Plasticization and antiplasticization of polymer melts diluted by low molar mass species

Advancing the dynamic mechanical analysis of organic semiconductor materials

Dynamic mechanical analysis (DMA) is a powerful technique for characterizing the mechanical properties of a wide range of materials. However, the importance of DMA in studying organic/polymer semiconductors has not been fully appreciated. In this Highlight, we explore recent advancements in the use of DMA in understanding the viscoelastic and mechanical properties and thermal transitions of organic semiconductor materials. In particular, the insights gained from DMA can serve as new guides for the device optimisation of organic solar cells towards stable operation. Furthermore, we present key findings, challenges, and future directions to advance the application of DMA in organic electronics.

Role of additive size in the segmental dynamics and mechanical properties of cross-linked polymers

Thermoset materials often involve the addition of molecular and nanoparticle additives to alter various chemo-physical properties of importance in their ultimate applications. The resulting compositional heterogeneities can lead to either enhancement or degradation of thermoset properties, depending on the additive chemical structure and concentration. We tentatively explore this complex physical phenomenon through the consideration of a model polymeric additive to our coarse-grained (CG) thermoset investigated in previous works by simply varying the size of additive segments compared to those of polymer melt. We find that the additive modified thermoset material becomes chemically heterogeneous from additive aggregation when the additive segments become much smaller than those of the thermoset molecules, and a clear evidence is observed in the spatial distribution of local molecular stiffness estimated from Debye-Waller factor 〈u2〉. Despite the non-monotonic variation trends observed in dynamical and mechanical properties with decreasing additive segmental size, both the structural relaxation time and moduli (i.e., shear modulus and bulk modulus) exhibit scaling laws with 〈u2〉. The present work highlights the complex role of additive size played in the dynamical and mechanical properties of thermoset polymers, which should provide a better understanding for the glass formation process of cross-linked polymer composites.

Framework for a High-Throughput Screening Method to Assess Polymer/Plasticizer Miscibility: The Case of Hydrocarbons in Polyolefins

Polymer composite materials require softening to reduce their glass transition temperature and improve processability. To this end, plasticizers (PLs), which are small organic molecules, are added to the polymer matrix. The miscibility of these PLs has a large impact on their effectiveness and, therefore, their interactions with the polymer matrix must be carefully considered. Many PL characteristics, including their size, topology, and flexibility, can impact their miscibility and, because of the exponentially large number of PLs, the current trial-and-error approach is very ineffective. In this work, we show that using coarse-grained molecular simulations of a small dataset of 48 PLs, it is possible to identify topological and thermodynamic descriptors that are proxy for their miscibility. Using ad-hoc molecular dynamics simulation setups that are relatively computationally inexpensive, we establish correlations between the PLs' topology, internal flexibility, thermodynamics of aggregation, and degree of miscibility, and use these descriptors to classify the molecules as miscible or immiscible. With all available data, we also construct a decision tree model, which achieves a F1 score of 0.86 ± 0.01 with repeated, stratified 5-fold cross-validation, indicating that this machine learning method can be a promising route to fully automate the screening. By evaluating the individual performance of the descriptors, we show this procedure enables a 10-fold reduction of the test space and provides the basis for the development of workflows that can efficiently screen PLs with a variety of topological features. The approach is used here to screen for apolar PLs in polyisoprene melts, but similar proxies would be valid for other polyolefins, while, in cases where polar interactions drive the miscibility, other descriptors are likely to be needed.

Effect of intermolecular hydrogen bonding strength on the dynamic fragility of amorphous polyamides

Small-molecular-induced intermolecular hydrogen bonding (inter-HB) interactions were reported to increase the glass transition temperature (Tg) while decrease the dynamic fragility (m) of polymers. Herein, enthalpy relaxation parameters heat capacity jump (ΔCp) at Tg and enthalpy hysteresis (ΔHR) were investigated to help clarify the effect of macromolecular-induced inter-HB on Tg and m using amorphous polyamides as model polymers. The inter-HB strength was weakened by random copolymerization with varied chain rigidity, but was enhanced by decreasing steric hindrance. It was found that Tg and m increased after copolymerization due to the increased chain rigidity. Nevertheless, increasing steric hindrance leads to an increased Tg while anomalously reduced m. Further results found that m can be well correlated to Tg·ΔCp/ΔHR. ΔCp increases more significantly than ΔHR in co-polyamides, and thus the entropy change dominates the activation free energy of cooperative rearrangement. By contrast, ΔHR increases more significantly than ΔCp with increasing steric hindrance, and thus it is reasonable that Tg increases while m decreases. Most importantly, ΔCp and ΔHR decrease with increasing inter-HB strength regardless of the variation of Tg. These results indicate that the inter-HB strength may be very strong and insensitive to temperature in polyamides, thus behaving like physical cross-linking.

