Microfluidic polymer multilayer adsorption on liquid crystal droplets for microcapsule synthesis

Exploiting microfluidic principles, the potential for chip-based multilayer assembly for the synthesis of polymer microcapsules was investigated. We demonstrate that continuous flow microfluidic multilayer synthesis is a fast, efficient, automated alternative to conventional batch synthesis. In this work, we dispersed liquid crystal (LC) molecules (organic phase) as monodisperse droplets in an aqueous continuous phase containing the primary polymer and a suitable surfactant. The primary polymer was coadsorbed with the surfactant at the organic/aqueous interface, stabilizing the LC droplets against coalescence and providing a template for subsequent polymer adsorption. As the droplet templates are transported through the microfluidic channel, the polymer-containing aqueous continuous phase is selectively withdrawn and replaced with rinse solution, and then with an alternative polymer solution. This selective withdrawal and infusion cycle was repeated to assemble polymer multilayers onto the emulsion droplets. The process was followed using fluorescence microscopy of the fluorescently-labelled polymers at the LC interface and of the flowing polymer solutions during the sequential rinse stages. Cross-linking of the multilayers and removal of the dispersed LC phase resulted in polymer capsules retaining the high monodispersity of the droplet templates. This microfluidic approach significantly reduces the multilayer formation time (to <2 min for 3-layer capsules) of well-defined capsules that are envisaged to have benefits in biomedical applications, including drug delivery and encapsulated biochemical reactions.