Xiaodong Caoabc,
Wenxiu Liabc,
Ting Maab and
Hua Dong
*abc
aDepartment of Biomedical Engineering, School of Materials Science and Engineering, South China University of Technology, Guangzhou, 510006, China. E-mail: donghua@scut.edu.cn
bNational Engineering Research Center for Tissue Restoration and Reconstruction, Guangzhou, 510641, China
cGuangdong Province Key Laboratory of Biomedical Engineering, South China University of Technology, Guangzhou, 510641, China
First published on 15th September 2015
We report in this paper a one-step route for the preparation of core–shell, patchy, patchy Janus and Janus particles via a microfluidic-assisted phase separation process. As a proof of concept, PLGA/PCL hybrid particles are fabricated and the results show that the four types of particles can be harvested with high yield and narrow size distribution by precise control over the phase separation process, or namely, interfacial tensions and spreading coefficients between immiscible phases, after generation of the single emulsion in microchannels. This new strategy described herein is rather simple and versatile for producing a wide range of other particles with simultaneously controlled size, shape and anisotropy.
In our earlier paper,23 we presented a simple method to synthesize Janus and microcapsule particles via droplet-based microfluidic technology. Herein, we further show one-step fabrication of core–shell, patchy, patchy Janus and Janus particles by subtle combination of droplet-based microfluidics and phase separation (Scheme 1). With the assistance of droplet-based microfluidics, oil-in-water (O/W) single emulsions with highly uniform size can be generated (Fig. S1, ESI†), which promises the homogeneity in the subsequent phase separation process and thus the high yield in one specific particle type. In our opinion, the key point to realize the diversity in particle architectures lies in the precise control over the phase separation of a droplet under various conditions, or namely, interfacial tensions and spreading coefficients between immiscible phases. In particular, we demonstrate that interfacial tensions and spreading coefficients can be deliberately and continuously tuned in our system, resulting in variable but controllable phase separation from single emulsion and then distinct particle anisotropy.
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1, w/w) was then poured onto the silicon wafer, degassed by vacuum oven and cured on a hotplate at 60 °C. The PDMS replica was subsequently peeled off and sealed with a glass slide via O2 plasma. The width of branch channel and collection channel were 100 μm and 250 μm, and the depth of all channels was 100 μm (see schematic illustration of the device in Fig. S1a†). To improve the hydrophilicity of microchannels and reduce the swelling problem of PDMS caused by dichloromethane, surface modification was conducted by injecting PVA/glycerol (2/5 wt%) aqueous solution and curing for 1 h.
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8, 3
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7, 5
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5 or 7
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3, w/w) dissolved in dichloromethane, dimethyl carbonate or their mixture (5
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1 or 1
:
2, v/v) with a total concentration of 40 mg mL−1 were used as the dispersed phase, whilst an aqueous solution containing 2 wt% of PVA was used as the continuous phase. Both the dispersed phase and continuous phase were delivered into the microfluidic channels using syringe pumps (Cole-Parmer, USA). Before injecting the dispersed phase, the microchannels were wetted with the continuous phase for several minutes to benefit the formation of O/W droplets. For microcapsule and patchy particles, the flow rates of the continuous and dispersed phases were set as 0.25 and 0.45 mL h−1 (the corresponding yield was ∼2.7 × 105 h−1). In the case of Janus and patchy Janus particles, the flow rates for the continuous and dispersed phases were held at 0.4 and 1.6 mL h−1 (the corresponding yield was ∼1.2 × 106 h−1). Droplets were generated continuously at the junction of the microchannels and then collected in 2 wt% aqueous solution of PVA (Fig. S1b and c†). After settling at room temperature for 24 h, the solidified microparticles were centrifuged, washed for 3 times with DI water and finally dried in a freeze-drier (Lyophilizer, VIRTIS, USA).
