Continuous generation of cross-linked polymer nanoparticles employing an ultrasonic microreactor.

In this article, a new system employing an ultrasonic microreactor coupled with a tubular reactor is presented for the continuous generation of polymer nanoparticles. The continuous generation of cross-linked polymer nanoparticles utilizing the monomer butyl methacrylate and the cross-linker ethylene glycol dimethacrylate is demonstrated. Firstly, the miniemulsion polymerization of a monomer-in-water miniemulsion is studied in a batch system. Secondly, a coiled tubular reactor is employed for the continuous polymerization of the miniemulsion generated by an ultrasonic microreactor. Finally, the influence of monomer volume fraction and surfactant concentration on the synthesized polymer nanoparticles is studied. Polymer particles in a size range of 50-250 nm are synthesized and a high polymerization conversion is achieved utilizing the system demonstrated in this article.

Sideways propelled bimetallic rods at the water/oil interface.

The motion of self-propelling microswimmers is significantly affected by confinement, which can enhance or reduce their mobility and also steer the direction of their propulsion. While their interactions with solid boundaries have already received considerable attention, many aspects of the influence of liquid-liquid interfaces (LLI) on active particle propulsion still remain unexplored. In this work, we studied the adsorption and motion of bimetallic Janus sideways propelled rods dispersed at the interface between an aqueous solution of hydrogen peroxide and oil. The wetting properties of the bimetallic rods result in a wide distribution of their velocities at the LLI. While a fraction of rods remain immotile, we note a significant enhancement of motility for the rest of the particles with velocities of up to 8 times higher in comparison to those observed near a solid wall. Liquid-liquid interfaces, therefore, can provide a new way to regulate the propulsion of bimetallic particles.

Encapsulation of Cadmium-Free InP/ZnSe/ZnS Quantum Dots in Poly(LMA-co-EGDMA) Microparticles via Co-flow Droplet Microfluidics.

Quantum dots (QDs) are semiconductor nanocrystals that are used in optoelectronic applications. Most modern QDs are based on toxic metals, for example Cd, and do not comply with the European Restriction of Hazardous Substances regulation of the European Union. Latest promising developments focus on safer QD alternatives based on elements from the III-V group. However, the InP-based QDs lack an overall photostability under environmental influences. One design path of achieving stability is through encapsulation in cross-linked polymer matrices with the possibility to covalently link the matrix to surface ligands of modified core-shell QDs. The work focuses on the formation of polymer microbeads suitable for InP-based QD encapsulation, allowing for an individual protection of QDs and an improved processibility via this particle-based approach. For this, a microfluidic based method in the co-flow regime is used that consists of an oil-in-water droplet system in a glass capillary environment. The generated monomer droplets are polymerized in-flow into poly(LMA-co-EGDMA) microparticles with embedded InP/ZnSe/ZnS QDs using a UV initiation. They demonstrate how a successful polymer microparticle formation via droplet microfluidics produces optimized matrix structures leading to a distinct photostability improvement of InP-based QDs compared to nonprotected QDs.

Constraint Release Rouse Mechanisms in Bidisperse Linear Polymers: Investigation of the Release Time of a Short-Long Entanglement.

Despite a wide set of experimental data and a large number of studies, the quantitative description of the relaxation mechanisms involved in the disorientation process of bidisperse blends is still under discussion. In particular, while it has been shown that the relaxation of self-unentangled long chains diluted in a short chain matrix is well approximated by a Constraint Release Rouse (CRR) mechanism, there is no consensus on the value of the average release time of their entanglements, τobs, which fixes the timescale of the CRR relaxation. Therefore, the first objective of the present work is to discuss the different approaches proposed to determine this time and compare them to a large set of experimental viscoelastic data, either newly measured (poly(methyl-)methacrylate and 1,4-polybutadiene blends) or coming from the literature (polystyrene and polyisoprene blends). Based on this large set of data, it is found that with respect to the molar mass of the short chain matrix, τobs follows a power law with an exponent close to 2.5, rather than 3 as previously proposed. While this slight change in the power law exponent does not strongly affect the values of the constraint release times, the results obtained suggest the universality of the CRR process. Finally, we propose a new description of τobs, which is implemented in a tube-based model. The accurate description of the experimental data obtained provides a good starting point to extend this approach to self-entangled binary blends.

Emulsification mechanism in an ultrasonic microreactor: Influence of surface roughness and ultrasound frequency.

