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Current Opinion in Solid State and Materials Science 7 (2003) 399–405<br />

<strong>Supercritical</strong> <strong>impregnation</strong> <strong>of</strong> <strong>polymers</strong><br />

Ireneo Kikic * , Febe Vecchione<br />

Chemical, Environmental and Raw Materials Engineering Department (DICAMP), University <strong>of</strong> Trieste, P.le Europa, 1, Trieste 34127, Italy<br />

Received 11 August 2003; received in revised form 4 September 2003; accepted 4 September 2003<br />

Abstract<br />

The interest in the supercritical fluid <strong>impregnation</strong> <strong>of</strong> polymeric materials stems from the opportunity to utilize high diffusivity,<br />

low surface tension and the ease <strong>of</strong> solvent recovery for the preparation <strong>of</strong> new polymeric materials. This term includes a wide range<br />

<strong>of</strong> applications <strong>of</strong> the supercritical <strong>impregnation</strong> process that will be discussed in this review: preparation <strong>of</strong> drug delivery systems<br />

via <strong>impregnation</strong> <strong>of</strong> an active principle in a polymer matrix, dye and organic metallic complexes <strong>impregnation</strong> and polymer blends<br />

preparation via <strong>impregnation</strong> <strong>of</strong> a monomer and an initiator in a swollen polymer matrix.<br />

Ó 2003 Elsevier Ltd. All rights reserved.<br />

1. Introduction<br />

Recently, supercritical fluids have been applied for<br />

polymerization, swelling, <strong>impregnation</strong>, fractionation,<br />

purification and formation <strong>of</strong> powdered <strong>polymers</strong>. One<br />

<strong>of</strong> the important effects on <strong>polymers</strong> is the plasticizing<br />

effect <strong>of</strong> CO 2 with a decrease <strong>of</strong> the glass transition<br />

temperature [1].<br />

<strong>Supercritical</strong> carbon dioxide (SCCO 2 ) can reversibly<br />

swell glassy and rubbery <strong>polymers</strong> and reduce the viscosity<br />

<strong>of</strong> the polymer melts by up to an order <strong>of</strong> magnitude<br />

[2].<br />

The <strong>impregnation</strong> process is feasible when the active<br />

substance (the solute) is soluble in the supercritical<br />

fluid, the polymer is swollen by the supercritical solution<br />

and the partition coefficient is favourable enough to<br />

allow the matrix to be charged with enough solute.<br />

The fact that a high product purity is obtained (free<br />

<strong>of</strong> residual solvent) is important when considering the<br />

production <strong>of</strong> foods and pharmaceuticals, where it reduces<br />

the costs incurred in the removal <strong>of</strong> residual solvent<br />

[3].<br />

The interactions within the SCCO 2 -assisted <strong>impregnation</strong><br />

system are reported in Fig. 1.<br />

Impregnation processes can be classified on the base<br />

<strong>of</strong> the following criteria:<br />

* Corresponding author. Tel.: +39-40-5583433; fax: +39-40-569823.<br />

E-mail address: ireneok@dicamp.units.it (I. Kikic).<br />

1. The solubility <strong>of</strong> the solute in the supercritical fluid.<br />

2. The solute modification inside the polymer matrix.<br />

Referring to the first one <strong>of</strong> these, it is important to<br />

distinguish between two different mechanisms; the first<br />

involves deposition <strong>of</strong> a substance soluble in a supercritical<br />

fluid into the polymer matrix upon depressurisation.<br />

In this case, even a solute that has low affinity for<br />

the polymer matrix can be trapped within a polymer<br />

matrix, but in this case we have the formation <strong>of</strong> recrystallized<br />

substances within the polymer matrix without<br />

a molecularly dispersed formulation. A different<br />

mechanism utilizes the high partition coefficient <strong>of</strong> solute<br />

between the polymer and fluid phases due to a high<br />

affinity <strong>of</strong> the solute for the polymer matrices. This<br />

mechanism has tremendous potential for the supercritical<br />

fluid <strong>impregnation</strong> <strong>of</strong> drug molecules into <strong>polymers</strong><br />

[4].<br />

Referring to the second criterion, it is possible to<br />

distinguish between:<br />

• Solutes which are not modified in the polymer matrix:<br />

drugs,<br />

dyes (both for polymer and textile).<br />

• Solutes which undergo a modification during the <strong>impregnation</strong><br />

process:<br />

organometallic complexes for the <strong>impregnation</strong> <strong>of</strong><br />

