Marangoni Flows during Nonsolvent Induced Phase Separation

Investigating microstructure evolution in block copolymer membranes

Block copolymer self-assembly in conjunction with nonsolvent-induced phase separation (SNIPS) has been increasingly leveraged to fabricate integral-asymmetric membranes. The large number of formulation and processing parameters associated with SNIPS, however, has prevented the reliable construction of high performance membranes. In this study, we apply dynamical self-consistent field theory to model the SNIPS process and investigate the effect of various parameters on the membrane morphology: solvent selectivity, nonsolvent selectivity, initial film composition, and glass transition composition. We examine how solvent selectivity and concentration of polymers in the film impact the structure of micelles that connect to form the membrane matrix. In particular, we find that preserving the order in the surface layer and forming a connection between the supporting and surface layer are nontrivial and sensitive to each parameter studied. The effect of each parameter is discussed, and suggestions are made for successfully fabricating viable block copolymer membranes.

Coated Porous Microneedles for Effective Intradermal Immunization with Split Influenza Vaccine

In order to alleviate the pain associated with subcutaneous injections, microneedles (MNs) are gaining increasing attention as a novel transdermal drug delivery modality. Among them, porous microneedles (pMNs) are particularly suitable for the delivery of drugs and vaccines whose activity is sensitive to the microneedle preparation process. They can carry drugs actively to achieve an effective load and deliver drugs into the skin. In this study, the biocompatible cellulose acetate (CA) microporous MNs with a large pore size of 1.13 μm ± 0.45 and a high porosity of 74.8% ± 2.8% were prepared by using a safe nonsolvent-induced phase separation (NIPS) method. The MN patches prepared after adsorption of appropriate concentrations of split influenza vaccine fully met the dose loading requirements. A biocompatible carboxymethyl cellulose (CMC) solution was used in the pMN coating to strengthen their mechanical properties, with an average maximum stress of 32.89 N, and to act as a medium for the dispersion of an adjuvant in the coating layer. The influenza vaccine adsorbed in the micropore and the adjuvant dispersed in the coating were released intradermally to exert synergistic effects with different release patterns and rates. The coated pMNs induced an efficient immune response in Wistar rats with a hemagglutination inhibition (HI) titer of ≥1024, which was comparable to that of intramuscular injection. The research is organized around the goal of engineering exploration of innovative technologies, suggesting that pMNs have a tantalizing prospect for future applications. It opens up the possibility of eventually obtaining a simple, easy-to-use, and efficient application technology for the prevention of global epidemics like influenza.

Mechanism of PVDF Membrane Formation by NIPS Revisited: Effect of Precipitation Bath Nature and Polymer-Solvent Affinity

A new interpretation of the mechanism of the polyvinylidene fluoride (PVDF) membrane formation using the nonsolvent-induced phase separation (NIPS) method based on an analysis of the complete experimental phase diagram for the three-component mixture PVDF-dimethyl acetamide (DMAc)-water is proposed. The effects of the precipitation bath's harshness and thermodynamic affinity of the polymer's solvent on the morphology, crystalline structure, transport and physical-mechanical properties of the membranes are investigated. These characteristics were studied via scanning electron microscopy, wide-angle X-ray scattering, liquid-liquid porosimetry and standard methods of physico-mechanical analysis. It is established that an increase in DMAc concentration in the precipitation bath results in the growth of mean pore size from ~60 to ~150 nm and an increase in permeance from ~2.8 to ~8 L m-2 h-1 bar-1. It was observed that pore size transformations are accompanied by changes in the tensile strength of membranes from ~9 to ~11 and to 6 MPa, which were explained by the degeneration of finger-like pores and appearance of spherulitic structures in the samples. The addition of water to the dope solution decreased both the transport (mean pore size changed from ~55 to ~25 nm and permeance reduced from ~2.8 to ~0.5 L m-2 h-1 bar-1) and mechanical properties of the membranes (tensile strength decreased from ~9 to ~6 MPa). It is possible to conclude that the best membrane quality may be reached using pure DMAc as a solvent and a precipitation bath containing 10-30% wt. of DMAc, in addition to water.

