Nonspherical Particle Stabilized Emulsions Formed through Destabilization and Arrested Coalescence.

To form nonspherical emulsion droplets, the interfacial tension driving droplet sphericity must be overcome. This can be achieved through interfacial particle jamming; however, careful control of particle coverage is required. In this work, we present a scalable novel batch process to form nonspherical particle-stabilized emulsions. This is achieved by concurrently forming interfacially active particles and drastically accelerating emulsion destabilization through addition of electrolyte. To achieve this, surfactant-stabilized oil-in-water emulsions in the presence of dopamine were first produced. These emulsions were then treated with tris(hydroxymethyl)aminomethane hydrochloride buffer to both simultaneously initiate polymerization of dopamine in the emulsion continuous phase and reduce the Debye length of the system, thus accelerating droplet coalescence while forming surface-active particles. The concentration of buffer and imposed shear was then systematically varied, and the behavior at the interface was studied using pendent drop tensiometry and interfacial shear rheology. It was found that polydopamine nanoparticles formed in the emulsion continuous phase adsorbed to the reducing interface during coalescence, resulting in anisotropic droplets formed via arrested coalescence. Greater shear rates resulted in accelerated coalescence and formation of secondary droplets, whereas lower shear rates resulted in thicker interfacial films. The efficacy of this method was further demonstrated with a second system consisting of sodium dodecyl sulfate as the surfactant and polypyrrole particles, which also resulted in nonspherical droplets for optimized conditions.