<strong>polymers</strong> (90% <strong>of</strong> cases),<br />

monomers with initiator for polymer blends preparation.<br />

1359-0286/$ - see front matter Ó 2003 Elsevier Ltd. All rights reserved.<br />

doi:10.1016/j.cossms.2003.09.001


400 I. Kikic, F. Vecchione / Current Opinion in Solid State and Materials Science 7 (2003) 399–405<br />

dissolving<br />

SC CO 2<br />

1<br />

Additive<br />

3<br />

swelling<br />

4<br />

plasticizing<br />

Before presenting the different processes, the behaviour<br />

<strong>of</strong> the binary system (supercritical fluid–polymer)<br />

will be considered.<br />

2. <strong>Supercritical</strong> fluid–polymer interaction<br />

loading<br />

<strong>Supercritical</strong> fluids can interact not only with <strong>polymers</strong><br />

at temperatures higher than the s<strong>of</strong>tening point but<br />

also with <strong>polymers</strong> in the glassy state. Three concomitant<br />

effects must be considered: the dissolution <strong>of</strong> the<br />

SCF (polymer sorption), the swelling <strong>of</strong> the polymer<br />

matrix and the glass transition temperature (T g ) depression,<br />

simply called plasticization.<br />

The plasticization effect is an important feature: the<br />

sorbed gas acts as a kind <strong>of</strong> Ôlubricant’, making it easier<br />

for chain molecules to slip over one another, and thus<br />

causing polymer s<strong>of</strong>tening. The measured depression<br />

reaches values as high as 60 °C for poly(methyl methacrylate)<br />

and poly(styrene).<br />

Measurements <strong>of</strong> glass transition temperatures at<br />

high pressures can be only indirect; recently, a new<br />

method has been developed for measuring the glass<br />

transition temperature: it is based on a supercritical fluid<br />

chromatographic technique. In this case, using the supercritical<br />

fluid at a given pressure as mobile phase and<br />

the polymer under investigation as stationary phase, the<br />

retention volumes <strong>of</strong> various organic solutes are measured<br />

at different temperatures [5,6].<br />

Some attempts can be found in the literature to model<br />

both the sorption <strong>of</strong> a supercritical fluid in a glassy<br />

polymer and the glass transition temperature depression<br />

induced by supercritical fluids.<br />

Regarding the shift <strong>of</strong> the glass transition temperature,<br />

the most important contribution is due to Condo<br />

et al. [7]. In this approach the Gibbs Di Marzio criterion<br />

(at the glass transition the entropy <strong>of</strong> the system is zero)<br />

is used together with the Sanchez–Lacombe equation <strong>of</strong><br />

state. The possibility <strong>of</strong> the so-called retrograde vitrification<br />

is suggested: when the temperature is reduced at<br />

constant pressure, it is possible to observe a first liquid–<br />

glass transition followed by a second transition from the<br />

glass-back to the liquid-state.<br />

A detailed description <strong>of</strong> the model and a discussion<br />

on the effects <strong>of</strong> different parameters is reported in [6,8].<br />

2<br />

Polymer<br />

Substrate<br />

Fig. 1. Interactions between the SCCO 2 -assisted <strong>impregnation</strong> system.<br />

Another approach proposed originally by Wissinger<br />

and Paulaitis [9] introduces an additional variable (order<br />

parameter) that describes the thermodynamic state <strong>of</strong> a<br />

system. As the order parameter, the fraction <strong>of</strong> holes in<br />

the lattice and the number <strong>of</strong> nearest-neighbour contacts<br />

between polymer segments on the lattice sites are used.<br />

The NELF model, recently proposed by Doghieri and<br />

Sarti [10] uses as an order parameter the density <strong>of</strong> the<br />

swollen polymeric phase and the Sanchez–Lacombe<br />

equation <strong>of</strong> state for the evaluation <strong>of</strong> the chemical<br />

potential <strong>of</strong> the supercritical fluid in the gas phase (pure<br />

supercritical fluid) and in the polymeric phase. This<br />

approach can also be modified using a different equation<br />

<strong>of</strong> state for the gas phase, and does not require any binary<br />