An ultrasonic microreactor with rough microchannels is presented in this study for oil-in-water (O/W) emulsion generation. Previous accounts have shown that surface pits or imperfections localize and enhance cavitation activity. In this study cavitation bubbles are localized on the rough microchannels of a borosilicate glass microreactor. The cavitation bubbles in the microchannel are primarily responsible for emulsification in the ultrasonic microreactor. We investigate the emulsification mechanism in the rough microchannels employing high-speed imaging to reveal the different emulsification modes influenced by the size and oscillation intensity of the cavitation bubbles. The effect of emulsification modes on the O/W emulsion droplet size distribution for different surface roughness and frequency is demonstrated. The positive effect of the frequency on minimizing the droplet size utilizing a reactor with large pits is presented. We also demonstrate microreactor systems for a successful generation of miniemulsions with high dispersed phase volume fractions up to 20%. The observed emulsification mechanism in the rough microchannel offers new insights into the utility and scale-up of ultrasonic microreactors for emulsification.

'Sweeping rods': cargo transport by self-propelled bimetallic microrods moving perpendicular to their long axis.

A possible application of self-propelling particles is the transport of microscopic cargo. Maximizing the collection and transport efficiency of particulate matter requires the area swept by the moving particle to be as large as possible. One such particle geometry are rods propelled perpendicular to their long axis, that act as "sweepers" for collecting particles. Here we report on the required Janus coating to achieve such motion, and on the dynamics of the collection and transport of microscopic cargo by sideways propelled Janus rods.

Unravelling the Miscibility of Poly(2-oxazoline)s: A Novel Polymer Class for the Formulation of Amorphous Solid Dispersions.

Water-soluble polymers are still the most popular carrier for the preparation of amorphous solid dispersions (ASDs). The advantage of this type of carrier is the fast drug release upon dissolution of the water-soluble polymer and thus the initial high degree of supersaturation of the poorly soluble drug. Nevertheless, the risk for precipitation due to fast drug release is a phenomenon that is frequently observed. In this work, we present an alternative carrier system for ASDs where a water-soluble and water-insoluble carrier are combined to delay the drug release and thus prevent this onset of precipitation. Poly(2-alkyl-2-oxazoline)s were selected as a polymer platform since the solution properties of this polymer class depend on the length of the alkyl sidechain. Poly(2-ethyl-2-oxazoline) (PEtOx) behaves as a water-soluble polymer at body temperature, while poly(2-n-propyl-2-oxazoline) (PPrOx) and poly(2-sec-butyl-2-oxazoline) (PsecBuOx) are insoluble at body temperature. Since little was known about the polymer's miscibility behaviour and especially on how the presence of a poorly-water soluble drug impacted their miscibility, a preformulation study was performed. Formulations were investigated with X-ray powder diffraction, differential scanning calorimetry (DSC) and solid-state nuclear magnetic resonance spectroscopy. PEtOx/PPrOx appeared to form an immiscible blend based on DSC and this was even more pronounced after heating. The six drugs that were tested in this work did not show any preference for one of the two phases. PEtOx/PsecBuOx on the other hand appeared to be miscible forming a homogeneous blend between the two polymers and the drugs.

Unraveling Particle Formation: From Single Droplet Drying to Spray Drying and Electrospraying.

Spray drying and electrospraying are well-established drying processes that already have proven their value in the pharmaceutical field. However, there is currently still a lack of knowledge on the fundamentals of the particle formation process, thereby hampering fast and cost-effective particle engineering. To get a better understanding of how functional particles are formed with respect to process and formulation parameters, it is indispensable to offer a comprehensive overview of critical aspects of the droplet drying and particle formation process. This review therefore closely relates single droplet drying to pharmaceutical applications. Although excellent reviews exist of the different aspects, there is, to the best of our knowledge, no single review that describes all steps that one should consider when trying to engineer a certain type of particle morphology. The findings presented in this article have strengthened the predictive value of single droplet drying for pharmaceutical drying applications like spray drying and electrospraying. Continuous follow-up of the particle formation process in single droplet drying experiments hence allows optimization of manufacturing processes and particle engineering approaches and acceleration of process development.

Mechanodegradation of Polymers: A Limiting Factor of Mechanochemical Activation in the Production of Amorphous Solid Dispersions by Cryomilling.

In this study, we report on the influence of mechanochemical activation on the chemical stability of amorphous solid dispersions made up of indomethacin and hydroxypropyl methyl cellulose (HPMC), poly(vinylpyrrolidone) (PVP), poly(vinylpyrrolidone vinylacetate) (PVPVA), or Soluplus. In agreement with our recently published work, all applied carriers were found to be prone to polymer degradation. Covalent bonds within the polymers were cleaved and mechanoradicals were generated. Furthermore, decomposition of indomethacin was also observed but occurred only in the presence of polymers. Hence, it is proposed that the generated mechanoradicals from the polymers are responsible for the chemical degradation of indomethacin. Our study also strongly suggests the existence of a critical polymer- and process-dependent molecular weight limit "M∞", below which only limited mechanodegradation takes place since the lower-molecular-weight polymer PVP K12PF had a less profound influence on the degradation of indomethacin in comparison to PVP K25.

