We have shown in a previous work that the combination of the emulsion solvent evaporation technique and droplet-based microfluidics allows for the synthesis of well-defined monodisperse mesoporous silica microcapsules (hollow microspheres), whose size, shape and composition may be finely and easily controlled. In this study, we focus on the crucial role played by the popular Pluronic® P123 surfactant, used for controlling the mesoporosity of synthesised silica microparticles. We show in particular, that although both types of initial precursor droplets, prepared with and without P123 meso-structuring agent, namely P123+ and P123- droplets, have a similar diameter (≃30 μm) and a similar TEOS silica precursor concentration (0.34 M), the resulting microparticles exhibit two noticeably different sizes and mass densities. Namely, 10 μm and 0.55 g/cm3 for P123+ microparticles, and 5.2 μm and 1.4 g/cm3 for P123- microparticles. To explain such differences, we used optical and scanning electron microscopies, small-angle X-ray diffraction and BET measurements to analyse structural properties of both types of microparticles and show that in the absence of Pluronic molecules, P123- microdroplets divide during their condensation process, on average, into three smaller droplets before condensing into silica solid microspheres with a smaller size and a higher mass density than those obtained in the presence of P123 surfactant molecules. Based on these results and on condensation kinetics analysis, we also propose an original mechanism for the formation of silica microspheres in the presence and in the absence of the meso-structuring and pore-forming P123 molecules.
Keywords: condensation; droplets; evaporation; meso-structuring agent; mesopores; microcapsules; microfluidics; silica; surfactants.