interaction parameter. In this way, the sorption<br />

behaviour can be predicted from the swelling data alone.<br />

Since swelling measurements are, in general, more<br />

difficult to perform, it was recently [11] proposed to use<br />

the model as an empirical method to correlate and<br />

predict sorption data. Using one experimental sorption<br />

data point, and applying the NELF model, it is possible<br />

to predict the sorption at other pressures and temperatures.<br />

3. <strong>Supercritical</strong> <strong>impregnation</strong> processes<br />

3.1. Drugs <strong>impregnation</strong><br />

Controlled-release products have recently received<br />

considerable attention in the pharmaceutical industry<br />

since their use significantly reduces the problems connected<br />

with excessive dosages.<br />

In the preparation <strong>of</strong> controlled-release drugs, a liquid<br />

solvent swelling the polymer matrix and serving as a<br />

carrier for the drug component, is used. An alternative is<br />

to substitute the liquid organic solvent by a supercritical<br />

fluid with the advantage that the final product is completely<br />

free <strong>of</strong> any residual solvent contamination.<br />

Guney and Akgerman [12] investigated the <strong>impregnation</strong><br />

<strong>of</strong> a biodegradable polymer matrix, poly-dllactide-co-glycolide<br />

(PLGA), with 5-fluorouracil and<br />

b-estradiol, drugs that are used for chemotherapy and<br />

estrogen hormone therapy, respectively.<br />

The experimental set-up includes a saturation column<br />

packed with the drug, and an <strong>impregnation</strong> vessel in<br />

which the polymer is placed. Sorption experiments require<br />

the introduction <strong>of</strong> a drug-saturated CO 2 stream<br />

into the <strong>impregnation</strong> column. That is why the experiment<br />

consists <strong>of</strong> two sections: solubility measurement<br />

followed by <strong>impregnation</strong>. The apparatus is also<br />

equipped for a qualitative determination <strong>of</strong> polymer<br />

swelling.<br />

For b-estradiol at 35 °C and 207 bar, the impregnated<br />

amount (q ¼ mg drug/g PLGA) was 10.24 while at 55 °C<br />

and 207 bar, it arrives at 26.80.


I. Kikic, F. Vecchione / Current Opinion in Solid State and Materials Science 7 (2003) 399–405 401<br />

For 5-fluorouracil at 55 °C and 207 bar, the impregnated<br />

amount was very low (0.49).<br />

For these specific applications the drug loadings obtained<br />

are even higher than necessary since the therapeutical<br />

level for these products is much lower [12].<br />

Kazarian and Martirosyan [4] used ATR-IR spectroscopy<br />

to study the process <strong>of</strong> <strong>impregnation</strong> <strong>of</strong> ibupr<strong>of</strong>en<br />

into poly(vinyl pyrrolidone) (PVP) from SCCO 2<br />

solution.<br />

In situ spectroscopy allows the continuous monitoring<br />

<strong>of</strong> the amount <strong>of</strong> the impregnated drug, and the<br />

process can be instantly stopped by depressurising the<br />

high-pressure cell once the desired level is achieved.<br />

It has been shown that the supercritical fluid <strong>impregnation</strong><br />

process results in ibupr<strong>of</strong>en being molecularly<br />

dispersed in a polymer matrix where all drug<br />

molecules are H-bonded to the polymer and without the<br />

presence <strong>of</strong> ibupr<strong>of</strong>en crystals.<br />

ATR-IR spectroscopy has also revealed specific interactions<br />

between CO 2 molecules and carbonyl groups<br />

<strong>of</strong> PVP and it has been shown that a competitive interaction<br />

<strong>of</strong> impregnated ibupr<strong>of</strong>en molecules with the<br />

carbonyl groups <strong>of</strong> PVP prevents CO 2 molecules from<br />

interacting with the carbonyl groups <strong>of</strong> PVP. In addition,<br />

IR spectroscopic evidence has proved that similar<br />

interactions have an effect on water uptake into PVP.<br />

Thus, the PVP films impregnated with ibupr<strong>of</strong>en show<br />

much lower water uptake, presumably due to the competitive<br />

interaction <strong>of</strong> ibupr<strong>of</strong>en with basic carbonyl<br />

