Magnetite (Fe3O4) microcapsules prepared using a glass membrane and solvent removal

Fine magnetite powders dispersed in polymer solution were encapsulated from an oil-in-water emulsion prepared by an emulsification process employing a porous glass membrane and subsequent evaporation of the solvent. Styrene-based copolymers were dissolved in a magnetic fluid, and then continuously pushed through the pores of glass membrane into the aqueous phase, which had dissolved polyvinyl alcohol (PVA) and sodium dodecyl sulphate (SDS) as a mixed stabilizer. P(styrene-co-acrylic acid) (PS-AA), P(stryrene-co-butyl acrylate) (PS-BA) and styrene-butadiene rubber (SBR) were dissolved in the specially ordered magnetite fluid (25 wt% magnetite dispersed in toluene) separately or as a mixture, and uniform droplets suspending the magnetic particles were obtained. After the evaporation of toluene, PS-AA capsules retained a spherical shape and uniformity, whereas PS-AA/PS-BA capsules revealed a creased surface and broader size distribution. The microcapsules entrapped 30-40 wt% of magnetite, and the encapsulation yield of magnetite was 20-40%. Glass membranes with 9.5, 5.25 and 1.42 microm pore size were employed and 5-40 microm microcapsules were obtained depending on the pore size. When magnetite suspended in chloroform was used, magnetite capsules with broader size distributions were obtained because of the sticking of the droplets to the membrane wall. The advantage of the membrane emulsification which provides uniform sized droplets was lost.