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3 and 5
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5, core–shell particles are harvested with high productivity. Instead, when the PLGA/PCL mass ratios change to 3
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7 and 2
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8, anisotropic patchy particles can be both obtained, expect that surface patches are bigger at higher mass ratio (3
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7). To figure out the distribution of PLGA and PCL on the particle surface, acetone treatment was introduced to selectively dissolve PLGA, because acetone is a good solvent for PLGA but relatively difficult to dissolve PCL in a very short time.25 As can be seen, core–shell particles still maintain an approximately spherical structure after treated with acetone but the particle surface is not smooth anymore, which proves the original shell is made of PLGA. The rough surface of remaining particle might be attributed to the semi-crystalline state of PCL. The smaller particle size in Fig. 1(A3) implies a thicker PLGA shell in the untreated core–shell particles prepared under the mass ratio of 7
:
3. On the other hand, patchy particles after acetone treatment show many surface dimples and the whole structure turns out to be golf ball-like, confirming that surface patches are composed of PLGA. Surprisingly, although core–shell and patchy particles exhibit distinct surface morphologies, their inner structures are quite similar, as supported by the SEM images of cross-sectioned particles where many tiny PLGA beads are encapsulated in the PCL matrix (Fig. S2, ESI†). In addition, rhodamine B, a hydrophilic fluorescent dye, was also used to stain hydrophilic PLGA in the PLGA/PCL particles with the CLSM images shown in Fig. 1(A4–D4). The locations of PLGA highlighted by rhodamine B are in good agreement with the conclusions drawn from acetone treatment.
In contrast, if dimethyl carbonate was employed as the organic solvent, the as-prepared particles show a typical Janus architecture with two well-defined regions and an apparent demarcation in between, indicative of the complete phase separation in the formation of such particles (Fig. 2). The shift of the demarcation line towards either the smooth or rough compartments with the variation in PLGA/PCL mass ratios verifies our anticipation, i.e., the smooth compartment belongs to PLGA whilst the rough one belongs to PCL. Once subjected to acetone for 30 s, all the Janus particles lose their PLGA components and the residual PCL becomes chesspiece-like, hemispheric and pileus-like respectively, as shown in Fig. 2(A3–C3). Interestingly, rhodamine B-stained Janus particles delineate the shape of PLGA compartments that are dissolved away in acetone treatment. Considering the significant difference in particle morphologies achieved by sole dichloromethane or dimethyl carbonate, it is conceivable of a transition structure in the case of mixed solvents. Fig. 3 presents the particles fabricated under two volume ratios of dichloromethane and dimethyl carbonate (1
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5 and 2
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1) and a constant mass ratio of PLGA/PCL (5
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5). It is clear that patchy Janus particles with a smooth hemisphere and a patchy hemisphere are finally formed. Compared with the particles shown in Fig. 3(A2), the demarcation line of the particle in Fig. 3(B2), intrudes towards the smooth hemisphere when the volume ratio of solvents is 2
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1. The acetone treatment reveals that the smooth hemisphere and surface patches on the other hemisphere disappear, suggesting that the missing parts are PLGA and the matrix of the patchy hemisphere is PCL. Similarly, CLSM images visualize the PLGA components on the particle surface and further prove patchy Janus structure.
In addition to acetone treatment and CLSM measurement, attenuated total reflection Fourier transform infrared spectroscopy (ATR-FTIR) and X-ray diffraction (XRD) were also recorded to identify the distribution of PLGA and PCL in the above-mentioned particles. The FTIR spectra in Fig. 4A show that only the characteristic peaks of PLGA at 2998, 2951, 1759, 1129 and 1086 cm−1 can be detected on the core–shell particle surface. This phenomenon implies that PCL is embedded inside the core–shell particles. Comparatively, except the PLGA peaks at 2997 and 1755 cm−1, the PCL peaks at 2946, 2865, 1737 and 731 cm−1 are also observed for patchy and Janus particles, which confirms the co-existence of PLGA and PCL on these two particle surfaces. Meanwhile, the XRD profiles of core–shell, patchy and Janus particles in Fig. 4B all display the diffraction peaks of amorphous PLGA and crystalline PCL, but the diffraction peak of PLGA is more remarkable on core–shell particles. A possible explanation is that only PLGA phase occupies the outside shell of core–shell particles.