groups <strong>of</strong> PVP [4].<br />

3.2. Dye <strong>impregnation</strong><br />

In the dyeing processes <strong>of</strong> the textile industry, the use<br />

<strong>of</strong> supercritical carbon dioxide as an alternate solvent<br />

instead <strong>of</strong> water-based processes has been gaining much<br />

interest for environmental reasons. The conventional<br />

dyeing process <strong>of</strong> PET fibers discharges much wastewater<br />

that is contaminated by various kinds <strong>of</strong> dispersing<br />

agents, surfactants and unused dye. It is very difficult<br />

to design a conventional biological process that treats<br />

the wastewater discharged from a conventional dyeing<br />

PET process.<br />

The environmentally friendly supercritical fluid dyeing<br />

(SFD) process does not require any water, dispersing<br />

agents or surfactants and also does not involve any<br />

drying stage after dyeing. However, supercritical fluid<br />

dyeing has not been adopted in any <strong>of</strong> the world dyeing<br />

industries yet due to the high initial investment cost.<br />

Therefore, it may be better to apply the SFD to the<br />

hard-to-dye materials such as aramid, PE and PP fibers<br />

and films.<br />

Although extensive studies have been performed by<br />

several researchers, only a limited amount <strong>of</strong> basic dyesorption<br />

data is available. The amount <strong>of</strong> dye sorption<br />

in <strong>polymers</strong> in the presence <strong>of</strong> supercritical carbon dioxide<br />

is closely related to both the solubility <strong>of</strong> dye in<br />

the fluids and the distribution <strong>of</strong> dye between the fluid<br />

and the polymer phases. The mobility <strong>of</strong> dye molecules<br />

between polymer chains is generally enhanced due to the<br />

swelling <strong>of</strong> <strong>polymers</strong> in the supercritical fluids [13].<br />

Park and Bae [14] performed the measurement <strong>of</strong><br />

equilibrium dye uptake in PET fiber at various temperatures<br />

and pressures using a flow-method. The distribution<br />

coefficient increases with the pressure increase,<br />

because the sorption <strong>of</strong> dye in PET fiber increases more<br />

slowly with the pressure than the dye solubility in carbon<br />

dioxide does. This tendency is weakened with increase<br />

<strong>of</strong> temperature [14].<br />

Shim et al. [13] investigated sorption <strong>of</strong> some disperse<br />

dyes (C. I. Disperse Blue 60 (B60), C.I. Disperse Red 60<br />

(R60), C.I. Disperse Yellow 54 (Y54), and C.I. Disperse<br />

Orange 30 (O30)) in polyethylene terephthalate (PET)<br />

and polytrimethylene terephthalate (PTT) fibers as well<br />

as difficult-to-dye fibers such as aramid and polypropylene<br />

using supercritical carbon dioxide at pressures<br />

between 10 and )33 MPa and temperatures between 35<br />

and 150 °C. For dyeing in a co-solvent laden supercritical<br />

fluid, ethanol, acetone, or N-methyl pyrrolidone<br />

was also introduced in the dyeing vessel.<br />

PET and PTT fibers were easily dyed with Y54 and<br />

other dispersed dyes. The amount <strong>of</strong> sorption <strong>of</strong> Y54<br />

dye in the crystalline polyester textile fibers increased<br />

with increasing pressure up to 33 MPa at various temperatures.<br />

The amount <strong>of</strong> sorption for PTT was (about<br />

10%) larger than that for PET because PET has a high<br />

degree <strong>of</strong> crystallinity <strong>of</strong> 30% which is larger than that<br />

for PTT.<br />

Dye molecules are generally large and their diffusion<br />

rate is very small. They may penetrate only into the<br />

glassy part and not in the crystalline part <strong>of</strong> a polymeric<br />

matrix.<br />

Dye sorption increased with pressure at the same<br />

temperature and increased with temperature at the same<br />

pressure, but this increasing rate was reduced with increasing<br />

pressure [13].<br />

Van der Kraan et al. [15] studied dyeing <strong>of</strong> synthetic<br />

and natural textiles with a reactive dichlorotriazine dye<br />

in the presence <strong>of</strong> supercritical carbon dioxide.<br />

Experiments were carried out on polyester, silk, wool,<br />

cotton and aminated cotton. Pressure and temperature<br />

were varied from 225 to 278 bar and from 100 to 116 °C.<br />

In these experiments a small quantity <strong>of</strong> water was added<br />

as an enhancer <strong>of</strong> reactivity and/or accessibility <strong>of</strong><br />

the natural fibers. Polyester was dyed well, with fixation<br />

percentages in the order <strong>of</strong> 95% and the color yield increased<br />

