Impact of Particle Size on Droplet Coalescence in Solid-Stabilized High Internal Phase Emulsions

High internal phase emulsions (HIPEs) comprise highly faceted droplets separated by thin films of fluid. Though surfactants are traditionally used in formulating HIPEs, growing interest in solid-stabilized HIPEs calls for a better understanding of how particles may affect the coalescence of droplets at high volume fractions of the dispersed phase. In this study, we address the effect of particle size on this issue. Using confocal microscopy, we examine the microstructures of four different solid-stabilized emulsion series and quantify droplet coalescence in each. We show that, systematically, HIPEs stabilized with smaller particles show a greater propensity for film rupture and the presence of partially coalesced droplets, whereas the use of larger particles results in a higher fraction of bridged particle monolayers between neighboring droplets. This result is in contrast with the behavior of dilute emulsions, where the use of smaller particles has been shown to impart greater stability against droplet coalescence. Utilizing a simple model of film rupture, we rationalize our experimental findings in the context of the capillary pressure profile within a solid-stabilized liquid film, and show that bridged monolayer formation is directly linked to improved film stability at high volume fractions of the dispersed phase. Therefore, particle size can impact the stability of solid-stabilized HIPEs by influencing their propensity for monolayer formation.