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Colloids and Surfaces A: Physicochemical and Engineering Aspects 641 (2022) 127955

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Colloids and Surfaces A: Physicochemical and


Engineering Aspects
journal homepage: www.elsevier.com/locate/colsurfa

Microfluidic preparation of monodisperse hollow polyacrylonitrile


microspheres for ICF
Lurong Qin a, b, Meifang Liu a, Yong Yi b, *, Qiang Yin a, *, Ke Cao c
a
Research Center of Laser Fusion, China Academy of Engineering Physics, Mianyang 621900, China
b
School of Materials Science and Engineering, Southwest University of Science and Technology, Mianyang 621010, China
c
State Key Laboratory for Environment-friendly Energy Materials, Southwest University of Science and Technology, Mianyang 621010, China

H I G H L I G H T S G R A P H I C A L A B S T R A C T

• Monodisperse hollow polyacrylonitrile


microspheres were successfully pre­
pared by the microfluidic technique.
• The effect of the surfactants on the sta­
bility of the compound droplets and the
quality of resulting microspheres was
investigated.
• The size relationship between the com­
pound droplets and the microspheres
was also studied.

A R T I C L E I N F O A B S T R A C T

Keywords: Hollow polyacrylonitrile (PAN) microspheres can be used as fuel carriers in inertial confinement fusion (ICF)
Hollow polyacrylonitrile microspheres experiments due to their high tensile strength, low permeability to hydrogen isotopes, and resistance to tritium
Microfluidic technique radiation corrosion. Monodisperse oil in water in oil (O1/W/O2) compound droplets were fabricated by the
Monospersity
microfluidic technique and then monodisperse hollow polyacrylonitrile microspheres were prepared by the
Stability
Sphericity
solvent evaporation method. The stability of O1/W/O2 compound droplets was improved by the addition of the
surfactant (Dow Corning 749), which reduced the interfacial tension between the O2 phase and the W phase as
well as the Laplace pressure on the surface of the compound droplets. The sphericity and the surface quality of
the microspheres were also improved by the introduction of DMF droplets into the O2 phase to avoid emulsi­
fication, decreasing the DMF mass transfer rate. Therefore, fine monodisperse PAN microspheres with the
diameter range of 700–800 µm were successfully prepared. Moreover, the size relationship between the com­
pound droplets and the resulting microspheres was also evaluated, which can be used to predict the sizes of the
PAN microspheres. The results provide a method for controllable preparation of monodisperse hollow PAN
microspheres for ICF experiments.

1. Introduction high specific surface area, and high utilization of internal space,
arousing tremendous interest in the field of drug delivery systems,
Polymer hollow microspheres exhibit the advantages of low density, cosmetics, catalysts, and so forth [1–3]. In particular, polymer hollow

* Corresponding authors.
E-mail addresses: yiyong@swust.edu.cn (Y. Yi), qyin839@sina.com (Q. Yin).

https://doi.org/10.1016/j.colsurfa.2021.127955
Received 4 September 2021; Received in revised form 15 November 2021; Accepted 20 November 2021
Available online 29 November 2021
0927-7757/© 2021 Published by Elsevier B.V.
L. Qin et al. Colloids and Surfaces A: Physicochemical and Engineering Aspects 641 (2022) 127955