with pressure, but not with temperature. Silk<br />

and wool were dyed with a color yield independent <strong>of</strong><br />

pressure and temperature. Fixation percentages on silk<br />

(76%) and wool (70%) were almost independent <strong>of</strong><br />

pressure and temperature. Comparison <strong>of</strong> the experimental<br />

results with literature data shows that silk can


402 I. Kikic, F. Vecchione / Current Opinion in Solid State and Materials Science 7 (2003) 399–405<br />

only be dyed in SCCO 2 when a small amount <strong>of</strong> water is<br />

dissolved in the SCCO 2 and in the silk.<br />

Cotton was dyed poorly under all conditions. Aminated<br />

cotton was dyed better than cotton but not as well<br />

as silk and wool. Fixation on aminated cotton was 87%.<br />

It was concluded that dichlorotriazine dye can react in<br />

moist SCCO 2 with amino groups <strong>of</strong> protein textile (e.g.<br />

silk and wool) but not with hydroxyl groups <strong>of</strong> cellulosic<br />

textiles (e.g. cotton) [15].<br />

3.3. Organic metallic complexes <strong>impregnation</strong><br />

Synthesis <strong>of</strong> metallopolymer nanocomposites has attracted<br />

much attention recently. Owing to their small<br />

size, metal particles exhibit some unusual structural,<br />

magnetic, catalytic and biological properties untypical<br />

for large particles.<br />

The process consists in the diffusion <strong>of</strong> an organometallic<br />

compound from the supercritical solution into<br />

the polymer matrix followed by its reduction/decomposition,<br />

achieved by application <strong>of</strong> heat, chemical reagents<br />

or radiations.<br />

The method <strong>of</strong> <strong>impregnation</strong> from solution in SCCO 2<br />

has several advantages:<br />

1. The matrix tends to prevent an agglomeration <strong>of</strong><br />

metal particles.<br />

2. SCCO 2 shows high penetrability into <strong>polymers</strong>.<br />

3. It is possible to control the solvent power and the <strong>impregnation</strong><br />

rate and, therefore, to control the composition<br />

and morphology <strong>of</strong> the obtained composite.<br />

4. The final product does not require special drying.<br />

5. Low surface tension allows <strong>impregnation</strong> even <strong>of</strong><br />

such barrier <strong>polymers</strong> as Teflon or obtaining <strong>of</strong> a<br />

continuous metal layer on their surface [16].<br />

Platinum (Pt) nanoparticles in poly(4-methyl pentene)<br />

and poly(tetrafluoroethylene), silver (Ag) nanoparticles<br />

on the surface <strong>of</strong> polyimide film, Ag nanoparticles in<br />

poly(ethylether ketone) and poly(styleneme-divinyl benzene)<br />

were investigated [17].<br />

Preparation <strong>of</strong> noble metal (Pt, Pd) particle-dispersed<br />

polyimide films as precursors <strong>of</strong> metal-doped carbon<br />

molecular sieve membranes (CMS) was performed by<br />

Yoda et al. [17] using <strong>impregnation</strong> <strong>of</strong> an acetyl-acetonate<br />

complex dissolved in supercritical CO 2 .<br />

Carbon molecular sieve membranes are known as<br />

good gas separation membranes even at high temperature.<br />

The gas separation properties <strong>of</strong> CMS membranes<br />

can be controlled by doping metal particles having an<br />

affinity to the relevant gas. Therefore, the hydrogen<br />

separation performance <strong>of</strong> CMS is expected to be improved<br />

by noble metals having an affinity to hydrogen.<br />

Significant increase <strong>of</strong> the Pt content will depend on<br />

the decomposition <strong>of</strong> polyimide catalyzed by Pt particles<br />

during thermal treatment, and on the temperature. Since<br />

the solubility <strong>of</strong> the Pt(II)(acac) 2 or Pd(II)(acac) 2 is independent<br />

<strong>of</strong> the temperature, the increase <strong>of</strong> the metal<br />

content should be ascribable to polyimide films, probably<br />

to thermal relaxation <strong>of</strong> the polymer network. Both<br />

Pt(II)(acac) 2 and Pd(II)(acac) 2 have similar solubility in<br />

SCCO 2 . The high dispersion <strong>of</strong> Pd particles could be<br />

related to lower decomposition temperature (>453 K in<br />

air) than Pt(II)(acac) 2 (its melting point is 523 K) and to<br />

chemical interactions with carboxyl structures <strong>of</strong> polyimide.<br />

