Morphology of block copolymer micelles formed via electrospray enabled interfacial instability.

Hypothesis: Elongated micelles may be preferred over spherical because of their increased loading capacity, differential mass transport and biodistribution. Although morphological transitions of block co-polymer (BCP) micelles have been extensively investigated in batch systems, research on continuous or semi-continuous scalable approaches such as flash nanoprecipitation and coaxial electrospray-enabled interfacial instability (Aero-IS) have primarily focused on producing spherical micelles. This paper investigates whether process changes intended to increase micelle production via Aero-IS also induce morphological transitions.

Experiments: BCP micelles were synthesized from carboxylated polystyrene-block-poly(ethylene oxide) (PS-b-PEO) (PS 9.5 kDa:PEO 18.0 kDa) using Aero-IS. Volumetric flowrates, polymer concentrations, and emulsion temperature were varied to investigate their effect on the micelle production rate and resulting micelle structure, including transitions to worm-like micelles.

Findings: These findings report the first worm-like micelles formed via a scalable, interfacial instability approach. The morphological transitions obtained by increasing polymer concentration occurred at lower nominal values than in corresponding batch processes. Optimizing operating conditions also led to a 12-fold increase in micelle production rates over prior electrospray reports (Duong, 2014). Thus, the Aero-IS approach holds promise for scalable nanomanufacturing of worm-like micelles, potentially enabling applications in drug delivery, imaging, diagnostics, and separations.