Highly Ordered Thermoplastic Polyurethane/Aramid Nanofiber Conductive Foams Modulated by Kevlar Polyanion for Piezoresistive Sensing and Electromagnetic Interference Shielding

Highly ordered and uniformly porous structure of conductive foams is a vital issue for various functional purposes such as piezoresistive sensing and electromagnetic interference (EMI) shielding. With the aids of Kevlar polyanionic chains, thermoplastic polyurethane (TPU) foams reinforced by aramid nanofibers (ANF) with adjustable pore-size distribution were successfully obtained via a non-solvent-induced phase separation. In this regard, the most outstanding result is the in situ formation of ANF in TPU foams after protonation of Kevlar polyanion during the NIPS process. Furthermore, in situ growth of copper nanoparticles (Cu NPs) on TPU/ANF foams was performed according to the electroless deposition by using the tiny amount of pre-blended Ti3C2Tx MXene as reducing agents. Particularly, the existence of Cu NPs layers significantly promoted the storage modulus in 2,932% increments, and the well-designed TPU/ANF/Ti3C2Tx MXene (PAM-Cu) composite foams showed distinguished compressive cycle stability. Taking virtues of the highly ordered and elastic porous architectures, the PAM-Cu foams were utilized as piezoresistive sensor exhibiting board compressive interval of 0-344.5 kPa (50% strain) with good sensitivity at 0.46 kPa-1. Meanwhile, the PAM-Cu foams displayed remarkable EMI shielding effectiveness at 79.09 dB in X band. This work provides an ideal strategy to fabricate highly ordered TPU foams with outstanding elastic recovery and excellent EMI shielding performance, which can be used as a promising candidate in integration of satisfactory piezoresistive sensor and EMI shielding applications for human-machine interfaces.

Porous Microneedles for Therapy and Diagnosis: Fabrication and Challenges

The use of microneedles (MNs), an innovative transdermal technology, enables efficient, convenient, painless, and controlled-release drug delivery. Porous microneedles (pMNs), special MNs with abundant interconnected pores that can produce capillary action, are gaining increasing attention as a novel MNs technology. pMNs can actively adsorb bioactive ingredients from solutions of drugs or vaccines for in vivo delivery or from interstitial skin fluids (ISFs) for wearable and point-of-care testing (POCT) products. Different pore sizes and porosities of pMNs can be achieved with different materials and preparation processes, which makes the application of pMNs adaptable to multiple scenarios. In addition, easier and faster detection will be accomplished by the smart combination of pMNs with other detection technologies. This paper aims to summarize the recent research progress of pMNs, focusing on the influence of various materials and their corresponding preparation methods on its structure and function display, discussing the key issues and looking forward to the future development.

Interfacial reaction-induced roughening in polymer thin films

Reactive blending of immiscible polymers is an important process for synthesizing polymer blends with superior properties. We use a phase-field model to understand reaction dynamics and morphology evolution by diffusive transport in layered films of incompatible, end-reactive polymers. We thoroughly investigate this phenomenon over a large parameter space of interface shapes, layer thicknesses, reaction rates specified by a Damkohler number (Da_f), and Flory-Huggins interaction parameter (χ), under static conditions with no external fields. For films of the same thickness, the dynamics of the system is not significantly influenced by the length of the film or the initial shape of the interface. The interface between the polymers is observed to roughen, leading to the formation of a spontaneous emulsion. The reaction progresses slower and the interface roughens later for thicker films, and systems with higher χ. Increasing Da_f increases the reaction rate and hastens the onset of roughening. The quasi-static interfacial tension decreases with the extent of reaction, but does not become vanishingly small or negative at the onset of roughening. Simulations with reversible reactions and systems where only a fraction of the homopolymers have reactive end groups show that a critical diblock (reaction product) concentration exists, below which interfacial roughening and spontaneous emulsification is not observed. We also demonstrate that thermal fluctuations accelerate the onset of interfacial roughening, and help sustain the system in an emulsified state.