Nazem et al. [18] investigated the preparation <strong>of</strong> reflective<br />

poly(etherether) ketone (PEEK) thin silvercoated<br />

films via supercritical fluid <strong>impregnation</strong> with<br />

CO 2 as the carrier and subsequent thermal reduction<br />

<strong>of</strong> (1,5-cyclooctadiene-1,1,1,5,5,5-hexafluoroacetylacetonato)silver(I)<br />

dimer, [Ag-(COD)HFA] 2 . No chemical<br />

reducing agent was needed to effect silver reduction.<br />

The resulting films were (a) reflective, (b) maintained<br />

their flexible nature and (c) had a surface electrical resistance<br />

higher than 10–11 X cm 1 , in spite <strong>of</strong> their<br />

metallic appearance.<br />

The reflectivity <strong>of</strong> the surface depends on the <strong>impregnation</strong><br />

and cure conditions. At constant CO 2 pressure<br />

(15 MPa) and <strong>impregnation</strong> time (120 min) at 20%<br />

additive, silver atomic concentration increased from<br />

7.5% to 18.5% as the <strong>impregnation</strong> temperature increased<br />

from 80 to 110 °C. At 10 wt.% additive and<br />

constant temperature and pressure (110 °C and 15 MPa)<br />

in another set <strong>of</strong> preliminary experiments, the amount <strong>of</strong><br />

silver increased from 9.6% to 15.5% in going from 60 to<br />

120 min <strong>impregnation</strong> time. At constant <strong>impregnation</strong><br />

conditions (e.g. 110 °C, 15 MPa, 120 min) the amount <strong>of</strong><br />

silver on the surface decreased as the weight percent <strong>of</strong><br />

additive changed from 20% to 10% and 5%, as might<br />

have been expected (e.g. 18.5%, 15.5%, 3.9%).<br />

At constant CO 2 pressure, the reflectivity <strong>of</strong> the surface<br />

increased increasing the <strong>impregnation</strong> temperature<br />

and the <strong>impregnation</strong> time.<br />

Thermal cure parameters at fixed <strong>impregnation</strong> conditions<br />

suggested that lower cure temperatures require<br />

longer cure times in order to obtain high reflectivity. Ten<br />

nanometer diameter silver particles appeared in the film<br />

bulk near the surface. Different sized silver clusters on<br />

the surface could be grown by controlling the <strong>impregnation</strong><br />

and cure conditions. The silver on the surface<br />

strongly adhered to the polymer surface [18].<br />

New chelate complexes <strong>of</strong> copper diiminate (Cu(II)–<br />

HFDI) and iron diiminate (Fe(III)–HFDI) were synthesized<br />

by Said-Galiyev et al. [16]. The <strong>polymers</strong><br />

impregnated via supercritical CO 2 were polyarylate<br />

(PAR) films with thicknesses <strong>of</strong> 12and 39 mm. The<br />

equilibrium degree <strong>of</strong> polyarylate swelling in SCCO 2 at<br />

45 °C and 8 MPa is 10%; this establishes the <strong>impregnation</strong><br />

operating conditions. In the case <strong>of</strong> Cu(II)–HFDI<br />

the <strong>impregnation</strong> can be as large as 11–51% while the<br />

content <strong>of</strong> pure copper in film is as large as 1.3–6.3 wt.%;


I. Kikic, F. Vecchione / Current Opinion in Solid State and Materials Science 7 (2003) 399–405 403<br />

in the case <strong>of</strong> Fe(III)–HFDI it arrives at 57.6% while the<br />

content <strong>of</strong> iron is 1.5–4.5%. It was shown that after<br />

thermal heating the copper atom is in a nearly univalent<br />

state. The size <strong>of</strong> metal-containing particles ranges from<br />

15 to 60 nm (with a maximum at 34 nm), which corresponds,<br />

for example, to the size range <strong>of</strong> catalytic particles<br />

used in heterogeneous catalysis (2–50 nm) [16].<br />

3.4. Monomer and initiator <strong>impregnation</strong> (polymer<br />

blends)<br />

One <strong>of</strong> the most interesting applications <strong>of</strong> supercritical<br />

fluid <strong>impregnation</strong> is the modification <strong>of</strong> <strong>polymers</strong><br />

via the infusion <strong>of</strong> a monomer and an initiator into<br />

aCO 2 -swollen polymer matrix with subsequent polymerization<br />

<strong>of</strong> a monomer within the polymer matrix for<br />

the preparation <strong>of</strong> polymer blends [19].<br />

With SCCO 2 it is possible to obtain polymer modifications<br />

by avoiding thermal stresses.<br />

The <strong>impregnation</strong> <strong>of</strong> styrene and acrylic acid into a<br />

series <strong>of</strong> polyamide products (nylon1212, nylon1010,<br />

nylon66, nylon6) using supercritical CO 2 as additive<br />

carrier and substrate-swelling agent was performed by<br />

Xu and Chang [20].<br />

The <strong>impregnation</strong> efficiency <strong>of</strong> additives into substrates<br />