microspheres can also be used as fuel containers of the inertial 2.2. Preparation of PAN hollow microspheres
confinement fusion (ICF) experiments [4,5], an effective method to
achieve controlled thermonuclear fusion, which is of great strategic 2.2.1. Formation of O1/W/O2 compound droplets
significance in the field of national defense security and new clean en­ As shown in Fig. 1, 50 cs silicone oil, 8% PAN/DMF solution and 50
ergy. To reduce hydrodynamic instability in the implosion for the ICF, it cs silicone oil were used as the inner oil (O1) phase, the water (W) phase,
is required that polymer hollow microspheres meet some stringent and the outer oil (O2) phase, respectively. The O1, W, and O2 phases
specifications such as fine monodispersity, very smooth surfaces, a high were transported into the droplet generator by three syringes controlled
order of wall thickness uniformity, and good sphericity [6,7]. Generally, by separate syringe pumps (LSP01–1 A, Baoding Lange Constant Flow
polymer hollow microspheres can be fabricated by the following steps Pump Co., Ltd.). The size of the co-flowing microfluidic device of the
[8], including the fabrication of the O1/W/O2 compound droplets, the three phases was shown in Table 1. The co-flowing microfluidic device
curing process (the removal of the solvent in the middle phase of the was a “one-step” device in which both the end of the steel needle and
compound droplets), and the drying process (the removal of the inner that of the plastic tube were on the same level. In the process of fabri­
phase). Therefore, it is important to precisely control every step, making cating O1/W/O2 compound droplets, the O1 phase left the O1 tube and
the quality of the microspheres satisfied for the ICF experiments. was surrounded by the W phase to form oil in water (O1/W) droplets at
Guglielmi firstly pointed out that the PAN could be used as a raw the end of the O1 tube. Then, they were stripped off from the O2 phase,
material for ICF targets due to its high tensile strength, low permeability forming the O1/W/O2 compound droplets in the competition of the
to hydrogen isotopes, and resistance to tritium radiation corrosion interfacial tension force, drag force, inertia force, and so on [26].
[9–12]. Much work about how to fabricate PAN hollow microspheres to
meet these stringent requirements was done for ICF experiments. Dong 2.2.2. Curing of O1/W/O2 compound droplets
et al. [13] firstly fabricated the PAN hollow microspheres via simple Two hundred compound droplets were collected in a rotary evapo­
mechanical stirring emulsification. However, it was hard to control the rating flask. Then, the flask was set into place in a water bath at the
distribution of the diameter and the wall thickness, and there was also temperature of 45 ℃ and stirred vertically at a certain speed (35 rpm)
more than one inner droplet in the compound droplets. Developed with for 48 h to remove the solvent DMF in the W phase. The PAN hollow
the microfluidic technology, PAN hollow microspheres were also microspheres containing the internal oil phase were prepared.
fabricated by an assembly double T-junction droplet generator [14,15].
The density matching principle was used to improve the wall thickness 2.2.3. Drying of PAN microspheres
uniformity and sphericity of those PAN microspheres [16]. The diameter To remove inner silicone oil of the PAN microspheres, 10 cs, 5 cs, 1
distribution of the microspheres in a bath was polydispersity, which was cs, 0.65 cs silicone oil, and ethanol were used to replace inner droplets
probably due to the polydispersity and instability of the initial com­ for 24 h, respectively. Consequently, the inner silicone oil with high
pound droplets [17–19], since compound droplets were thermody­ viscosity was replaced by ethanol with volatility. To avoid the collapse
namically unstable and tended to rupture and coalescence to get a low of the hollow microspheres, a supercritical dryer was employed to
energy position, resulting in diameter change and polydispersity [20, remove ethanol to obtain the solvent-free PAN hollow microspheres at
21]. Consequently, to improve the monodispersity of the PAN micro­ the temperature of 45 ℃ for 6 h under 280 bar carbon dioxide (CO2)
spheres, it was necessary to further improve that of initial compound pressure and 5 g⋅min− 1 flow rate of CO2.
droplets and their stability.
During the past few decades, kinds of microfluidic devices with 2.3. Characterization
different geometric structures were employed to prepare monodisperse
O1/W/O2 compound droplets, including the co-flowing, flow-focusing, Both the size of compound droplets and the PAN microspheres were
and double T-junctions [22,23]. Among these microfluidic devices, Wu observed and measured by a high-precision optical microscope. The
et al. [24,25] studied the dynamic behaviors of compound droplets other characterization of surface is shown in Supporting Information
formation process, and the results showed that the compound droplets (SI). The density of the W phases was measured precisely by a densi­
prepared by the co-flowing microfluidic device processed narrower size tometer (Anton Paar®, DMA 5000) at room temperature. The dynamic
distribution since the shearing force (the continuous phase bringing to interfacial tension (IFT) between W and O2 phase was measured pre­
disperse phase) was more uniform. Herein, a co-flowing microfluidic cisely by an interfacial tension meter (Krüss DSA25) via the pendant
device was fabricated to controllable prepare O1/W/O2 compound drop method [27].
droplets. Then, to avoid the adverse effect of the unstable behavior of the Thirty O1/W/O2 compound droplets were taken to measure their
compound droplets on the monodispersity of the microspheres, different diameter, and the coefficient variation (CV) was used to estimate their
surfactants were preferably used to inhibit the coalescence and the monodispersity:
rupture of the compound droplets. Later, the size relationship between
the compound droplets and the resulting microspheres was also evalu­ CV(%) = σ/d × 100% (1)
ated. Finally, monodisperse PAN hollow microspheres with good sphe­
ricity and surface quality were successfully fabricated by the Where σ and d are the standard deviation and average diameter of the
optimization of the curing process. compound droplets, respectively.
According to Eq. (2), the sphericity of microspheres can be
2. Experimental calculated:
( )
Lmax − Lmin
2.1. Materials s = 1− × 100% (2)
Lave

