Controlled Emulsion Droplet Solvent Evaporation for Particle Production

In this work, we are motivated by the need to produce particles of well-controlled size, shape and morphology for general application in catalysis, environmental remediation, nanomedicine, pharmaceuticals, the development of new materials, and other fields. Moreover, our approaches are guided by the desire for continuous and scalable production, in contrast to the batch-wise processes typically used. We employ the emulsion droplet solvent evaporation method, which is extremely versatile, to create, for example, magnetic nanoparticles, polymeric Janus beads, and crystalline particles. The emulsion droplets act as confined spaces, or templates, within which the particles can form. Upon removal of the solvent, primary magnetite nanoparticles pack into dense magnetic clusters, polymers precipitate as beads, or small molecules crystallize out of the solution to form spherical particulates. The thesis is comprised of experimental, theoretical and computational work that discusses the control of polymeric Janus bead morphology; demonstrates the potential of various operations for integration into large-scale manufacturing systems for monodisperse particle production; and offers insight into solvent and particle diffusion during the solvent evaporation process. The formation of Janus beads by solvent evaporation-induced phase separation of polymer blends is studied using a model system of polystyrene (PS), poly(propylene carbonate) (PPC) and chloroform. The phase separation of the polymer solutions in the bulk is analyzed and a phase diagram is constructed. PS/PPC Janus beads of varying composition are synthesized and we demonstrate the ability to tune the morphology by varying the type and concentration of the