Competing Effects of Molecular Additives and Cross-Link Density on the Segmental Dynamics and Mechanical Properties of Cross-Linked Polymers

The introduction of molecular additives into thermosets often results in changes in their dynamics and mechanical properties that can have significant ramifications for diverse applications of this broad class of materials such as coatings, high-performance composites, etc. Currently, there is limited fundamental understanding of how such additives influence glass formation in these materials, a problem of broader significance in glass-forming materials. To address this fundamental problem, here, we employ a simplified coarse-grained (CG) model of a polymer network as a model of thermoset materials and then introduce a polymer additive having the same inherent rigidity and polymer-polymer interaction strength as the cross-linked polymer matrix. This energetically "neutral" or "self-plasticizing" additive model gives rise to non-trivial changes in the dynamics of glass formation and provides an important theoretical reference point for the technologically more important case of interacting additives. Based on this rather idealized model, we systematically explore the combined effect of varying the additive mass percentage (m) and cross-link density (c) on the segmental relaxation dynamics and mechanical properties of a model thermoset material with additives. We find that increasing the additive mass percentage m progressively decreases both the glass-transition temperature Tg and the fragility of glass formation, a trend opposite to increasing c so that these thermoset variables clearly have a competing effect on glass formation in these model materials. Moreover, basic mechanical properties (i.e., bulk, shear, and tensile moduli) likewise exhibit a competitive variation with the increase of m and c, which are strongly correlated with the Debye-Waller parameter ⟨u2⟩, a measure of material stiffness at a molecular scale. Our findings prove beneficial in the development of structure-property relationships for the cross-linked polymers, which could help guide the design of such network materials with tailored physical properties.

Understanding the balance between additives' miscibility and plasticisation effect in polymer composites: a computational study

Plasticisers are small organic molecules routinely added to polymer composites that modify the processability of the compounds by adsorbing on the filler's surface or dispersing into the polymer matrix. Here using a simple yet chemically specific coarse-grained model, we demonstrate that the filler surface coverage and the degree of dispersion into the polymer matrix can be tuned without modifying the chemistry of the plasticisers but only by varying their conformational flexibility. We show that when the adsorption mechanism and clustering into the bulk are entropically driven as in this work, this is a general phenomenon independent on the polymer chemistry and its molecular weight. Our findings suggest a simple practical design rule that requires only minor modifications of the plasticisers' chemistry to achieve maximum adsorption onto the filler surface or dispersion into the polymer matrix.

The Glass Transition Temperature of Heterogeneous Biopolymer Systems

Biopolymers are abundant, renewable, and biodegradable resources. However, bio-based materials often require toughening additives, like (co)polymers or small plasticizing molecules. Plasticization is monitored via the glass transition temperature versus diluent content. To describe this, several thermodynamic models exist; nevertheless, most expressions are phenomenological and lead to over-parametrization. They also fail to describe the influence of sample history and the degree of miscibility via structure-property relationships. We propose a new model to deal with semi-compatible systems: the generalized mean model, which can classify diluent segregation or partitioning. When the constant k_GM is below unity, the addition of plasticizers has hardly any effect, and in some cases, even anti-plasticization is observed. On the other hand, when the k_GM is above unity, the system is highly plasticized even for a small addition of the plasticizer compound, which indicates that the plasticizer locally has a higher concentration. To showcase the model, we studied Na-alginate films with increasing sizes of sugar alcohols. Our k_GM analysis showed that blends have properties that depend on specific polymer interactions and morphological size effects. Finally, we also modeled other plasticized (bio)polymer systems from the literature, concluding that they all tend to have a heterogeneous nature.