Polyacrylonitrile (PAN, Mw = 150000, ρs = 1.184 g cm-− 3) and Where Lmax, Lmin, Lave, are the maximum, minimum, and average
Aliquat◦ 336 were from Sigma-Aldrich Company. Both Ethanol and N, N- diameter of microspheres, respectively.
dimethylformamide (DMF) were obtained from Chengdu Kelong
Chemical Reagent Factory. Silicone oil with different viscosity was 3. Results and discussion
purchased from Japan Shinetsu Chemical Co. Ltd., Japan. Dow Corning
749 was from Guangzhou DaiXun Trading Co., Ltd. 3.1. Controllable preparation of monodisperse compound droplets

According to the formation principle of compound droplets in the co-

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L. Qin et al. Colloids and Surfaces A: Physicochemical and Engineering Aspects 641 (2022) 127955

Fig. 1. Preparation process of PAN hollow microspheres.

rupture of the compound droplets is not only the basic condition for
Table 1 obtaining hollow microspheres but also conducive to the monodispersity
Size of the co-flowing microfluidic device of three phases.
of the microspheres. Hence, the effect of different surfactants, including
Tube Material Inner diameter (μm) Outer diameter (μm) the water-soluble surfactant (Aliquat◦ 336) and the oil-soluble surfactant
Inner phase tube Steel needle 250 500 (Dow Corning 749) on the stability of the compound droplets were
Middle phase tube Teflon tube 750 1500 investigated. As shown in Fig. 3(a), for the compound droplets without
Outer phase tube Glass tube 1800 2500 any surfactant, the coalescence (the solid circle) occurred in 1 min.
Meanwhile, some compound droplets ruptured (the dashed circle). The
flowing microfluidic device, when the volume of internal phase droplets stabilization time was prolonged with 10% Aliquat◦ 336, but the com­
increased to a certain point, the shearing force of the middle phase is pound droplets still coalesced and ruptured. The coalescence occurred in
greater than its interfacial tension, so the O1/W droplets are stripped off some compound droplets stay closed. Specifically, two nearly compound
from the O2 phase, forming the O1/W/O2 compound droplets [26]. droplets coalesced to form a bigger compound droplet, leading to that
Therefore, the effect of the three-phase flow rates on the diameter of the containing more than one inner droplet, and then the inner droplets
compound droplets was investigated since the flow rates influenced the fused to form single O1 droplets (Fig. 3(b)). The diameter of the new
shearing force and the size of the droplets. The monodisperse PAN compound droplets became larger and the wall thickness was different
compound droplets with the diameter in the range of 800 µm − 1800 µm from that of the initial compound droplets. Consequently, it can be
could be prepared by adjusting the flow rates in this co-flowing micro­ speculated that the size of the whole compound droplets presented
fluidic device. polydispersity. For compound droplets with the addition of 3% Dow
For example, the compound droplets were prepared with three-phase Corning 749, which showed better stability. There was no coalescence
flow rates of 1 ml/h, 3 ml/h, and 30 ml/h (Fig. 2). The average inner and no rupture in 2 h (Fig. 3(c)), which benefited the monodispersity of
diameter and outer diameter of the compound droplets were 749 µm and the microspheres. Compared with Aliquat◦ 336, a smaller amount of
1204 µm, respectively. The corresponding coefficient variation value Dow Corning 749 could achieve a good stabilizing effect for the
was 2.1% and 0.3%, respectively. It indicated that compound droplets O1/W/O2 compound droplets.
with fine monodispersity were successfully prepared, which was The stable mechanism of the surfactants was also investigated. As
significantly better than the reported value [16]. shown in Table 2, when there was no surfactant, the interfacial tension
between the W phase and the O2 phase was 2.0 mN/m. The interfacial
tension did not change with Aliquat◦ 336. Nevertheless, the W/O2
3.2. Effect of surfactants on stability of compound droplets interfacial tension was reduced by nearly 55% with the addition of Dow
Corning 749. PAN initial compound droplets were ellipsoidal (Fig. 4),
Compound droplets are thermodynamically unstable systems and are and the inner droplets were eccentric, which was similar to the literature
prone to coalesce and rupture [28]. Avoiding the coalescence and the

