Preparation of novel and unique nonspherical particles with almond-shell-like shape via dual-seeded dispersion polymerization in the presence of saturated hydrocarbon droplets

In this study, the preparation of micron-sized polymer particles having a novel and unique nonspherical shape which we called almond-shell-like by dual-seeded dispersion polymerization (DSDP) of 2-ethylhexyl methacrylate (EHMA) with polystyrene (PS) and poly(methyl methacrylate) (PMMA) seed particles in the presence of decane droplets and evaporation of decane after the polymerization was discussed. The experimental results showed that mushroom-like morphology which is a precursor of the almond-shell-like shape was obtained from DSDP of EHMA. It was found that with changing the PS/PMMA seed particles' weight ratio, the size of the dents on the surface of the particles can be controlled. Furthermore, it was observed that various nonspherical particles can be produced using different methacrylic seed particles and initiators.     

Preparation of nonspherical particles via dual-seeded dispersion polymerization in the presence of saturated hydrocarbon droplets

In this study, the effect of various polymerization conditions on the shape of the particles produced by dual-seeded dispersion polymerization of a second monomer with polystyrene (PS) and poly(methyl methacrylate) (PMMA) seed particles in the presence of saturated hydrocarbon droplets in a polar media was discussed. It was observed that with changing the affinity between the hydrocarbon and PS seed particles, second monomer type, polarity, and alcohol type of the medium nonspherical particles with a variety of shapes can be produced. Furthermore, we suggested that the presence of PMMA seed particles in the medium affects the distribution of the second polymer domains on the surface of the PS seed particles in addition to the absorbed amount of the hydrocarbon by PS particles and second polymer domains and the distribution of the hydrocarbon between them. Moreover, the experimental results showed that almond shell-like PS particles can be prepared under certain conditions.     

Fabrication of cage-like particles via unstable seeded dispersion polymerization: A new concept in the polymerization-induced self-assembly

The formation mechanism of hollow micron-sized polystyrene (PS) particles having numerous dents on the surface, so-called cage-like particles, obtained from seeded dispersion polymerization (SDP) of 2-ethylhexyl methacrylate (EHMA) with low molecular weight (MW) PS particles stabilized by poly(vinyl alcohol) (PVA) in the presence of hexadecane droplets was investigated. It was found that association of poly(2-ethylhexyl methacrylate) (PEHMA)/hexadecane phases which occurs due to the instability of the obtained composite particles followed by a diffusion of PS ellipsoidal particles into each other is the main process responsible for the production of such unique morphology. Time course monitoring of the SDP showed that diffusion of hexadecane and/or PS and/or PEHMA phase into PS/PEHMA/hexadecane composite particles through PS shell which happens based on Ostwald ripening is the main phenomenon which results in the formation of the dents on the surface of final particles. Moreover, the experimental results revealed that in this reaction system, the polymerization develops in a faster manner rather than the SDP employing seed particles having higher MWs. Furthermore, it was observed that particles with different surface morphologies can be produced by using different hydrocarbons. The elimination of small particles which are produced in addition to the cage-like ones via decreasing the concentration of the stabilizer was another interesting finding of this research. The acquired results showed that unstable SDP is expected to be a new concept in polymerization-induced self-assembly (PISA) which employs instability of a dispersion for self-assembly of polymeric particles, and therefore, production of polymeric unique objects.     

Facile Method to Synthesis of Golf Ball-Like Particles via Early-Ceased Seeded Dispersion Polymerization

Golf ball-like poly(methyl methacrylate) particles were produced via seeded dispersion polymerization of 2-ethylhexyl methacrylate with poly(methyl methacrylate) seed beads in the presence of saturated hydrocarbon droplets and evaporation of the hydrocarbon after the polymerization. It was observed that the particles are acquired in the form of a stable dispersion if the reaction is ceased around 42% of monomer conversion. Moreover, the effect of different reaction conditions (e.g. hydrocarbon and stabilizer type, initiator and monomer content, and polarity of the medium) on the shape and stability of the produced particles was investigated. It was revealed that the number and size of the dents on the surface of the golf ball-like particles could be manipulated easily with a simple change in each one of the parameters referred to above. In addition, the experimental results showed that some of the particles become unstable and diffuse into each other during polymerization, resulting in the formation of huge golf ball-like objects. The production of disk-like poly(methyl methacrylate) particles via fully developed seeded dispersion polymerization in the presence of a hydrocarbon which owns lengthy alkyl chain was another interesting finding of this study.     

