From Electrospun Polymer Core–Shell Fibers to Polymer Hemispheres and Spheres: Two Types of Transformation Processes and Tearing Films with Linearly Arranged Cavities

Polymeric Microparticles Generated via Confinement-Free Fluid Instability

In-fiber fluid instability can be harnessed to realize scalable microparticles fabrication with tunable sizes and multifunctional characteristics making it competitive in comparison to conventional microparticles fabrication methods. However, since in-fiber fluid instability has to be induced via thermal annealing and the resulting microparticles can only be collected after dissolving the fiber cladding, obtaining contamination-free particles for high-temperature incompatible materials remains great challenge. Herein, confinement-free fluid instability is demonstrated to fabricate polymeric microparticles in a facile manner induced by the ultralow surface energy of the superamphiphobic surface. The polymer solution columns break up into uniform droplets then form spherical particles spontaneously in seconds at ambient temperature. This method can be applied to a variety of polymers spanning an exceptionally wide range of sizes: from 1 mm down to 1 µm. With the aid of microfluidic spinning instrument, a large quantity of microparticles can be obtained, making this method promising for scaling up production. Notably, through simple modification of the feed solution configuration, composite/structured micromaterials can also be produced, including quantum-dots-labeled fluorescent particles, magnetic particles, core-shell particles, microcapsules, and necklace-like microfibers. This method, with general applicability and facile control, is envisioned to have great prospects in the field of polymer microprocessing.

Snake Tracks in Polymer Land: Wavy Polymer Structures via Selective Solvent Vapor Annealing

Wavy patterns are interesting geometric patterns and commonly seen in nature, such as serpentine streams or snake tracks in the sand. Although many efforts have been devoted to fabricating artificial wavy structures, it remains a great challenge to obtain wavy structures with controllable curvatures and desired functional properties. Here, we present an unprecedented approach to generate wavy polymer structures by annealing electrospun core-shell fibers on polymer films. Polystyrene (PS)/poly(methyl methacrylate) (PMMA) core-shell fibers, produced via the viscosity-induced phase separation in the electrospinning process, are annealed on PMMA films using vapors of acetic acid, a selective solvent for PMMA but not for PS. After the swollen PMMA chains of the PMMA shells are shed, the revealed PS cores start to buckle, driven by the elastic force from the strain release, forming the wavy structures. The degrees of the buckling, measured by the curvatures and the amplitudes of the wavy structures, are controlled by the annealing times. Furthermore, fluorescent properties are selectively introduced to the wavy structures using pyrene solutions or pyrene-containing vapors, demonstrating the potential application as fluorescent wavy materials.

The Effect of Solvent Vapor Annealing on Drug-Loaded Electrospun Polymer Fibers

Electrospinning has emerged as a powerful strategy to develop controlled release drug delivery systems but the effects of post-fabrication solvent vapor annealing on drug-loaded electrospun fibers have not been explored to date. In this work, electrospun poly(ԑ-caprolactone) (PCL) fibers loaded with the hydrophobic small-molecule spironolactone (SPL) were explored. Immediately after fabrication, the fibers are smooth and cylindrical. However, during storage the PCL crystallinity in the fibers is observed to increase, demonstrating a lack of stability. When freshly-prepared fibers are annealed with acetone vapor, the amorphous PCL chains recrystallize, resulting in the fiber surfaces becoming wrinkled and yielding shish-kebab like structures. This effect does not arise after the fibers have been aged. SPL is found to be amorphously dispersed in the PCL matrix both immediately after electrospinning and after annealing. In vitro dissolution studies revealed that while the fresh fibers show a rapid burst of SPL release, after annealing more extended release profiles are observed. Both the rate and extent of release can be varied through changing the annealing time. Further, the annealed formulations are shown to be stable upon storage.

Fabrication of Electrospun Polymer Nanofibers with Diverse Morphologies

Fiber structures with nanoscale diameters offer many fascinating features, such as excellent mechanical properties and high specific surface areas, making them attractive for many applications. Among a variety of technologies for preparing nanofibers, electrospinning is rapidly evolving into a simple process, which is capable of forming diverse morphologies due to its flexibility, functionality, and simplicity. In such review, more emphasis is put on the construction of polymer nanofiber structures and their potential applications. Other issues of electrospinning device, mechanism, and prospects, are also discussed. Specifically, by carefully regulating the operating condition, modifying needle device, optimizing properties of the polymer solutions, some unique structures of core⁻shell, side-by-side, multilayer, hollow interior, and high porosity can be obtained. Taken together, these well-organized polymer nanofibers can be of great interest in biomedicine, nutrition, bioengineering, pharmaceutics, and healthcare applications.

Fabrication and Thermal Insulation Properties of Bamboo-Shaped Polymer Fibers by Selective Solvent Vapor Annealing

Fibrillar materials have gained much attention recently because of their unique properties and potential applications. Although many methods have been developed to fabricate materials, it remains challenging to prepare fibrillar materials containing multicomponent materials or even with complex structures. Here, a facile strategy is developed to fabricate bamboo-shaped fibers by treating electrospun polymer core-shell fibers with solvent vapor annealing. Electrospun polystyrene (PS)/poly(methyl methacrylate) (PMMA) core-shell fibers are first prepared by electrospinning PS/PMMA blend solutions via a phase separation process. When the PS/PMMA core-shell fibers are annealed with the vapor of cyclohexane, which swells and delocalizes the PS domains selectively, the fibers transform into bamboo-shaped structures. The bamboo-shaped structures can be further examined by swelling and delocalizing the PMMA domains selectively, revealing the undulated PS structures. The thermal insulation properties of the fibers with bamboo-shaped structures are observed to be enhanced compared with the original polymer core-shell fibers.