilic-hydrophobic-hydrophilic variation is shown to be governed by a combination of geometrical and chemical surface properties. Furthermore, the deposited Al₂O₃ could substantially improve aerogels strength and reduce permanent deformation after cyclic compression. The Young's modulus of aerogels increased from 5.54 to 33.27 kPa, and the maximum stress at 80% strain went up from 31.13 to 176.11 kPa, after 100 cycles of trimethyl-aluminum (TMA)/water ALD. Thermogravimetric analysis (TGA) results confirm that ALD can effectively improve the heat resistance characteristics of polymeric aerogel. The onset temperature and the residual mass increased with increasing numbers of ALD cycles. During pyrolysis, the nanofiber cores were decomposed, and the brittle pure Al₂O₃ self-supporting nanotube aerogels with the continuous hollow nanotubular network were formed. A coating of continuous thickness Al₂O₃ layer on individual nanofiber was achieved after 100 ALD cycles. In additional to mechanical strength and physical property changes, the ALD modified aerogel also shows a superhydrophobic and oleophilic surface chemistry, which could potentially be used to remove oils/organic solvents from water. The resultant aerogels exhibit excellent absorption capacity (31-73 g/g) for various liquids, and the material could be reused after distillation or squeezing. A successful scale-up of such materials could provide some insights into the design and development of thermoplastic polymeric NFAs with substantial industrial applications.

Development, In Vitro Characterization, and In Vivo Toxicity Evaluation of Chitosan-Alginate Nanoporous Carriers Loaded with Cisplatin for Lung Cancer Treatment

Polysaccharide-based aerogels are promising drug carriers. Being nanoporous with a high specific surface area allows their use as a drug vehicle for various delivery routes. Intratracheal and intravenous administration of free cisplatin causes toxicity in the rat liver, lungs, and kidneys. In this work, microspherical particles based on alginate-chitosan without a traditional crosslinker were evaluated for targeted delivery of cisplatin by intratracheal administration. The aerogel particles were prepared using the emulsion gelation method, followed by supercritical carbon dioxide extraction. Loading of cisplatin on the prepared porous particles was performed by impregnation using supercritical fluid technology. The prepared carrier and the loaded drug were evaluated for drug content, release, and in vivo acute and subacute toxicity. Cisplatin was successfully loaded (percent drug loading > 76%) on the prepared carrier (particle size = 0.433 ± 0.091 μm) without chemically interacting with the carrier and without losing its crystal form. Sixty percent of cisplatin was released within 2 h, and the rest was loaded inside the polymer pores and had a sustained first-order release over 6 h. Loading cisplatin on the carrier developed herein reduced the cisplatin lung toxicity but increased the liver toxicity after intratracheal administration with nephrotoxicity being proportional to cisplatin dose in case of carrier-loaded cisplatin. Moreover, loading cisplatin on the carrier significantly reduced mortality rate and prevented weight loss in rats as compared to free cisplatin in subacute studies after intratracheal administration. Thus, the developed carrier showed high potential for targeted delivery of cisplatin for lung cancer treatment by inhalation. Graphical abstract.

New Trends in Bio-Based Aerogels

(1) Background: The fascinating properties of currently synthesized aerogels associated with the flexible approach of sol-gel chemistry play an important role in the emergence of special biomedical applications. Although it is increasingly known and mentioned, the potential of aerogels in the medical field is not sufficiently explored. Interest in aerogels has increased greatly in recent decades due to their special properties, such as high surface area, excellent thermal and acoustic properties, low density and thermal conductivity, high porosity, flame resistance and humidity, and low refractive index and dielectric constant. On the other hand, high manufacturing costs and poor mechanical strength limit the growth of the market. (2) Results: In this paper, we analyze more than 180 articles from recent literature studies focused on the dynamics of aerogels research to summarize the technologies used in manufacturing and the properties of materials based on natural polymers from renewable sources. Biomedical applications of these bio-based materials are also introduced. (3) Conclusions: Due to their complementary functionalities (bioactivity, biocompatibility, biodegradability, and unique chemistry), bio-based materials provide a vast capability for utilization in the field of interdisciplinary and multidisciplinary scientific research.