Kinetics of the Glass Transition of Silica-Filled Styrene-Butadiene Rubber: The Effect of Resins

Resins are important for enhancing both the processability and performance of rubber. Their efficient utilization requires knowledge about their influence on the dynamic glass transition and their miscibility behavior in the specific rubber compound. The resins investigated, poly-(α-methylstyrene) (AMS) and indene-coumarone (IC), differ in molecular rigidity but have a similar aromaticity degree and glass transition temperature. Transmission electron microscopy (TEM) investigations show an accumulation of IC around the silanized silica in styrene–butadiene rubber (SBR) at high contents, while AMS does not show this effect. This higher affinity between IC and the silica surface leads to an increased compactness of the filler network, as determined by dynamic mechanical analysis (DMA). The influence of the resin content on the glass transition of the rubber compounds is evaluated in the sense of the Gordon–Taylor equation and suggests a rigid amorphous fraction for the accumulated IC. Broadband dielectric spectroscopy (BDS) and fast differential scanning calorimetry (FDSC) are applied for the characterization of the dielectric and thermal relaxations as well as for the corresponding vitrification kinetics. The cooling rate dependence of the vitrification process is combined with the thermal and dielectric relaxation time by one single Vogel–Fulcher–Tammann–Hesse equation, showing an increased fragility of the rubber containing AMS.

Mediating the slow dynamics of polyacrylates by small molecule-bridged hydrogen bonds

This report studied the changes in the slow dynamics of polyacrylate by adding a hindered phenol (CA) capable of forming three intermolecular hydrogen bonds (inter-HBs) per molecule with the polymer chain. The CA molecule apparently diminishes the slow modes (with lower peak temperatures and peak heights) of the polyacrylate, although it has a higher glass transition temperature (T_g) than the acrylic matrix, and the rigid CA-bridged HB network significantly amplifies the α-relaxation near T_g (with higher peak temperatures and peak heights). Consequently, the mixtures exhibit a diminishing slow mode that gradually merges with the prominent α-peak with increasing CA loadings. The anomalous dynamics concerning the opposite behaviors of the slow mode and α-relaxation was further rationalized in terms of dissociation of inter-HBs when the temperature is higher than T_g, together with the small molecule-alleviated macromolecular connectivity. This work provides essential insights into the slow dynamics of such HB-driven hybrids, and paves the way for tailoring the viscous flow properties of the hybrid material from a molecular level perspective.

Tuning the dynamic fragility of acrylic polymers by small molecules: the interplay of molecular structures

This report studied changes in the dynamic fragility (m) of poly(butyl methacrylate) (PBMA) by introducing guest hindered phenols capable of forming two or three intermolecular hydrogen bonds (inter-HBs) per molecule with the host polymer. The small molecules effectively decrease the m value, even if they apparently increase the glass transition temperature (T_g) of mixtures. The reduction in m was confirmed by enthalpy relaxation in two aspects: adding the guest molecule leads to a stronger cooling rate dependence of the limiting fictive temperature together with an apparent increase in aging rate of PBMA hybrids at low concentrations. By varying the molecule size and steric hindrance of the hydroxyl group on the hindered phenols, we clarified that m is primarily governed by the strength of inter-HB interactions, while the T_g value of mixtures depends on a combined effect of additive bulkiness and HB interaction. The anomalous dynamics was further rationalized not only by the HB-induced flexibility balance between side groups and backbone, but also by the reduction of cooperative rearranging sizes and alleviation of long-chain connectivity in such HB-driven hybrids.

Strengthening Regenerated Cellulose Fibers Sourced from Recycled Cotton T-Shirt Using Glucaric Acid for Antiplasticization

The recycling of cellulose from cotton textiles would minimize the use of virgin crop fibers, but recycled polymers are generally inferior in mechanical performance to those made from virgin resins. This challenge prompted the investigation of biobased additives that were capable of improving the mechanical properties of fibers by means of antiplasticizing additives. In this study, regenerated cellulose (RC) fibers were spun from cellulose found in cotton T-shirts, and fibers were mechanically strengthened with glucaric acid (GA), a nontoxic product of fermentation. The recycled pulp was activated using aqueous sodium hydroxide and then followed by acid neutralization, prior to the direct dissolution in lithium chloride/N,N-dimethylacetamide (LiCl/DMAc) at 3 wt.% cellulose. At 10% (w/w) GA, the tensile modulus and strength of regenerated cellulose from recycled cotton fibers increased five-fold in contrast to neat fibers without GA. The highest modulus and tenacity values of 664 cN/dtex and of 9.7 cN/dtex were reported for RC fibers containing GA.