Fig. 2. O1/W/O2 compound droplets (a) optical image and (b) size distribution.

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L. Qin et al. Colloids and Surfaces A: Physicochemical and Engineering Aspects 641 (2022) 127955

Fig. 3. Stability of O1/W/O2 compound droplets with different surfactants. (a) No addition, (b) Aliquat◦ 336, and (c) Dow Corning 749.

bottom, the pressure difference (ΔP) between the top and the bottom in
Table 2
the W phase can be calculated by Eq. (2).
Interfacial tension between W phase and O2 phase.
Sample W phase O2 phase Interfacial tension of W/O2 (Rmax − Rmin )
ΔP = 2γ(W/O2) (2)
(mN/m) Rmax Rmin
1 DMF 5cs silicone oil 2.0
2 DMF- 5cs silicone oil 2.0
Where the γ(W/O2) is interfacial tension between the W phase and the O2
Aliquat◦ 336 phase. The bigger the pressure difference, the quicker the flow rate.
3 DMF 5cs silicone oil Dow 0.9 Therefore, the W phase film became thinner until the interfacial film
Corning 749 cannot resist Pmax, so the compound droplets rupture to form a single
droplet. For the Dow Corning 749, the pressure difference decreased
with the decrease of interfacial tension, leading to the W phase flowing
from the top to the bottom slowly, which benefited the stability of the
compound droplets. Furthermore, coalescence processes could also be
prevented by the Dow Corning 749, which may attribute to the low
interfacial tension decreasing in the subsequently free energy of the
interface.

3.3. Effect of surfactants on quality of PAN microspheres

Fig. 5(a) and (c) showed the microspheres prepared with no surfac­
tant and Aliquat◦ 336, respectively. The surface of the microspheres was
smoother, but the monodispersity was bad because of unstable behavior
among the compound droplets. Some bigger microspheres appeared due
to the coalescence during the curing process. In addition, there were also
some pellets due to the rupture. The size distribution of these micro­
spheres showed bad monodispersity (Fig. 5(b), and (d)), which was
attributed to the bad stability of the compound droplets. For the PAN
microspheres prepared with Dow Corning 749 (Fig. 6), there were no
bigger microspheres and pellets. However, the shape of the micro­
spheres was similar to that of the initial compound droplets. They were
Fig. 4. Role of the interfacial tension on the rupture process in com­ ellipsoid and some small holes appeared on the microspheres. Besides,
pound droplets. the microspheres with the crumpled surface were obtained.
The schematic diagram of the curing process is shown in Fig. S2, and
it has been reported that the interfacial tension is the driving force for
[29]. Moreover, the density of the O1 phase was less than that of the W
the compound droplets becoming spherical in the curing process [31].
phase, which led to the O1 phase droplets floating in the compound
Cook et al. [32] deduced the empirical formula of δOOR (out of round­
droplets, and thus the thickness of the W phase film was different. That is
ness) based on a large number of process experimental results:
to say, the film on the top of O1 was very thin, and the film on the
bottom of O1 was thick. Hence, The smallest outer radius (Rmin) 5gr3 Δρ
appeared at the top, and the largest outer radius (Rmax) appeared at the δOOR = (3)

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L. Qin et al. Colloids and Surfaces A: Physicochemical and Engineering Aspects 641 (2022) 127955

Fig. 5. PAN hollow microspheres and their size distribution (a, b) No additions, and (c, d) Aliquat◦ 336.

Fig. 6. PAN hollow microspheres with the Dow Corning 749.