A phase field model for dynamic simulations of reactive blending of polymers

A facile way to generate compatibilized blends of immiscible polymers is through reactive blending of end-functionalized homopolymers. The reaction may be reversible or irreversible depending on the end-groups and is affected by the immiscibility and transport of the reactant homopolymers and the compatibilizing copolymer product. Here we describe a phase-field framework to model the combined dynamics of reaction kinetics, diffusion, and multi-component thermodynamics on the evolution of the microstructure and reaction rate in reactive blending. A density functional with no fitting parameters, which is obtained by adapting a framework of Uneyama and Doi and qualitatively agrees with self-consistent field theory, is used in a diffusive dynamics model. For a symmetric mixture of equal-length reactive polymers mixed in equal proportions, we find that depending on the Flory χ parameter, the microstructure of an irreversibly reacting blend progresses through a rich evolution of morphologies, including from two-phase coexistence to a homogeneous mixture, or a two-phase to three-phase coexistence transitioning to a homogeneous blend or a lamellar copolymer. The emergence of a three-phase region at high χ leads to a previously unreported reaction rate scaling. For a reversible reaction, we find that the equilibrium composition is a function of both the equilibrium constant for the reaction and the χ parameter. We demonstrate that phase-field models are an effective way to understand the complex interplay of thermodynamic and kinetic effects in a reacting polymer blend.

Nonequilibrium Processes in Polymer Membrane Formation: Theory and Experiment

Porous polymer and copolymer membranes are useful for ultrafiltration of functional macromolecules, colloids, and water purification. In particular, block copolymer membranes offer a bottom-up approach to form isoporous membranes. To optimize permeability, selectivity, longevity, and cost, and to rationally design fabrication processes, direct insights into the spatiotemporal structure evolution are necessary. Because of a multitude of nonequilibrium processes in polymer membrane formation, theoretical predictions via continuum models and particle simulations remain a challenge. We compiled experimental observations and theoretical approaches for homo- and block copolymer membranes prepared by nonsolvent-induced phase separation and highlight the interplay of multiple nonequilibrium processes─evaporation, solvent-nonsolvent exchange, diffusion, hydrodynamic flow, viscoelasticity, macro- and microphase separation, and dynamic arrest─that dictates the complex structure of the membrane on different scales.

Patterning of a Drying Emulsion Film

Stabilizing layers of colloidal dispersions or emulsions to obtain homogeneous films is a real challenge. We describe here a new kind of instability in drying films of emulsions: during evaporation of the internal phase, cracks appear between the droplets that create aggregates according to a regular pattern. We show that this pattern only appears if the emulsion is adhesive, i.e., if droplets stick together. The pattern exhibits a characteristic length which depends on the adhesion strength and film thickness. These experimental results support a model where this instability is due to the gel structure and elastic properties of adhesive emulsions. Understanding this phenomenon will allow us to get a homogeneous film or to control it to get structured materials.

Interface Engineered Microcellular Magnetic Conductive Polyurethane Nanocomposite Foams for Electromagnetic Interference Shielding

Lightweight microcellular polyurethane (TPU)/carbon nanotubes (CNTs)/ nickel-coated CNTs (Ni@CNTs)/polymerizable ionic liquid copolymer (PIL) composite foams are prepared by non-solvent induced phase separation (NIPS). CNTs and Ni@CNTs modified by PIL provide more heterogeneous nucleation sites and inhibit the aggregation and combination of microcellular structure. Compared with TPU/CNTs, the TPU/CNTs/PIL and TPU/CNTs/Ni@CNTs/PIL composite foams with smaller microcellular structures have a high electromagnetic interference shielding effectiveness (EMI SE). The evaporate time regulates the microcellular structure, improves the conductive network of composite foams and reduces the microcellular size, which strengthens the multiple reflections of electromagnetic wave. The TPU/10CNTs/10Ni@CNTs/PIL foam exhibits slightly higher SE values (69.9 dB) compared with TPU/20CNTs/PIL foam (53.3 dB). The highest specific EMI SE of TPU/20CNTs/PIL and TPU/10CNTs/10Ni@CNTs/PIL reaches up to 187.2 and 211.5 dB/(g cm^-3), respectively. The polarization losses caused by interfacial polarization between TPU substrates and conductive fillers, conduction loss caused by conductive network of fillers and magnetic loss caused by Ni@CNT synergistically attenuate the microwave energy.

Viscoelastic phase separation model for ternary polymer solutions

When a polymer solution undergoes viscoelastic phase separation, the polymer-rich phase forms a network-like structure even if it is a minor phase. This unique feature is induced by polymer dynamics, which are constrained by the temporal entanglement of polymer chains. The fundamental mechanisms of viscoelastic phase separation have already been elucidated by theory and experiments over the past few decades; however, it is not yet well understood how viscoelastic phase separation occurs in multicomponent polymer solutions. Here, we construct a new viscoelastic phase separation model for ternary polymer solutions that consist of a polymer, solvent, and nonsolvent. Our simulation results reveal that a network-like structure is formed in the ternary bulk system through a phase separation mechanism similar to that observed in binary polymer solutions. A difference in dynamics is also found in that the solvent, whose affinity to the polymer is similar to that of the nonsolvent, moves freely between the polymer-rich and water-rich phases during phase separation. These findings are considered important for understanding the phase separation mechanism of ternary mixtures often used in the manufacture of polymeric separation membranes.

