Formation of polymer microrods in shear flow by emulsification--solvent attrition mechanism

Rodlike polymer particles could have interesting properties and could find many practical applications; however, few methods for the production of such particles are available. We report a systematic study of a droplet shearing process for the formation of polymer rods with micrometer or submicrometer diameter and a length of up to tens of micrometers. The process is based on emulsification of a polymer solution under shear, combined with solvent attrition in the surrounding organic medium. The droplets deform and elongate into cylinders, which solidify when the solvent transfers to the dispersion medium. Stopped flow experiments allow distinguishing all stages of the mechanism. The results are interpreted on the basis of the theory of droplet elongation and breakup under shear. The effects of the viscosity ratio and shear stress are matched against the theoretical expectations. The method is simple, efficient, and scalable, and we demonstrate how it can be controlled and modified. The experimental parameters that allow varying the rod size and aspect ratio include shear rate, medium viscosity, and polymer concentration. Examples of the specific properties of the polymer rods, including self-organization, alignment in external fields and in fluid flows, and stabilization of bubbles, droplets, and capsules, are presented.