Effect of second monomer and initiator type, mixing method, and stabilizer content on the shape of the particles produced by seeded dispersion polymerization in the presence of saturated hydrocarbon droplets

In this work, the preparation of micron-sized polymer particles with nonspherical shapes via seeded dispersion polymerization of 2-ethylhexyl methacrylate with polystyrene seed particles in the presence of hydrocarbon droplets and evaporation of hydrocarbon after the polymerization under various polymerization conditions was discussed. The effect of second monomer and initiator type, mixing method, and stabilizer content on the shape of the obtained particles was investigated. It was observed that particles with more nonspherical shapes were obtained with increasing the alkyl chain length of ester group of the methacrylate of the second monomer which is because of increasing the absorption amounts of hydrocarbon by second polymer domains. Moreover, the experimental results showed that shape of the particles which was produced by shaking is more nonspherical than the shape of the particles which was obtained from tumbling. Furthermore, particles with different nonspherical shapes were prepared by changing the initiator type and stabilizer content.     

Dispersion polymerization of methyl methacrylate in supercritical CO2 in the presence of non-fluorous random copolymers

A series of non-fluorous random copolymers, composed of 3-[tris(trimethylsilyloxy)silyl] propyl methacrylate and 2-dimethylaminoethyl methacrylate, poly(SiMA-co-DMAEMA) with different comonomer ratios were prepared and utilized as stabilizers for the free radical dispersion polymerization of methyl methacrylate (MMA) in supercritical carbon dioxide (scCO₂). It was demonstrated that the composition and concentration of the stabilizer have a dramatic effect on the morphology of resulting poly methyl methacrylate (PMMA) latex. When the copolymeric stabilizer poly(SiMA-co-DMAEMA) (71:29) was employed, free-flowing spherical PMMA particles were produced in high yield. As the concentration of stabilizer increases, the resulting size of colloidal particles decreases. In addition, the monomer concentration and initial pressure affected the particle diameter of PMMA.     

Shape of the particles produced by seeded dispersion polymerization of styrene

In this work, seeded dispersion polymerization of styrene was carried out in the presence of various types of seed particles. We found that in the case of polystyrene and poly(methyl methacrylate) seeds, the shape of the resulting particles remained spherical. For styrene/poly(nbutyl methacrylate) (PnBMA) and styrene/poly(lauryl methacrylate) seeding particles, raspberry like particles were produced along with those of occluded morphology. We studied the effects of various polymerization factors such as concentrations of a stabilizer, an initiator, and a monomer, a weight ratio of methanol to water, a type of initiator, weight ratio of styrene to Pn-BMA seed particles, and polymerization temperature on the formation of these raspberry-like particles. The experimental results showed that the increase of concentrations of the initiator and the stabilizer as well as that of methanol favors the formation of such particles by increasing their surface roughness. An increase of the temperature of polymerization had the same effect on the morphology of resulting product. We hypothesized that the nucleation and growth of specifically fine-structured polystyrene domains on the surface of the Pn-BMA particles guides the formation of non-linear morphology during seeded polymerization in colloidal solution.     

Production of micron-sized, monodispersed, multilayered composite polymer particles by multistep seeded dispersion polymerization

 Micron-sized, monodispersed, poly(methyl methacrylate) (PMMA)/polystyrene (PS)/PMMA/PS multilayered composite particles were successfully produced by three-step seeded dispersion polymerizations in methanol/water media. The first seeded dispersion polymerization was carried out with 2-μm-sized, monodispersed PMMA particles.     

Effect of colloidal stabilizer on the shape of polystyrene/poly(methyl methacrylate) composite particles prepared in aqueous medium by the solvent evaporation method

Effects of the kind and concentration of stabilizers on the nonspherical shape of polystyrene (PS)/poly(methyl methacrylate) (PMMA) composite particles prepared by release of toluene from PS/PMMA/toluene droplets dispersed in stabilizer aqueous solution were examined. In the case of poly(vinyl alcohol), the surfaces of the obtained particles always had a single dimple. In the case of sodium dodecyl sulfate (SDS), the shapes of the composite particles changed from the dimple, via acorn, to spherical with increasing SDS concentration. It was clarified that the dimple and acorn shapes of the PS/PMMA composite particles were caused by contraction of the PS phase after hardening of the PMMA phase in excentered core-shell and hemisphere morphologies, respectively, which were formed by phase separation during toluene evaporation.     

