Natural extract-polymer monodisperse submicron particles from Plateau-Rayleigh microjets

Abstract

Particles of interest in food, pharmaceutical, and nutraceutical sectors are often formulated with a polymer and one or more natural or synthetic active compound. The two components frequently have distinct hydrophilicity. Submicrometric particles with narrow size dispersion can be made by the droplet-to-particle route by electrospray. In the steady cone-jet mode a liquid Taylor cone (TC) continuously emits a Plateau-Rayleigh microjet which breaks up spontaneously and periodically into tiny droplets, which later dry up to form solid particles. To achieve a stable process of this kind, we argue that it is necessary to: (i) operate near the minimum solution flow rate compatible with TC stability, (ii) prevent the drying of the TC by surrounding it with a gentle gas stream saturated in solvent vapor, and (iii) monitor the electric current and image the TC. We demonstrate this process in the preparation of curcumin (CUR) loaded polyvinylpyrrolidone (PVP) submicrometric particles as a function of solution composition and ambient relative humidity. In the atomization step (jet and droplet formation), the initial droplet size and charge are determined by the liquid properties and flow rate. The particles’ shapes were spherical (with or without internal voids), corrugated due to shell buckling (with compact interiors), and filamented due to Coulombic instabilities, depending on the interplay of different factors at the droplet drying step. These included the droplet size and charge, solvent evaporation, solute diffusion, water uptake from the ambient, mechanical forces, and solution thermodynamics. The electric current and droplet size are suitably predicted by scaling laws developed for simple Newtonian fluids. Hence, our particle sizes lie always between the predicted droplet and compact-sphere sizes, at a distance which depends on the particle morphology. CUR-loaded PVP quasi-monodisperse submicron particles could be an interesting model for drug delivery and biomedical applications.