The influence of additives on polymer matrix mobility and the glass transition

In the region near an interface, the microscopic properties of a glass forming liquid may be perturbed from their equilibrium bulk values. In this work, we probe how the interfacial effects of additive particles dispersed in a matrix can influence the local mobility of the material and its glass transition temperature, Tg. Experimental measurements and simulation results indicate that additives, such as nanoparticles, gas molecules, and oligomers, can shift the mobility and Tg of a surrounding polymer matrix (even for relatively small concentrations of additive; e.g., 5-10% by volume) relative to the pure bulk matrix, thus leading to Tg enhancement or suppression. Additives thus provide a potential route for modifying the properties of a polymer material without significantly changing its chemical composition. Here we apply the Limited Mobility (LM) model to simulate a matrix containing additive species. We show that both additive concentration, as well as the strength of its very local influence on the surrounding matrix material, will determine whether the Tg of the system is raised or lowered, relative to the pure matrix. We demonstrate that incorporation of additives into the simple LM simulation method, which has successfully described the behavior of bulk and thin film glassy solids, leads to direct connections with available experimental and simulation results for a broad range of polymer/additive systems.

Glucaric acid additives for the antiplasticization of fibers wet spun from cellulose acetate/acetic acid/water

Cellulose acetate (CA) receives notable attention as an environmentally friendly, biodegradable polymer from renewable, low-cost resources. CA polymers are believed to have a critical role in shaping a greener and more circular textile economy. However, the mechanical properties of CA fibers are among the lowest in terms of its tensile strength, poor wet strength, and low flexural strength. This study investigates the effect of biobased additives for antiplasticizing the mechanical performance and structure of CA fibers. At up to 5 % of CA, glucaric acid (GA) and its monoammonium salt were added to CA fibers. With 1.5 % GA additive, tensile modulus improved by 155%, tensile strength by 55 %, and CA flexibility according to knot to straight fiber tenacity ratios improved by 107 % when compared to neat CA fibers. Based on the results, green small molecule antiplasticizers do exist, but their performance improvements are observed at low percentages of loading.

Constructed microbubble porous scaffolds of polyvinyl alcohol for subchondral bone formation for osteoarthritis surgery

Osteoarthritis (OA) is a disease that leads to the damage of subchondral bone. To treat OA, patients can have surgery to implant biomaterials into the damaged area. In this research, biomaterials of 3D porous scaffolds were fabricated by the use of air microbubbles for subchondral bone formation proposed for OA surgery. Microbubbles were generated in a polyvinyl alcohol solution at various air flow rates of 20 (F20), 100 (F100), 200 (F200), and 300 (F300) cc min^-1. Molecular organization, structure, and morphology of the scaffolds were characterized and observed by Fourier transform infrared spectroscopy, a differential scanning calorimeter, and a scanning electron microscope, respectively. Physical and mechanical properties based on swelling behavior and compressive strength of the scaffolds were also evaluated. Biological performance by means of osteoblast proliferation, protein synthesis, and alkaline phosphatase activity of the scaffolds were studied. The scaffolds showed molecular organization via interaction of -OH and C = O. They had residual water in their structures. The scaffolds exhibited a morphology of a spherical-like cell shape with small pores and a rough surface produced on each cell. Each cell was well connected with the others. The cell size and porous structure of the scaffolds depended significantly on the flow rate used. The molecular organization, structure, and morphology of the scaffolds had an effect on their physical and mechanical properties and biological performance. F100 was found to be an optimum scaffold offering a molecular organization, structure, morphology, physical and mechanical properties, and biological performance which was suitable for subchondral bone formation. This research deduced that the F100 scaffold is promising for OA surgery.

Effect of Poly(phenylene sulfide) (PPS) as Functional Additive on the Physical Properties of Poly(phenylene ether) (PPE)/PPS Blends

In this study, polyphenylene sulfide (PPS) was introduced in polyphenylene ether (PPE) blend to improve the processability of PPE and to secure the flame retardancy of the blend without deteriorating physical properties. Through the study of the binary blend of PPE/PPS, it was found that the shear thinning behavior and the external lubrication effect of PPS can improve the processability of PPE. Thermal analysis of the blend showed that the glass transition temperature of the PPS component decreases by the plasticization while that of the PPE component increases by the anti-plasticization effect. The modulus of the binary blend increased with the PPS content, and the tensile strength decreased but followed the additive rule. The change in tensile properties can be explained by the synergy effect of partial miscibility between PPE and PPS due to structural similarity, and non-isotropic morphology formation. Impact strength increased sharply in PPE60 due to the mechanical grafting effect by co-continuous phase formation. In the ternary blend with SEBS-MAH applied to PPE60, the impact strength steep increased at a content of 10 wt% or more due to the dramatic morphology change based on the compatibilization effect. Flame retardancy of V0 was also observed in all compositions where SEBS-MAH was applied within 20 phr.