Non-bioaccumulative, environmentally preferable stabilizer architectures for the dispersion polymerization of MMA in supercritical CO2

To overcome the environmental concerns associated with long-chain perfluorinated compounds, in this report, non-bioaccumulative, environmentally friendly stabilizer architectures based on short-chain fluorinated polymers have been designed for the dispersion polymerization of methyl methacrylate (MMA) in supercritical CO₂. Random copolymers composed of 2-(diisopropylamino)ethyl methacrylate (DPAEMA) and 2,2,3,3,4,4,4-heptafluorobutyl methacrylate (FBMA) or 2,2,3,3,4,4,5,5-octafluoropentyl methacrylate were prepared with various comonomer ratios and utilized as stabilizers. It was found that the copolymers effectively stabilized PMMA latexes in CO₂, leading to the formation of free-flowing, spherical PMMA particles. With increase in the concentration of the stabilizer poly(FBMA-co-DPAEMA) from 2% to 6% (w/w with respected to MMA), the particles diameter decreased from 3.02 to 1.0 μm.     

Preparation of monodisperse PMMA microspheres in nonpolar solvents by dispersion polymerization with a macromonomeric stabilizer

We discuss a dispersion polymerization procedure for preparing monodisperse and micron-sized poly(methyl methacrylate) (PMMA) particles in hexanes with methacryloxypropyl-terminated polydimethylsiloxane stabilizers. We investigate the effects of the stabilizer molecular weight, stabilizer concentration, and monomer concentration on the particle size and polydispersity. We find that a minimum molecular weight of 10 000 g/mol is necessary to synthesize colloidally stable PMMA dispersions. The particle polydispersity is minimal (=5%) for stabilizer to monomer weight ratios of 0.02 to 0.1, while PMMA particles prepared under conditions outside this range are polydisperse. The particle diameter can be varied from 0.4 to 1.5 µm by appropriate choices of stabilizer and monomer concentrations. Stable PMMA suspensions can be prepared at up to 26.3% solids. The dispersions are stable in most liquid aliphatics, and are monodisperse enough to form ordered domains at high concentration. This single-stage synthesis, requiring only commercially available materials, may be of interest to those seeking a simple way to prepare highly monodisperse non-aqueous dispersions in the micron size range.     

Dispersion polymerization of MMA in supercritical CO2 stabilized by random copolymers of 1H,1H–perfluorooctyl methacrylate and 2‐(dimethylaminoethyl methacrylate)

A series of random copolymers, composed of 1H,1H‐perfluorooctyl methacrylate (FOMA) and 2‐dimethylaminoethyl methacrylate (DMAEMA) were prepared as stabilizers for the dispersion polymerization of methyl methacrylate in supercritical CO₂ (scCO₂). Free‐flowing, spherical poly(methyl methacrylate) (PMMA) particles were produced in high yield by the effective stabilization of poly(FOMA‐co‐DMAEMA) containing 34–67 w/w % (15–41 m/m %) FOMA structural units. Less stabilized but micron‐sized discrete particles could be obtained even with 25 w/w % (10 m/m %) FOMA stabilizer. The result showed that the composition of copolymeric stabilizers had a dramatic effect on the size and morphology of PMMA. The particle size was controllable with the surfactant concentration. The effect of the monomer concentration and the initial pressure on the polymerization was also investigated. The dry polymer powder obtained from dispersion polymerization could be redispersed to form stable aqueous latexes in an acidic buffered solution (pH = 2.1) by an electrostatic stabilization mechanism due to the ionization of DMAEMA units in the stabilizer. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 1365–1375, 2008     

Emulsion polymerization of styrene and methyl methacrylate using a hydrophobically modified inulin and comparison with other surfactants

The use of a new class of graft polymer surfactants, based on inulin, in emulsion polymerization of poly(methyl methacrylate) (PMMA) and polystyrene (PS) particles is described. PS and PMMA were synthesized by emulsion polymerization, and stable particles with a high monomer content (50 wt %) were obtained with a very small amount of polymeric surfactant ([surfactant]/[monomer] = 0.0033). The latex dispersions were characterized by dynamic light scattering and by transmission electron microscopy to obtain the average particle size and the polydispersity index, and the stability was determined by turbidimetry measurements and expressed in terms of critical coagulation concentration. The last section gives a comparison of PMMA particles prepared by emulsion polymerization using classical surfactants from different types as emulsifiers with that obtained using the copolymer surfactant. It shows the superiority of INUTEC SP1 as it is the only one that allows stable particles at 20 wt % monomer content, with a smaller ratio [surfactant]/[monomer] = 0.002.     