Where g is the acceleration of gravity, Δρ is the density difference be­ leading to the bad sphericity and rough surface. From the experimental
tween the compound droplets and the external phase, r is the radius of results, the introduction of Dow Corning 749 could improve the stability
the compound droplets, and γ is the interfacial tension between the of the compound droplets, but it brought adverse effects on the sphe­
water phase and the external oil phase. It could be seen that the smaller ricity and surface quality of the microspheres.
the γ, the higher the δOOR, so the γ has an apparent influence on the
microstructure of PAN microspheres. The Dow Corning 749 greatly 3.4. Improvement on quality of PAN microspheres
reduced the oil-water interfacial tension, which was not in favor of the
spheroidization of the compound droplets. Moreover, it had been The curing process of PAN compound droplets is a mass transfer
observed that the Dow Corning 749 caused DMF to emulsify in the O2 process in which DMF diffuses from the water phase and dissolves into
phase to form DMF/O2 microemulsion during the curing process, which the O2 phase continuously. At this time, PAN concentration increases
accelerated the solvent transfer of DMF between the compound droplets rapidly, and the spherical shells gradually harden [30]. To improve the
and the O2 phase. It also made the O2 phase became white, resulting in quality of PAN microspheres prepared with Dow Corning 749, the DMF
quick curing and capsulation of the W film. As a consequence, there was mass transfer from the W phase to the O2 phase should be decreased. It
not enough time for ellipsoid compound droplets to become spherical, had been reported that the introduction of the solvent droplets in the
external phase could decrease the mass transfer, improving the

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L. Qin et al. Colloids and Surfaces A: Physicochemical and Engineering Aspects 641 (2022) 127955

sphericity [33]. Intuitively, the addition of DMF in the O2 phase could the addition of 1.5 g and 2.0 g DMF, the microspheres appeared spher­
reduce the concentration difference between the W phase and O2 phase, ical, and it seemed that the wall thickness was uniform. Moreover, there
resulting in a slower mass transformation rate and longer curing time was no hole on the surface, and the surface quality was improved. The
(Fig. 7). Herein, the additional amount of DMF droplets was firstly SEM image of original microspheres and improved microspheres were
calculated. Under the experimental condition, the whole system con­ consistent with the results of optical image that a lower solvent migra­
sisted of the O2 phase and the air above the rotary evaporating flask. tion makes microspheres with a smooth inner and outer surface, leaving
According to the ideal gas law, the total quantity of DMF saturated in the a higher surface quality (Fig. S3). The improvement of surface quality
whole system could be calculated: can also be verified by white light interferometer, the Ra, Rq, and Rt
values decreased with the increase amount of DMF (Fig. S4). In addition,
PV
mDMF(air) = MDMF × (4) the introduction of the DMF could also improve the sphericity of the
RT
microspheres. The sphericity of most PAN microspheres prepared with
mDMF(O2) = S × VO2 (5) 2.0 g DMF was more than 97% (Fig. 9). It could be seen that the
decreased DMF mass transfer could eliminate the adverse defects
m = mDMF(O2) + mDMF(air) (6) brought by Dow Corning 749. Therefore, we optimize the curing method
that calculated DMF droplets are added in the O2 phase for a lower
Where P is the saturated vapor pressure of DMF under the curing tem­ solvent migration, thus sphericity and surface quality have been further
perature, V is the volume of the gas phase, R is the ideal gas constant, improved.
and S is the saturability of DMF in the O2 phase (it was assumed to be
0.1% in this work). mDMF(air) and mDMF(O2) are the mass of DMF in the air 3.5. Size relationship between compound droplets and microspheres
and the O2 phase, respectively. M is the total DMF quantity saturated in
the whole system. So it indicated that 0.22 g DMF was required to The size of the compound droplets changed due to the evaporation of
saturate the whole system at least. the solvent DMF from the W phase during the curing process, there was a
Meanwhile, the quantity of DMF in 200 O1/W/O2 compound size relationship between the compound droplets and the microspheres.
droplets was: According to the mass conservation law, the mass of PAN in the com­
(
4 4
) ( ) pound droplets should be the same as that in the microspheres. There­
mDMF(O1/W/O2) = ρ1 × πRout 3 − πRin 3 × 1 − C × 200 (7) fore, the theoretical outer diameter of the resulting microsphere could
3 3
be calculated (the inner diameter was assumed not to change [34]):
Finally, the addition of DMF can be calculated using Eq. (7): ( )
4 4
maddition = m − mDMF(O1/W/O2) (8) mPAN(O1/W/O2) = ρ1 × πR1out 3 − πRin 3 ∗ C (9)
3 3