Preparation of Amorphous Solid Dispersions by Cryomilling: Chemical and Physical Concerns Related to Active Pharmaceutical Ingredients and Carriers.

In this work, a chemical (and physical) evaluation of cryogenic milling to manufacture amorphous solid dispersions (ASDs) is provided to support novel mechanistic insights in the cryomilling process. Cryogenic milling devices are considered as reactors in which both physical transitions (reduction in crystallite size, polymorphic transformations, accumulation of crystallite defects, and partial or complete amorphization) and chemical reactions (chemical decomposition, etc.) can be mechanically triggered. In-depth characterization of active pharmaceutical ingredient (API) (content determination) and polymer (viscosity, molecular weight, dynamic vapor sorption, Fourier transform infrared spectroscopy, dynamic light scattering, and ANS and thioflavin T staining) chemical decomposition demonstrated APIs to be more prone to chemical degradation in case of presence of a polymer. A significant reduction of the polymer chain length was observed and in case of BSA denaturation/aggregation. Hence, mechanochemical activation process(es) for amorphization and ASD manufacturing cannot be regarded as a mild technique, as generally put forward, and one needs to be aware of chemical degradation of both APIs and polymers.

Feasibility of electrospraying fully aqueous bovine serum albumin solutions.

Electrospraying or electrohydrodynamic atomisation, i.e. the formation of tiny droplets from a jet of conductive liquid under the influence of an electric field, has been gaining in popularity as a particle engineering technique in recent years. In addition to general benefits for particle engineering, e.g. the ability to generate nanometre sized particles with a very narrow size distribution, electrospraying also possesses a number of characteristics, like its applicability at ambient conditions, which could make it especially interesting for formulating therapeutic proteins. However, as fully aqueous solutions of proteins tend to have relatively high electrical conductivities and surface tensions, obtaining a stable Taylor cone-jet mode for these solutions is inherently challenging. This is why in the majority of studies reporting the successful electrospraying of proteins, either emulsions, aqueous suspensions or a mixture of water and one or more organic solvents were used instead of fully aqueous solutions. Therefore, an ab initio electrospraying formulation development study was conducted, using only fully aqueous feed solutions containing protein stabilising excipients commonly used in spray- and freeze-drying of therapeutic proteins. The study included bovine serum albumin (BSA) as a model protein and consisted out of two parts: (1) a one parameter at a time screening study, designed to improve the understanding of how various formulation components influence relevant physicochemical properties and the electrospraying process and (2) two subsequent mixture design of experiments (DoE) studies, designed to aid in the statistical description and prediction of the influence of different protein-excipient combinations on the electrospraying process. Additionally, the influence of physicochemical properties relevant to the electrospraying process, i.e. the volumetric mass density, electrical conductivity, kinematic viscosity and surface tension, was assessed for all feed solutions included in the study.

Gastro-resistant encapsulation of amorphous solid dispersions containing darunavir by coaxial electrospraying.

The relatively simple technique of coaxial electrospraying allows to produce core-shell microparticles with potentially high encapsulation efficiencies. In this study, amorphous solid dispersions of a hydroxypropyl methylcellulose or polyvinlypyrrolidone based polymer matrix containing the active pharmaceutical ingredient darunavir were coated with a gastro-resistant shell polymer that does not dissolve at lower pH present in the stomach, but only later at a higher pH in the small intestine. A multitude of shell polymers were tested with the aim to identify a material that limits the drug release to less than 10% after two hours at a pH of 1 to comply with the European Pharmacopoeia regarding gastro-resistant formulations. In parallel, the core-shell structure of the particles was determined with confocal imaging and their surface morphology with SEM imaging. While the structural analysis revealed significant differences between the different formulations, all investigated shell polymers exhibited a burst drug release followed by a slow release for the remainder of a two hour period. Ultimately, the shell copolymer poly(methacrylic acid-co-methyl methacrylate), in particular for a monomer ratio 1/2, resulted consistently in darunavir release below the 10% upper limit compared to the other tested polymers, where such low releases were inaccessible. Further investigation of this shell polymer revealed that both the monomer ratio of methacrylic acid to methyl methacrylate in the copolymer and the utilized solvent are determining factors in the release performance of the final particles.

Fixed dose combinations for cardiovascular treatment via coaxial electrospraying: Coated amorphous solid dispersion particles.