Fig. 5 summarizes the effects of the volume ratio of dichloromethane/dimethyl carbonate and mass ratio of PLGA/PCL on particle structures. High volume ratio of dichloromethane/dimethyl carbonate and high mass ratio of PLGA/PCL benefit the fabrication of core–shell particles, whereas high volume ratio of dichloromethane/dimethyl carbonate and low mass ratio of PLGA/PCL yields predominantly patchy particles. In comparison, Janus particles show weak relationship with the mass ratio of PLGA/PCL and can be generated under low volume ratio of dichloromethane/dimethyl carbonate. If medium volume ratio of dichloromethane/dimethyl carbonate and medium mass ratio of PLGA/PCL are used, anisotropic patchy Janus particles are the main products.
Although monodisperse core–shell, patchy, patchy Janus and Janus particles can be fabricated using the same device and analogous conditions, it should be pointed out that the particle type and size is almost invariable in terms of given parameters (see average particle size and size distribution in Fig. S3 and Table S1, ESI†), mainly owing to precise control over droplet formation via microfluidic devices and phase separation during solvent extraction.26 As we know, the equilibrium type of two immiscible phases in a third phase can be theoretically predicted from the interactive interfacial tensions between different phases (γij, γik, γjk) and spreading coefficients (Si),27 as stated in eqn (1):
| Si = γjk − (γij + γik) | (1) |
In our system, the oil phase containing PLGA, the aqueous solution of 2 wt% PVA and the oil phase containing PCL are defined as phase 1, 2 and 3, respectively. Table 1 lists the interfacial tensions measured via the Wilhelmy plate method and the spreading coefficients calculated using eqn (1). Since the solubility of dichloromethane in water is quite low (2 wt% at 20 °C), the dissolved PLGA and PCL in dichloromethane or its mixture with dimethyl carbonate are completely miscible for a long time (∼3–4 h for pure dichloromethane). Therefore, their interfacial tension γ13 is assumed as zero. Compared with dichloromethane, dimethyl carbonate shows much higher solubility in water (13.9 wt% at 20 °C20) and thus can be extracted from the emulsion quickly (<30 s). As a result, the interfacial tension between PLGA and PCL dissolved in dimethyl carbonate cannot be measured via the Wilhelmy plate method and is actually calculated based on their surface energy (see Table S2 for detailed measurement and calculation, ESI†).
| DCM/DMC (v/v) | PLGA/PCL (w/w) | γ12 (mN m−1) | γ13 (mN m−1) | γ23 (mN m−1) | S1 (mN m−1) | S2 (mN m−1) | S3 (mN m−1) | Equilibrium type | Particle structure |
|---|---|---|---|---|---|---|---|---|---|
| a Note: γ12 and γ23 were measured via the Wilhelmy plate method. γ13 was assumed as 0 for PLGA–PVA–PCL systems containing dichloromethane (DCM) and calculated via the surface energy of PLGA and PCL for PLGA–PVA–PCL systems containing pure dimethyl carbonate (DMC). The total concentrations of PLGA and PCL in the oil phase were 40 mg mL−1 except the sample marked by * where the total concentration was 80 mg mL−1. | |||||||||
| DCM | 7 : 3 |
0.620 | 0 | 1.016 | +0.396 | −1.636 | −0.395 | Wetting | Core–shell |
5 : 5 |
2.170 | 0 | 2.330 | +0.160 | −4.500 | −0.160 | Wetting | Core–shell | |
5 : 5* |
2.87* | 0* | 1.72* | −1.15* | −4.59* | +1.15* | Wetting* | Core–shell* | |
3 : 7 |
1.381 | 0 | 0.933 | −0.448 | −2.314 | +0.448 | Wetting | Patchy | |
2 : 8 |
1.367 | 0 | 1.197 | −0.170 | −2.564 | +0.170 | Wetting | Patchy | |
1 : 5 |
5 : 5 |
1.005 | 0 | 0.765 | −0.240 | −1.770 | +0.240 | Wetting | Patchy Janus |
2 : 1 |
5 : 5 |
1.151 | 0 | −0.022 | −1.173 | −1.129 | +1.173 | Wetting | Patchy Janus |
| DMC | 7 : 3 |
