Tsutomu Ono

Microfluidics is a fascinating tool for colloidal materials design. It precisely controls the interface of immiscible fluids in a microchannel such as droplets, slug flow and jet flow. Monodisperse droplets prepared by microfluidic emulsification are readily converted into monodisperse particles by solvent diffusion. Furthermore, controlling the inner phase separation leads to construct the capsule structure containing oil or aqueous liquid. Based on the same concept, the rapid solidification from jet flow enables wet-spinning of nanofibers. In this review, we show our experimental procedure and the leading results and discuss key factors to develop such a microfluidic process to produce well-defined materials.

A simple approach to preparing monodisperse poly(D,L-lactide) (PDLLA) microcapsules with a single aqueous core is developed. The method is based on automatic water-in-oil-in-water double emulsion formation from oil-in-water single emulsion via spontaneous emulsification which voluntarily disperses part of continuous aqueous phase into the dispersed oil phase dissolving oil-soluble amphiphilic diblock copolymer, poly(D,L-lactide)-b-poly(2-dimethylaminoethyl methacylate)(PDLLA-b-PDMAEMA), followed by coalescence of tiny water droplets within the polymer droplets, coupled with quick precipitation of polymers by diluting the emulsion with water. In this study, we have investigated the effect of PDLLA to PDLLA-b-PDMAEMA ratios and flow rates of each solution during preparing the emulsion on the final morphology and the size of the microcapsules. It was found that the polymer blend ratio played a crucial role in determining internal structure of the microcapsules. The microcapsules size decreased with the increment of the flow rate ratios of the continuous phase to the dispersed phase and eventually reached 10 μm, while maintaining narrow size distribution. In addition, we have demonstrated that the microcapsules can encapsulate both hydrophilic and hydrophobic compounds during the formation.

We describe a versatile and facile route to the continuous production of monodisperse polylactide (PLA) microcapsules with controllable structures. With the combination of microfluidic emulsification, solvent diffusion, and internal phase separation, uniform PLA microcapsules with a perfluorooctyl bromide (PFOB) core were successfully obtained by simply diluting monodisperse ethyl acetate (EA)-in-water emulsion with pure water. Rapid extraction of EA from the droplets into the aqueous phase enabled the solidification of the polymer droplets in a nonequilibrium state during internal phase separation between a concentrated PLA/EA phase and a PFOB phase. Higher-molecular-weight PLA generated structural complexity of the microcapsules, yielding core–shell microcapsules with covered with small PFOB droplets. Removal of the PFOB via freeze drying gave hollow microcapsules with dimpled surfaces. The core–shell ratios and the diameter of these microcapsules could be finely tuned by just adjusting the concentration of PFOB and flow rates on emulsification, respectively. These biocompatible microcapsules with controllable size and structures are potentially applicable in biomedical fields such as drug delivery carriers of many functional molecules.

Polymeric micro‐ and nanoparticles receive the attention of researchers in different areas such as drug delivery, sensing, imaging, cosmetics, diagnostics, and biotechnology. However, processes with conventional equipment do not always allow precise control of their morphology, size, size distribution, and composition. On the other hand, microreaction technology offers improved control over the hydrodynamics, mass and heat transfer, allowing production of polymeric particles with better defined or new characteristics. Thus new horizons in polymer particle engineering arise from the use of microstructured or microfluidic devices. This article gives an insight into the latest developments and trends in the production of polymeric micro‐ and nanoparticles realized by microreaction technology directly.

Monodisperse polylactide (PLA) microspheres were continuously fabricated by microfluidic emulsification and subsequent dilution in water. The diameter was precisely tuned from 6 to 50 μm by changing the flow rate of the fluids in microfluidics or the PLA concentration in the dispersed phase. The use of amphiphilic oil-soluble poly(ethylene glycol)-b-polylactide (o-PEG–PLA) as a matrix resulted in a highly porous microsphere morphology, and the porosity was controlled by blending PLA. Therefore, monodisperse PLA microspheres with the predetermined surface porosity were continuously produced by just enough reagents and energy.

The liquid–liquid extraction dynamics of an ethyl ester of docosahexaenoic acid (DHA‐Et) with silver ion was investigated. The kinetic model was derived according to the following stepwise processes: Diffusion of DHA‐Et across the organic film, complex‐formation between DHA‐Et and silver ion at the interface, and diffusion of extracted complex across the aqueous film. The kinetic parameters for the complex‐formation reaction were determined from the investigation with the stirred transfer cell. With the proposed model and determined parameters, we predicted the uptakes of DHA‐Et for the extraction system utilizing a slug flow prepared by a microchip. The calculated uptakes showed good correlation to the experimental data. The theoretical investigation suggested that the fast equilibration realized for the slug flow extraction system was due to the large specific interfacial area of the slug caused by the presence of wall film and the thin liquid film caused by the internal circulation. © 2009 American Institute of Chemical Engineers AIChE J, 2010