As a result of an aging population, the need for fixed dose combinations in the treatment of cardiovascular diseases, that are easy to swallow and administer, has been growing remarkably. In this work, the feasibility of coaxial electrospraying (CES) was investigated to manufacture in one single step, a powder of individually coated particles containing atenolol (ATE), lovastatin (LOV) and acetylsalicylic acid (ASA). To improve the dissolution rate of the poorly water soluble LOV, an amorphous solid dispersion (ASD) of LOV with Soluplus® (SOL) was formulated and Eudragit S100®, an enteric copolymer that only dissolves above pH 7, was applied as coating to avoid LOV hydrolysis in acidic medium. Furthermore, ATE was added to the inner ASD compartment and the acidic ASA was embedded in the coating layer. With regard to the uncoated ASD particles, which were prepared with single nozzle electrospraying, the rate and extent of the LOV dissolution was increased, even to an extent of 100% for the 1/1/6 (ATE/LOV/SOL) ratio. Hence, this ratio was selected and coated particles with proper release of the three APIs could be successfully produced via CES. However, a peculiar behaviour of the coating performance was observed. Regarding LOV, the enteric layer of the particles performed as expected in acidic medium and supersaturation was obtained after the switch to a neutral pH, but in contrast, over 50% of ATE was released after 90 min in acidic medium. Nonetheless, hardly any ATE was released under acidic circumstances from ATE tablets that were, as a benchmark, manually dip-coated with Eudragit S100®. Two different model APIs, namely paracetamol (well soluble) and fenofibrate (poorly soluble) were tested as well, revealing similar discrepancy in the coating performance. The coating layer formed during CES is most likely less dense as compared to the layer produced with tablet coating and consequently, more permeable for highly soluble APIs, but not for the poorly soluble compounds.

Nonmonotonic Stress Relaxation after Cessation of Steady Shear Flow in Supramolecular Assemblies.

Stress relaxation upon cessation of shear flow is known to be described by single-mode or multimode monotonic exponential decays. This is considered to be ubiquitous in nature. However, we found that, in some cases, the relaxation becomes anomalous in that an increase in the relaxing stress is observed. Those observations were made for physicochemically very different systems, having in common, however, the presence of self-associating units generating structures at large length scales. The nonmonotonic stress relaxation can be described phenomenologically by a generic model based on a redistribution of energy after the flow has stopped. When broken bonds are reestablished after flow cessation, the released energy is partly used to locally increase the elastic energy by the formation of deformed domains. If shear has induced order such that these elastic domains are partly aligned, the reestablishing of bonds gives rise to an increase of the overall stress.

Effects of particle stiffness on the extensional rheology of model rod-like nanoparticle suspensions.

The linear and nonlinear rheological behavior of two rod-like particle suspensions as a function of concentration is studied using small amplitude oscillatory shear, steady shear and capillary breakup extensional rheometry. The rod-like suspensions are composed of fd virus and its mutant fdY21M, which are perfectly monodisperse, with a length on the order of 900 nm. The particles are semiflexible yet differ in their persistence length. The effect of stiffness on the rheological behavior in both, shear and extensional flow, is investigated experimentally. The linear viscoelastic shear data is compared in detail with theoretical predictions for worm-like chains. The extensional properties are compared to Batchelor's theory, generalized for the shear thinning nature of the suspensions. Theoretical predictions agree well with the measured complex moduli at low concentrations as well as the nonlinear shear and elongational viscosities at high flow rates. The results in this work provide guidelines for enhancing the elongational viscosity based on purely frictional effects in the absence of strong normal forces which are characteristic for high molecular weight polymers.

Tumbling of Quantum Dots: Rheo-Optics.

Linear flow dichroism is shown to be a powerful tool to characterize the hydrodynamic dimensions of extremely small nonspherical colloids in solution. Dispersions of prolate and oblate quantum dots (QDs) are employed to investigate the validity of flow dichroism as a characterization tool. Shape-anisotropic QDs are important from an application perspective, where it is necessary to have a good knowledge of their hydrodynamic dimensions to predict and control their orientation during solution processing. Flow dichroism quantifies the tumbling motion of QDs in shear flow by optical means, which provides a characteristic signature of the particle shape, hydrodynamic friction, and size distribution. The effects of particle size and shape, size polydispersity, and shear rate on the temporal evolution of the flow-induced alignment are discussed in detail on the basis of numerical solutions of the Smoluchowski equation that describes the motion for the probability of the orientation of colloids in shear flow. It is shown that the combination of flow-dichroism experiments and the theoretical approach on the basis of the Smoluchowski equation provides a means to measure hydrodynamic aspect ratios and polydispersity, which for such small particles is not feasible with standard methods similar to light scattering. Flow dichroism will be useful not only for shape-anisotropic colloidal QDs, but also for other nanoscale systems.