is attributed to complicated interactions within<br />

the systems.<br />

In the examined pressure range from 8 to 16 MPa,<br />

acrylic acid always has a higher <strong>impregnation</strong> uptake<br />

than styrene.<br />

It was found that the relative solubility <strong>of</strong> the additive<br />

in the polymer substrate and CO 2 is a major factor<br />

governing the incorporated amount; however swelling <strong>of</strong><br />

the substrate and CO 2 -induced crystallization also contribute<br />

to the value [20].<br />

Li et al. [21] studied the preparation <strong>of</strong> nanometer<br />

dispersed polypropylene/polystyrene (PP/PS) interpenetrating<br />

networks (IPNs) by the radical polymerization<br />

and crosslinking <strong>of</strong> styrene (St) within supercritical CO 2 -<br />

swollen PP substrates. In this method, monomer styrene<br />

(St), crosslinking agent divinyl benzene (DVB), and the<br />

initiator benzoyl peroxide (BPO) were first impregnated<br />

into PP matrix using SCCO 2 as a solvent and swelling<br />

agent at 35.0 °C, and then the polymerization and<br />

crosslinking were carried out at 120 °C.<br />

The PP/PS IPNs mass uptake increases initially with<br />

soaking time, and it is independent <strong>of</strong> soaking time after<br />

about 13 h when equilibrium conditions are reached.<br />

A maximum <strong>of</strong> PP/PS IPNs mass uptake is shown at<br />

about 140 bar. This is due to the competition between<br />

two opposite effects with increasing pressure: the degree<br />

<strong>of</strong> swelling <strong>of</strong> the polymeric matrix and the solubility <strong>of</strong><br />

the monomers in the CO 2 -rich phase.<br />

The composition <strong>of</strong> the IPNs can be controlled by<br />

SCCO 2 pressure and concentrations <strong>of</strong> St and DVB in<br />

the fluid phase.<br />

The synthesis <strong>of</strong> conducting <strong>polymers</strong> has become an<br />

important research area since its discovery in the past 20<br />

years. Most conducting <strong>polymers</strong>, such as polypyrrole<br />

(PPy), poly(3-octyl thiophene), polyaniline, were synthesized<br />

by oxidative or electro-chemical polymerization [21].<br />

One way to overcome the poor mechanical properties<br />

<strong>of</strong> these conductive <strong>polymers</strong> is to blend them with another<br />

insulating polymer.<br />

Tang et al. [22,23] investigated the preparation <strong>of</strong><br />

electrically conductive polypyrrole–polystyrene composites<br />

by supercritical carbon dioxide <strong>impregnation</strong>.<br />

These authors studied:<br />

1. The effect <strong>of</strong> the blending conditions;<br />

2. The effect <strong>of</strong> doping conditions.<br />

The host polymer was blended with pyrrole monomer<br />

using either supercritical carbon dioxide or high-pressure<br />

liquid carbon dioxide (HPLCO 2 ) near the supercritical<br />

conditions as the carrying solvent. After the<br />

blending process, the blended host polymer was soaked<br />

in an oxidant metallic salt solution.<br />

For blending the host polymer with pyrrole monomer,<br />

SCCO 2 provides better conditions than HPLCO 2<br />

at the same density. The maximum conductivity <strong>of</strong> the<br />

polymer composites also increases with temperature and<br />

pressure at the same SCCO 2 density and it is about one<br />

order <strong>of</strong> magnitude higher in SCCO 2 than in HPLCO 2 .<br />

This result can be explained by the swelling efficiency in<br />

the blending period, which is a controlling factor for the<br />

structure and conductivity <strong>of</strong> the resulting composites.<br />

Referring to the doping conditions, acetonitrile and<br />

water were used as the doping solvents and iron<br />

perchlorate, and iron nitrate were selected as oxidants at<br />

temperatures between 15 and 45 °C.<br />

The maximum conductivity <strong>of</strong> the composites with<br />

iron compounds as oxidants decreases in the following<br />

order <strong>of</strong> anions: chloride > sulfate > perchloride > nitrate<br />

