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Using microfluidics, we were able to synthesize monodisperse water-in-monomer emulsions with styrene and divinylbenzene (DVB) as monomers. When polymerizing and drying these emulsions, we found that the structure of the resulting macroporous polymer strongly depends on the type of initiator. With the oil-soluble azobisisobutyronitrile (AIBN), an open-cell structure with spherical pores was obtained. However, with the water-soluble potassium peroxydisulfate (KPS), a closed-cell structure with rhombic dodecahedron-shaped pores and thick, layered pore walls was formed. In the latter case, a yet unexplained mechanism counteracts the capillary pressure arising from surface minimization: the surface area of a rhombic dodecahedron is ~ 10% larger than that of a sphere. In our previous work, we suggested that the underlying mechanism may be osmotic transport of DVB from the plateau borders to the films. We argued that this transport also explains the layered pore walls, i.e., the formation of two outer poly-DVB-rich layers and one inner polystyrene-rich layer. In order to prove or disprove this mechanism, we carried out additional experiments. However, none of those experiments corroborated our hypothesis of osmotic transport! This study provides clear experimental evidence that our previously suggested mechanism via which spherical droplets become polyhedral pores is incorrect. We will describe (a) the rationale behind the additional experiments, (b) our expectations, and (c) our findings. Last but not least, we will discuss all of this in the light of the proposed osmotic transport.

Porous polymers via emulsion templating: pore deformation during solidification cannot be explained by an osmotic transport!