Where Rout and Rin are the outer radii and inner radii of the compound (
4 4
)
droplets, respectively. VW and ρ1 are the volume and density of the W mPANmicrosphere = mPAN(O1/W/O2) = ρ2 × πR2out 3 − πRin 3 (10)
3 3
phase, respectively. C is the mass fraction of the PAN solution. According
to the calculation results, the mass of DMF in the total compound Where mPAN(O1/W/O2) and mPAN(microsphere) are the mass of PAN in
droplets was 0.12 g, so it could be seen that 0.1 g DMF droplets in the O2 the O1/W/O2 compound droplets and the microspheres, respectively. ρ1
phase could saturate the whole system at least, except for the mass of and ρ2 are the density of the W phase and the PAN at room temperature,
DMF in the compound droplets. 0.5 g, 1.0 g, 1.5 g, and 2.0 g DMF (the which are 0.96 g⋅cm− 3 and 1.18 g⋅cm− 3, respectively. R1out, R2out, R1in,
density of DMF at 25 ℃ is around 1 g⋅cm− 3) were added to the O2 phase, R2in are the outer and inner radii diameter of the compound droplets and
respectively. To reduce the effect of emulsification, the actual volume of the PAN microspheres, respectively. For the compound droplets with the
the addition was more than that calculated in this process. As shown in average outer diameter (1204 µm) and inner diameter (749 µm), the
Fig. 8, when the amount of DMF added was 0.5 g, the degree of spher­ calculated result showed that theoretical outer diameter and wall
oidicity of the microspheres weakened, there were fewer surface wrin­ thickness of the PAN microspheres were 797 µm, 24 µm, respectively.
kles, and the wall thickness of the microspheres was more uniform, but The experimental results (Fig. 10) showed that the inner diameter of the
there were still some microspheres with a hole on the surface. When the PAN microspheres was 767 µm, larger than that of the initial compound
amount of DMF increased to 1.0 g, the spheroidicity decreased further, droplets, which probably attributed to the migration of the silicone oil
and the number of microspheres with a hole on the surface was also from the O2 phase to the inside during the curing process. According to
reduced, but the wall thickness of the microspheres was still uneven. For the calculation formula ((9) and (10)), the theoretical shrinkage rate of

Fig. 7. Experimental design of effect of solvent migration on sphericity and quality of PAN microspheres.

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Fig. 8. PAN hollow microspheres with different addition of DMF (a) 0.5 g, (b) 1.0 g, (c) 1.5 g, and (d) 2.0 g.

Fig. 10. Size distribution of PAN hollow microspheres with 2.0 g DMF.
Fig. 9. Sphericity of PAN hollow microspheres with the introduction of DMF.

4. Conclusion
wall thickness from compound droplets to microspheres was 89% when
the W phase concentration was 8%, but experimental results showed To fabricate PAN hollow microspheres meeting the requirements of
that the wall thickness did not shrink to that extent. Specifically, the size ICF experiments, monodisperse millimeter-sized O1/W/O2 compound
measurements showed that the wall thickness of the resulting micro­ droplets were successfully prepared by the microfluidic technique. The
spheres was 30 µm, larger than the calculation value, which indicated unstable behaviors including the rupture and the coalescence of these
that there was some solvent (DMF or silicone oil) that remained in the compound droplets were suppressed by the surfactant (Dow Corning
wall at the microspheres. This problem could be solved by the extension 749), which benefited the monodispersity of the resulting microspheres.
of curing time or the increase of the curing temperature in the later The sphericity and surface quality of the microspheres were also
experiment. For the resulting microspheres, the value of CV for inner improved by the introduction of the DMF droplets into the O2 phase,
diameter and outer diameter was 0.5% and 1.9%, respectively. It indi­ decreasing the DMF mass transfer rate. Therefore, fine monodisperse
cated fine monodispersity of the resulting microspheres. PAN hollow microspheres were successfully fabricated. Moreover, the
inner diameter increased during the curing process due to the migration

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L. Qin et al. Colloids and Surfaces A: Physicochemical and Engineering Aspects 641 (2022) 127955

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