2.946 | 7.480 | 2.581 | −7.845 | +1.953 | −7.115 | Dewetting | Janus |
5 : 5 |
3.080 | 7.480 | 2.920 | −7.640 | +1.480 | −7.320 | Dewetting | Janus | |
3 : 7 |
3.585 | 7.480 | 3.123 | −7.942 | +0.772 | −7.018 | Dewetting | Janus | |
With respect to the emulsion using dichloromethane as organic solvent, the signs of S1, S2 and S3 are variable, as functions of the mass ratio of PLGA/PCL and total concentration of these two components. At high PLGA/PCL mass ratio (7
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3 and 5
:
5) and low total concentration (for example, the initial total concentration of 40 mg mL−1), the positive S1, negative S2 and S3 meet the criteria of complete wetting, indicative of a core–shell structure with PLGA as the shell and PCL as the core. With the extraction of more dichloromethane into the water, the total concentration of PLGA and PCL increases, accompanying by the increase of γ12 and decrease of γ23 (in our study, 80 mg mL−1 was used for the measurement of γ12 and γ23 at high total concentration). This triggers the inversion of S1 and S3, leading to the encapsulation of PLGA in the PCL matrix inside the particle. However, the movement of PLGA molecules would be greatly slowed down in high-molecular-weight PCL matrix and thus the coalescence of tiny PLGA beads into larger PLGA core are restricted. At low PLGA/PCL mass ratio (3
:
7 and 2
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8), only S3 is positive regardless of the total concentration. In principle, PLGA should be encapsulated into the PCL matrix during the solidification process. However, the PLGA beads formed at the particle surface by phase separation show low mobility across the PCL matrix, which causes the formation of surface patches.
Instead of the complexity induced by dichloromethane, the equilibrium type of emulsion using dimethyl carbonate is quite stable, i.e., the spreading coefficient S2 is always positive and the other two (S1 and S3) are negative, satisfying the condition of dewetting. As a consequence, only Janus particles can be fabricated, no matter how to change the mass ratio of PLGA/PCL. In the case of the mixed solvents, the measurements show S1 < 0, S2 < 0, and S3 > 0, similar to the results of patchy particles. However, due to the presence of dimethyl carbonate and its high solubility in water, phase separation between PLGA and PCL in mixed solvents starts dynamically according to dewetting mode just like pure dimethyl carbonate before it completely diffuses into water. Thereafter, phase separation continues according to wetting mode like pure dichloromethane. The former causes the formation of Janus structure whereas the latter results in patchy structure, which finally combines into patchy Janus shape. Obviously, the volume percentage of patchy compartment in patchy Janus particles can be tuned via the volume ratio of dichloromethane and dimethyl carbonate. As the volume ratio of dichloromethane and dimethyl carbonate increases (for example, 1
:
5), it takes more time to finish the first-step of phase separation (dewetting mode) and thus the patchy compartment is smaller.
Nevertheless, although only PLGA/PCL particles were investigated in the current study, our new strategy can be adopted to fabricate a wide range of other particles, if the corresponding emulsion system can meet the requirements predicted by the spreading and partial wetting theory, i.e., S1 > 0, S2 < 0 and S3 < 0 for core–shell structure, S1 < 0, S2 < 0 and S3 > 0 for patchy or patchy Janus structure, S1 < 0, S2 > 0 and S3 < 0 for Janus structure.
Footnote |
| † Electronic supplementary information (ESI) available. See DOI: 10.1039/c5ra16504k |
| This journal is © The Royal Society of Chemistry 2015 |