in aqueous solutions [22,23].<br />

The modification <strong>of</strong> the polymeric substrates bisphenol<br />

A poly(carbonate) (PC), poly(vinyl chloride)<br />

(PVC) and poly(tetrafluoro ethylene) (PTFE) by the<br />

vinylic monomers styrene (S), methyl methacrylate<br />

(MMA) and methacrylic acid (MAA) under supercritical<br />

conditions was performed by Muth et al. [24].<br />

The monomers solubility in SCCO 2 and their phase<br />

behaviour have been investigated in order to achieve<br />

<strong>impregnation</strong> in homogeneous phase and to prevent the<br />

extraction <strong>of</strong> the impregnated monomers during the<br />

polymerization.<br />

At 40 °C pressure conditions must be higher than 11<br />

MPa, while at 80 °C pressures below 11 MPa must be<br />

chosen.<br />

In a first step, the <strong>polymers</strong> were impregnated with<br />

the monomers and a radical initiator (azoisobutyrodinitrile<br />

(AIBN) for all cases), followed by a polymerization


404 I. Kikic, F. Vecchione / Current Opinion in Solid State and Materials Science 7 (2003) 399–405<br />

inside the swollen substrates. The process parameters<br />

were controlled by the concentration <strong>of</strong> the radical initiator<br />

and by the solubility <strong>of</strong> the monomers in SCCO 2 .<br />

As a result, PTFE shows the least ability to be<br />

modified due to its limited swelling capability and high<br />

crystallinity degree (<strong>impregnation</strong> occurs only in amorphous<br />

domains).<br />

In contrast the highest mass gains are obtained for<br />

PC and PVC as substrates, and styrene and MMA as the<br />

impregnating monomers.<br />

PVC–PMAA was chosen as a model system for the<br />

investigation <strong>of</strong> the limits <strong>of</strong> supercritical polymer<br />

modification, because this system seems to be most interesting<br />

for the possibility to generate a water-soluble<br />

polymer PMAA inside a hydrophobic PVC matrix.<br />

CO 2 treatment causes no changes in the chemical<br />

structure <strong>of</strong> PVC since the thermogram <strong>of</strong> CO 2 -treated<br />

PVC equals that <strong>of</strong> pure PVC. PMAA starts to decompose<br />

by dehydration at 125 °C, and the decomposition<br />

is complete by the degradation <strong>of</strong> the polymer<br />

backbone at 400 °C, causing relatively high mass losses<br />

in comparison to PVC and CO 2 -treated PVC [24].<br />

One advantage <strong>of</strong> supercritical polymer modification<br />

is the possibility to synthesize new polymer mixtures<br />

with thermally unstable components.<br />

With the generation <strong>of</strong> the water-soluble poly(methacrylic<br />

acid) (PMAA) inside the hydrophobic PVC or<br />

PMMA substrates, it was possible to obtain polymer<br />

mixtures inaccessible by common techniques such as<br />

melt mixing, because the PMAA would definitely decompose<br />

during the extrusion at temperatures >175 °C.<br />

4. Conclusions<br />

An overview <strong>of</strong> supercritical <strong>impregnation</strong> processes<br />

in the presence <strong>of</strong> supercritical fluids has been presented.<br />

<strong>Supercritical</strong> carbon dioxide dissolved in glassy<br />

<strong>polymers</strong> increases the diffusivities <strong>of</strong> additives in the<br />

polymer matrix because <strong>of</strong> the CO 2 plasticization effect.<br />

<strong>Supercritical</strong> fluid <strong>impregnation</strong> is a useful method<br />

for the preparation <strong>of</strong> pharmaceutical forms. This<br />

method presents the advantages related to the plasticizing<br />

ability <strong>of</strong> the CO 2 that enhances drug diffusion<br />

rates into the polymer and the ease <strong>of</strong> solvent removal.<br />

<strong>Supercritical</strong> dye <strong>impregnation</strong> is a process based on<br />

the affinity <strong>of</strong> the dye for the polymeric matrix. Moreover,<br />

supercritical dye <strong>impregnation</strong> replaces water in<br />

dyeing processes, overcoming the problem <strong>of</strong> wastewater<br />

treatment.<br />

SCF properties are successfully adopted for charging a<br />

polymer matrix with metallic organic complexes in order<br />

to prepare metal-containing nanocomposite metals.<br />

An interesting application <strong>of</strong> supercritical <strong>impregnation</strong><br />

is the polymer blend preparation by the <strong>impregnation</strong><br />

<strong>of</strong> a polymer matrix with a monomer and an<br />

initiator to perform the polymerization within the<br />

polymer matrix. With this particular method it is possible<br />

to obtain polymer blends not easy obtainable with<br />

common techniques, i.e. melt mixing.<br />

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