Antiplasticization of Polymer Materials: Structural Aspects and Effects on Mechanical and Diffusion-Controlled Properties

Antiplasticization of glassy polymers, arising from the addition of small amounts of plasticizer, was examined to highlight the developments that have taken place over the last few decades, aiming to fill gaps of knowledge in the large number of disjointed publications. The analysis includes the role of polymer/plasticizer molecular interactions and the conditions leading to the cross-over from antiplasticization to plasticization. This was based on molecular dynamics considerations of thermal transitions and related relaxation spectra, alongside the deviation of free volumes from the additivity rule. Useful insights were gained from an analysis of data on molecular glasses, including the implications of the glass fragility concept. The effects of molecular packing resulting from antiplasticization are also discussed in the context of physical ageing. These include considerations on the effects on mechanical properties and diffusion-controlled behaviour. Some peculiar features of antiplasticization regarding changes in Tg were probed and the effects of water were examined, both as a single component and in combination with other plasticizers to illustrate the role of intermolecular forces. The analysis has also brought to light the shortcomings of existing theories for disregarding the dual cross-over from antiplasticization to plasticization with respect to modulus variation with temperature and for not addressing failure related properties, such as yielding, crazing and fracture toughness.

Solid-State Biology and Seed Longevity: A Mechanical Analysis of Glasses in Pea and Soybean Embryonic Axes

The cytoplasm of anhydrobiotes (organisms that persist in the absence of water) solidifies during drying. Despite this stabilization, anhydrobiotes vary in how long they persist while dry. In this paper, we call upon concepts currently used to explain stability of amorphous solids (also known as glasses) in synthetic polymers, foods, and pharmaceuticals to the understand variation in longevity of biological systems. We use embryonic axes of pea (Pisum sativum) and soybean (Glycine max) seeds as test systems that have relatively long and short survival times, respectively, but similar geometries and water sorption behaviors. We used dynamic mechanical analysis to gain insights on structural and mobility properties that relate to stability of other organic systems with controlled composition. Changes of elastic and loss moduli, and the dissipation function, tan δ, in response to moisture and temperature were compared in pea and soybean axes containing less than 0.2 g H2O g-1 dry mass. The work shows high complexity of structure-regulated molecular mobility within dried seed matrices. As was previously observed for pea cotyledons, there were multiple relaxations of structural constraints to molecular movement, which demonstrate substantial localized, "fast" motions within solidified cytoplasm. There was detected variation in the coordination among long-range slow, diffusive and short-range fast, vibrational motions in glasses of pea compared to soybean, which suggest higher constraints to motion in pea and greater "fragility" in soybean. We are suggesting that differences in fragility contribute to variation of seed longevity. Indeed, fragility and coordination of short and long range motions are linked to stability and physical aging of synthetic polymers.

Electrospun Composite Liquid Crystal Elastomer Fibers

We present a robust method to prepare thin oriented nematic liquid crystalline elastomer-polymer (LCE-polymer) core-sheath fibers. An electrospinning setup is utilized to spin a single solution of photo-crosslinkable low molecular weight reactive mesogens and a support polymer to form the coaxial LCE-polymer fibers, where the support polymer forms the sheath via in situ phase separation as the solvent evaporates. We discuss the effect of phase separation and compare two different sheath polymers (polyvinylpyrrolidone and polylactic acid), investigating optical and morphological properties of obtained fibers, as well as the shape changes upon heating. The current fibers show only irreversible contraction, the relaxation most likely being hindered by the presence of the passive sheath polymer, increasing in stiffness on cooling. If the sheath polymer can be removed while keeping the LCE core intact, we expect LCE fibers produced in this way to have potential to be used as actuators, for instance in soft robotics and responsive textiles.