Production of starch aerogel in form of monoliths and microparticles

Pea and amylomaize starches were used to produce aerogel in form of monoliths and microparticles. The formation of starch gel was investigated, and we showed that each starch needed a different pasting temperature for its complete dissolution. The gelation kinetics was investigated with oscillatory rheometry for both systems as a function of the starch concentration. The gelation and retrogradation temperature of the starch gel were varied and its impact on the final aerogel evaluated. The emulsion gelation was carried out batch wise in a stirred vessel with different impeller geometries, concentrations of surfactant (Span80 and PGPR) and stirring rates. A particle size prediction approach based on idealized flow (Couette, 2D hyperbolic and turbulent) during the emulsification was proposed. A semi-continuous set-up for the emulsion gelation was developed in which the emulsification occurs in a single pass through a colloid mill and the gelation is triggered in-line with a counter-current heat exchanger.

Cellulose Aerogel Microparticles via Emulsion-Coagulation Technique

Cellulose aerogel microparticles were made via emulsification/nonsolvent induced phase separation/drying with supercritical CO₂. Cellulose was dissolved in NaOH-based solvent with and without additives in order to control solution gelation. Two emulsions, cellulose solution/oil and cellulose nonsolvent/oil, were mixed to start nonsolvent induced phase separation (or coagulation) of cellulose inside each cellulose droplet leading to the formation of so-called microgels. Different options of triggering coagulation were tested, by coalescence of droplets of cellulose solution and cellulose nonsolvent and by diffusion of nonsolvent partly soluble in the oil, accompanied by coalescence. The second option was found to be the most efficient for stabilization of the shape of coagulated cellulose microgels. The influence of gelation on particle formation and aerogel properties was investigated. The aerogel particles' diameter was around a few tens of microns, and the specific surface area was 250-350 m²/g.

Spherical amine grafted silica aerogels for CO2 capture

The objective of this research was to develop a novel spherical amine grafted silica aerogel for CO₂ capture. A spherical silica gel was synthesized by dropping a sodium silicate based silica sol into an oil bath. Amine grafting was achieved by bonding 3-aminopropyltriethoxysilane onto the framework of the silica gel. The spherical amine grafted silica gels were dried using vacuum drying to prepare the spherical amine grafted silica aerogels (SASAs). The synthetic mechanism of the SASAs was proposed. The structures and the CO₂ adsorption performances of SASAs were researched. The amine loading of the SASAs increased with the grafting time, however, the specific surface area and pore volume sharply decreased owing to the blockage of the pore space. Excess amine loading led to the decrease of the CO₂ adsorption capacity. The optimal CO₂ adsorption capacity was 1.56 mmol g⁻¹ with dry 1% CO₂ and at 35 °C. This work provides a low-cost and environmentally friendly way to design a capable and regenerable adsorbent material.

The objective of this research was to develop a novel spherical amine grafted silica aerogel for CO₂ capture.

Polyurea-crosslinked biopolymer aerogel beads

Polyurea-crosslinked calcium alginate and chitosan aerogel beads: novel fibrous biopolymer-based aerogels.

Synthetic Polymer Aerogels in Particulate Form

Aerogels have been defined as solid colloidal or polymeric networks of nanoparticles that are expanded throughout their entire volume by a gas. They have high surface areas, low thermal conductivities, low dielectric constants, and high acoustic attenuation, all of which are very attractive properties for applications that range from thermal and acoustic insulation to dielectrics to drug delivery. However, one of the most important impediments to that potential has been that most efforts have been concentrated on monolithic aerogels, which are prone to defects and their production requires long and costly processing. An alternative approach is to consider manufacturing aerogels in particulate form. Recognizing that need, the European Commission funded “NanoHybrids”, a 3.5 years project under the Horizon 2020 framework with 12 industrial and academic partners aiming at aerogel particles from bio- and synthetic polymers. Biopolymer aerogels in particulate form have been reviewed recently. This mini-review focuses on the emerging field of particulate aerogels from synthetic polymers. That category includes mostly polyurea aerogels, but also some isolated cases of polyimide and phenolic resin aerogels. Particulate aerogels covered include powders, micro granules and spherical millimeter-size beads. For the benefit of the reader, in addition to the literature, some new results from our laboratory concerning polyurea particle aerogels are also included.