Reactive Surfactants for Achieving Open-Cell PolyHIPE Foams from Pickering Emulsions

PolyHIPEs, highly porous polymers synthesized within high internal phase emulsions (HIPEs), emulsions with over 74% internal phase, are of interest for applications such as absorbents, reaction supports, and tissue engineering scaffolds. Typically, the surfactant contents for HIPE stabilization are relatively high, ranging from 20 to 30 wt% of the external phase, with the monomers usually being the remainder. One drawback of using surfactants for these applications is the potential for leachables, necessitating intensive purification processes for their removal. Pickering HIPEs, HIPEs stabilized using amphiphilic solid nanoparticles that spontaneously migrate to the oil–water interface, can be used as an alternative HIPE stabilization strategy. Although nanoparticles can add surface functionality advantageous for the application, polyHIPEs from Pickering HIPEs often lack the interconnecting holes needed for the high permeability required for such applications. This work describes a successful approach for designing an HIPE stabilization system that is based on a combination of nanoparticles and reactive surfactants and that generates the desired surface functionality, an interconnected porous structure, and a low leachable content. Such an approach can extend the applicative utility of such polyHIPEs by circumventing the need for extensive purification.