Evaporation-Induced Liquid Expansion and Bubble Formation in Binary Mixtures

We observe an anomalous liquid expansion after quenching a binary mixture at coexistence to low pressures in the vapor phase by numerical calculations. This evaporation-induced expansion can be attributed to the pressure imbalance near the liquid-vapor interface, which originates from the interplay between the complex thermodynamics of binary mixtures both in the vapor and liquid phases, as well as their dynamical asymmetries. In addition, careful modulation of the pressure quench in the vapor phase can result in spinodal bubble formation inside liquid phase. The results indicate that the thermodynamics-kinetics interplay could foster our fundamental understanding of the evaporation process and promote its practical applications.

Mechanisms of Asymmetric Membrane Formation in Nonsolvent-Induced Phase Separation

We report the first simulations of nonsolvent-induced phase separation (NIPS) that predict membrane microstructures with graded asymmetric pore size distribution. In NIPS, a polymer solution film is immersed in a nonsolvent bath, enriching the film in nonsolvent, and leading to phase separation that forms a solid polymer-rich membrane matrix and polymer-poor membrane pores. We demonstrate how mass-transfer-induced spinodal decomposition, thermal fluctuations, and glass-transition dynamics-implemented with mobility contrast between the polymer-rich and polymer-poor phases-are essential to the formation of asymmetric membrane microstructures. Specifically, we show that the competition between the propagation of the phase-separation and glass-transition fronts determines the degree of pore-size asymmetry. We also explore the sensitivity of these microstructures to the initial film composition, and compare their formation in 2D and 3D.

100th Anniversary of Macromolecular Science Viewpoint: Integrated Membrane Systems

Membranes fabricated from self-assembled materials are one recent example of how polymer science has been leveraged to advance membrane technology. Due to their well-defined nanostructures, the performance of membranes made from these materials is pushing the boundaries of size-selective filtration. Still, there remains a need for higher performance and more selective membranes. The advent of functional membrane platforms that rely on mechanisms beyond steric hindrance (e.g., charge-selective membranes and membrane sorbents) is one approach to realize improved solute-solute selectivity and further advance membrane technology. To date, the lab-scale demonstration of these platforms has often relied on fabrication schemes that require extended processing times. However, in order to translate lab-scale demonstrations to larger-scale implementation, it is critical that the rate of the functionalization scheme is reconciled with membrane manufacturing rates. In this viewpoint, it is postulated that substrates lined by reactive moieties that are amenable to postfabrication modification would enable the production of membranes with controlled nanostructures while providing access to a diverse array of pore wall chemistries. A comparison of reaction and manufacturing rates suggests that mechanisms that exhibit second-order reaction rate constants of at least 1 M^-1 s^-1 are needed for roll-to-roll processing. Furthermore, for mechanisms that exhibit rate constants greater than 300 M^-1 s^-1, it may be possible to integrate multiple functional domains over the membrane surface such that useful properties emerge. These multifunctional systems can expand the capabilities of membranes when the patterned chemistries interact at the heterojunctions between domains (e.g., Janus and charge-patterned mosaic membranes) or if they exhibit cooperative responses to external operating conditions (e.g., membrane pumps).

Mass-transfer driven spinodal decomposition in a ternary polymer solution

Nonsolvent induced phase separation (NIPS) is a widely occuring process used in industrial membrane production, nanotechnology and Nature to produce microstructured polymer materials. A variety of process-dependent morphologies are produced when a polymer solution is exposed to a nonsolvent that, following a period where mass is exchanged, precipitates and solidifies the polymer. Despite years of investigation, both experimental and theoretical, many questions surround the pathways to the microstructures that NIPS can produce. Here, we provide simulation results from a model that simultaneously captures both the processess of solvent/nonsolvent exchange and phase separation. We show that the time it takes the nonsolvent to diffuse to the bottom of the film is an important timescale, and that phase separation is possible at times both much smaller and much larger than this scale. Our results include both one-dimensional simulations of the mass transfer kinetics and two- and three-dimensional simulations of morphologies at both short and long times. We find good qualitative agreement with experimental heuristics, but we conclude that an additional model for the vitrification process will be key for fully explaining experimental observations of microstructure formation.