Orthogonal superposition rheometry of colloidal gels: time-shear rate superposition.

We explore the relaxation behavior of model colloidal gels under steady shear flow by means of orthogonal superposition rheometry. Fumed silica and carbon black dispersions in Newtonian matrices are used as a model system. As shear rate increases, the frequency dependent orthogonal moduli of the gels shift along the frequency axis without changing their shape, which finally can be superimposed to yield a single master curve. This indicates that the shear rate tunes a master clock for overall relaxation modes in the sheared colloidal gels to produce a "time-shear rate superposition (TSS)", as temperature does in polymeric liquids to produce a time-temperature superposition (TTS). The horizontal shift factor required at each shear rate to obtain the master curve is found to be directly proportional to the suspension viscosity for all the cases. From this result, we suggest that the suspension viscosity determines the overall relaxation time of the particles in the flowing colloidal gel.

Amorphous solid dispersions of darunavir: Comparison between spray drying and electrospraying.

The interest in using electrospraying as a manufacturing method for amorphous solid dispersions has grown remarkably. However, the impact of formulation and process parameters needs further clarification. In this study, amorphous solid dispersions of darunavir and hydroxypropyl methylcellulose (HPMC), hydroxypropyl methylcellulose acetate succinate (HPMC AS) and polyvinylpyrrolidone K-30 (PVP) were prepared with electrospraying and spray drying, in order to compare both solvent based manufacturing techniques. Our results revealed that electrospraying was as successful as spray drying. The formulations prepared with the two methods were amorphous and had similar characteristics concerning the residual solvent and drug release. Although differences in the morphology and the particle size distributions were observed, this was not reflected in the pharmaceutical performance of the formulations. Electrosprayed amorphous solid dispersions made up of darunavir and PVP were studied in more detail by means of a full factorial experimental design. The impact of two process and two formulation parameters on the properties of the amorphous solid dispersions was determined. The feed flow rate had a significant effect on the diameter and morphology of the particles whereas the tip-to-collector distance had no significant impact within the tested range. The drug loading influenced the homogeneity and the residual solvent, and the total solids concentration had an impact on the homogeneity and the morphology.

Spreading Dynamics of Molten Polymer Drops on Glass Substrates.

Wetting dynamics drive numerous processes involving liquids in contact with solid substrates with a wide range of geometries. The spreading dynamics of organic liquids and liquid metals at, respectively, room temperature and >1000 °C have been studied extensively, both experimentally and numerically; however, almost no attention has been paid to the wetting behavior of molten drops of thermoplastic polymers, despite its importance, for example, in the processing of fiber-reinforced polymer composites. Indeed, the ability of classical theories of dynamic wetting, that is, the hydrodynamic and the molecular-kinetic theories, to model these complex liquids is unknown. We have therefore investigated the spreading dynamics on glass, over temperatures between 200 and 260 °C, of two thermoplastics: polypropylene (PP) and poly(vinylidene fluoride) (PVDF). PP and PVDF showed, respectively, the highest and lowest slip lengths due to their different interactions with the glass substrate. The jump lengths of PP and PVDF are comparable to their Kuhn segment lengths, suggesting that the wetting process of these polymers is mediated by segmental displacements. The present work not only provides evidence of the suitability of the classical models to model dynamic wetting of molten polymers but also advances our understanding of the wetting dynamics of molten thermoplastics at the liquid/solid interface.

Electrospraying of polymer solutions: Study of formulation and process parameters.

Over the past decade, electrospraying has proven to be a promising method for the preparation of amorphous solid dispersions, an established formulation strategy to improve the oral bioavailability of poorly soluble drug compounds. Due to the lack of fundamental knowledge concerning adequate single nozzle electrospraying conditions, a trial-and-error approach is currently the only option. The objective of this paper is to study/investigate the influence of the different formulation and process parameters, as well as their interplay, on the formation of a stable cone-jet mode as a prerequisite for a reproducible production of monodisperse micro- and nanoparticles. To this purpose, different polymers commonly used in the formulation of solid dispersions were electrosprayed to map out the workable parameter ranges of the process. The experiments evaluate the importance of the experimental parameters as flow rate, electric potential difference and the distance between the tip of the nozzle and collector. Based on this, the type of solvent and the concentration of the polymer solutions, along with their viscosity and conductivity, were identified as determinative formulation parameters. This information is of utmost importance to rationally design further electrospraying methods for the preparation of amorphous solid dispersions.