Expression, crosslinking, and developing modulus master curves of recombinant resilin

Resilin is a disordered elastomeric protein found in specialized regions of insect cuticles, where low stiffness and high resilience are required. Having a wide range of functions that vary among insect species, resilin operates across a wide frequency range, from 5Hz for locomotion to 13kHz for sound production. We synthesize and crosslink a recombinant resilin from clone-1 (exon-1+exon-2) of the gene, and determine the water content (approximately 80wt%) and dynamic mechanical properties, along with estimating surface energies relevant for adhesion. Dynamic moduli master curves have been developed, by applying the time-temperature superposition principle (TTSP) and time-temperature concentration superposition principle (TTCSP), and compared with reported master curves for natural resilin from locusts, dragonflies, and cockroaches. To our knowledge, this is the first time dynamic moduli master curves have been developed to explore the dynamic mechanical properties of recombinant resilin and compare with resilin behavior. The resulting master curves show that the synthetic resilin undergoes a pronounced transition with increasing ethanol concentrations, with the storage modulus increasing by approximately three orders of magnitude. Although possibly a glass transition, alternate explanations include the formation of intramolecular hydrogen bonds or that the chitin binding domain (ChBD) in exon-2 might change the secondary structure of the normally disordered exon-1 into more ordered conformations that limit deformation.

Effects of Solvent Crystallization in Swollen net-Poly(ethyl acrylate) α Relaxation Dynamics

The polymer α relaxation process for net-PEA gels swollen with nonpolar p-xylene is studied by employing dielectric relaxation spectroscopy. The results present the in situ monitoring of the dielectric behavior of α relaxation process under p-xylene cold crystallization, isothermal crystallization as well as crystallization from quenching. For the partially crystallized systems, the results exhibit that the amount of p-xylene crystal phase has no remarkable effects on the time scale, being controlled mainly by the amount of the noncrystallized p-xylene (c_px= 0.11-0.15) gel phase. Surprisingly, the stretching exponent β_KWW obtains higher values in the isothermal crystallization process as the p-xylene crystallization is in progress and the reorganization of p-xylene through diffusion to crystallites approaches thermodynamic equilibrium. This directly indicates that any α process broadening is originated not solely from the amount of p-xylene crystallites and the induced heterogeneities, but from the presence of remarkable concentration fluctuations close to respective effective glass transition temperature, enhanced for higher solvent contents as well. Finally, the results suggest that the existence of p-xylene crystallites decrease significantly the dielectric strength of α process. The effective medium theory is applied to check whether this recorded reduction originates from the induced spatial heterogeneities (p-xylene crystallites) or from the immobilization in parts of polymer configurations.

Tuning Polymer Glass Formation Behavior and Mechanical Properties with Oligomeric Diluents of Varying Stiffness

Small-molecule diluents are important tools in the control of polymers' glass formation, transport, and mechanical properties. While recent work has indicated that these diluents can impose a more diverse range of effects than previously appreciated, use of these additives to rationally control polymer properties requires a predictive understanding of their effects. Here we employ molecular dynamics simulations to show that diluent-induced changes in a polymer's glass transition temperature T_g can be predicted based on the diluent's Debye-Waller factor ⟨u²⟩, a measure of picosecond time scale rattle-space, via a functional form previously found to predict nanoconfinement-induced shifts in polymer T_g. Moreover, we show that diluent-induced alterations in polymer segmental relaxation time are related to changes in modulus and ⟨u²⟩ via the Generalized Localization Model of relaxation. These results provide new design principles for the use of oligomeric diluents in achieving independent, targeted control of structural relaxation and glassy moduli.

Controlled porosity solubility modulated osmotic pump tablets of gliclazide

A system that can deliver drug at a controlled rate is very important for the treatment of various chronic diseases such as diabetes, asthma, and heart disease. Poorly water-soluble drug with pH-dependent solubility such as gliclazide (GLZ) offers challenges in the controlled-release formulation because of low dissolution rate and poor bioavailability. Solid dispersion (SD) of GLZ consisted of hydroxypropyl cellulose (HPC-SSL) as a polymeric solubilizer was manufactured by hot melt extrusion (HME) technology. Then, controlled porosity osmotic pump (CPOP) tablet of gliclazide was designed to deliver drug in a controlled manner up to 16 h. The developed formulation was optimized for type and level of pore former and coating weight gain. The optimized formulation was found to exhibit zero order kinetics independent of pH and agitation speed but depends on osmotic pressure of dissolution media indicated that mechanism of drug release was osmotic pressure. The in vivo performance prediction of developed formulation using convolution approach revealed that the developed formulation was superior to the existing marketed extended-release formulation in terms of attaining steady state plasma levels and indicated adequate exposure in translating hypoglycemic response. The prototype solubilization method combined with controlled porosity osmotic pump based technique could provide a unique way to increase dissolution rate and bioavailability of many poorly water-soluble, narrow therapeutic index drugs used in diabetes, cardiovascular diseases, etc.