Progress Report on Phase Separation in Polymer Solutions

Polymeric porous media (PPM) are widely used as advanced materials, such as sound dampening foams, lithium-ion batteries, stretchable sensors, and biofilters. The functionality, reliability, and durability of these materials have a strong dependence on the microstructural patterns of PPM. One underlying mechanism for the formation of porosity in PPM is phase separation, which engenders polymer-rich and polymer-poor (pore) phases. Herein, the phase separation in polymer solutions is discussed from two different aspects: diffusion and hydrodynamic effects. For phase separation governed by diffusion, two novel morphological transitions are reviewed: "cluster-to-percolation" and "percolation-to-droplets," which are attributed to an effect that the polymer-rich and the solvent-rich phases reach the equilibrium states asynchronously. In the case dictated by hydrodynamics, a deterministic nature for the microstructural evolution during phase separation is scrutinized. The deterministic nature is caused by an interfacial-tension-gradient (solutal Marangoni force), which can lead to directional movement of droplets as well as hydrodynamic instabilities during phase separation.

All-atom molecular dynamics study on the non-solvent induced phase separation: Thermodynamics of adding water to poly(vinylidene fluoride)/N-methyl-2-pyrrolidone solution

The change in the thermodynamics when adding water in poly(vinylidene fluoride) (PVDF)/N-methyl-2-pyrrolidone (NMP) solution is studied from all atom molecular dynamics (MD) simulations. This is done by estimating the free energy of mixing of PVDF/NMP solution with increasing volume fraction of water (ϕ_w) using an appropriately chosen thermodynamic cycle and the Bennett acceptance ratio method. The MD calculations predict the thermodynamic phase separation point of water/NMP/PVDF to be at ϕ_w = 0.08, in close agreement with the experimental cloud point measurement (ϕ_w = 0.05). Examining the enthalpic and entropic components of the free energy of mixing reveals that at low concentrations of water, the enthalpy term has the most significant contribution to the miscibility of the ternary system, whereas at higher concentrations of water, the entropy term dominates. Finally, the free energy of mixing was compared with the Flory-Huggins (FH) free energy of mixing by computing the concentration-dependent interaction parameters from MD simulations. The FH model inadequately predicted the miscibility of the PVDF solution, mainly due to its negligence of the excess entropy of mixing.

Self-Assembly of Cellulose in Super-Cooled Ionic Liquid under the Impact of Decelerated Antisolvent Infusion: An Approach toward Anisotropic Gels and Aerogels

Assembly of (bio)polymers into long-range anisotropic nanostructured gels and aerogels is of great interest in advanced material engineering since it enables directional tuning of properties, such as diffusivity, light, heat, and sound propagation, cell proliferation, and mechanical properties. Here we present an approach toward anisotropic cellulose II gels and aerogels that employs specific diffusion and phase separation phenomena occurring during decelerated infusion of an antisolvent into isotropic supercooled solutions of cellulose in an ionic liquid to effectuate supramolecular assembly of cellulose in anisotropic colloidal network structures. At the example of the distillable ionic liquid 1,1,3,3-tetramethylguanidinium acetate, the antisolvent ethanol, and spherocylindrical porous molds, we demonstrate that the proposed facile, environmental-benign and versatile route affords gels and aerogels whose specific anisotropic nanomorphology and properties reflect the preferred supramolecular cellulose orientation during phase separation, which is perpendicular to the direction of antisolvent diffusion. Comprehensive X-ray scattering experiments revealed that the (aero)gels are composed of an interconnected, fibrous, highly crystalline (CrI ≈ 72%), cellulose II with a cross-sectional Guinier radius of the struts of about 2.5 nm, and an order parameter gradient from about 0.1 to 0.2. The obtained gels and aerogels feature high specific surface areas (350-630 m² g^-1) and excellent mechanical properties like high toughness (up to 471 kJ m^-3 for a 60% compression, ρ_B = 80 mg cm^-3) and resilience (up to 13.4 kJ m^-3, ρ_B = 65 mg cm^-3).