Production of micron-sized monodispersed core/shell composite polymer particles by seeded dispersion polymerization

 The effect of the weight ratio of seed polymer/monomer on the morphology of the poly(methyl methacrylate) (PMMA)/polystyrene (PS) monodispersed composite particles produced by batch seeded dispersion polymerization of styrene with 1.64-μm-sized monodispersed PMMA seed particles in a methanol/water medium (4/1 w/w) was examined. In the PMMA/PS weight ratios of 3/1 and 2/1, the composite particles had a clear morphology consisting of a PMMA core and a PS shell. In the ratio of 1/1, a lot of small PS domains were observed in the PMMA core though the PS shell was still formed. By stepwise addition of styrene monomer, the formation of the small PS domain was depressed and complete core/shell morphology was formed. Absorption/release treatments of toluene into/from the PMMA/PS (1/1 w/w) composite particles resulted in a drastic morphological change from the core/shell structure to a multi- layered one. Received: 2 February 1999 Accepted in revised form: 7 April     

Synthesis of submicron-sized peanut-shaped poly(methyl methacrylate)/polystyrene particles by seeded soap-free emulsion polymerization

Submicron-sized peanut-shaped poly(methyl methacrylate)/polystyrene(PMMA/PS) particles were successfully synthesized by seeded soap-free emulsion polymerization of styrene on the spherical crosslinked PMMA seed particles.The obtained peanut-shaped particles showed a novel internal morphology:PS phase formed one domain which linked to the other domain having PMMA core encased by PS shell.     

悬浮-乳液复合聚合聚苯乙烯-聚甲基丙烯酸甲酯复合粒子的颗粒特性和成粒机理

采用在苯乙烯 (St)悬浮聚合过程中滴加甲基丙烯酸甲酯 (MMA)乳液聚合组分的悬浮 乳液复合聚合方法 ,制备大粒径聚苯乙烯 聚甲基丙烯酸甲酯 (PS PMMA)复合粒子 .研究聚合物粒径分布和颗粒形态的变化发现 ,在St悬浮反应中期滴加MMA乳液聚合组分后 ,聚合体系逐渐由悬浮粒子与乳胶粒子并存向形成单峰分布复合粒子转变 ,最终形成核 壳结构完整的大粒径PS PMMA复合粒子 ;在St悬浮反应初期滴加MMA乳液聚合组分 ,St与MMA一起分散成更小液滴 ,反应后期凝并成非核 壳结构复合粒子 ;在St悬浮反应后期滴加MMA乳液聚合组分 ,PMMA乳胶粒子与PS悬浮粒子基本独立存在 .根据以上结果 ,提出了St MMA悬浮 乳液复合聚合的成粒机理 .     

Suspension Polymerization of Methyl Methacrylate Stabilized Solely by Palygorskite Nano Fibers简

A kind of fibrous clay, palygorskite(PAL), was used as the sole stabilizer in suspension polymerization without the using of any other stabilizer usually used, especially polymeric stabilizers. In order to improve the compatibility with the organic monomer, PAL nano fibers were organically modified with silane coupling agent methacryloxypropyltrimethoxysilane(MPS). Transmission electron microscopy(TEM) and Fourier-transform infrared(FTIR) spectroscopy results show that the hydrolyzed MPS was attached onto PAL surface through Si―O―Si bonds formation without morphology change of PAL. At a loading amount of PAL to monomer as low as 0.36 wt%, effective stabilization could be achieved. After suspension polymerization, spherical poly(methyl methacrylate)(PMMA) particles were obtained. Scanning electron microscopy(SEM) analysis on both the outer surface and the inner cracked surface of the spherical PMMA particles indicates that the PAL particles reside on the surface of the PMMA spheres. The densely stacked PAL together with attached silane coupling agent stabilized the droplets throughout the suspension polymerization.     

Effect of monomer and hydrocarbon content and polarity of the medium on the preparation of nonspherical particles via seeded dispersion polymerization in the presence of saturated hydrocarbon droplets

In this work, the preparation of micron-sized polymer particles with nonspherical shapes via seeded dispersion polymerization of 2-ethylhexyl methacrylate (EHMA) with polystyrene (PS) seed particles in the presence of decane droplets and evaporation of decane after the polymerization under various polymerization conditions was discussed. The effect of monomer and decane content and polarity of the medium on the shape of the obtained particles was investigated. The experimental results showed that decreasing the amount of monomer and hydrocarbon volume of PEHMA/hydrocarbon domains, the particles decreased but they grew symmetrically, resulting in symmetric shapes. Furthermore, it was suggested that because of changing the solubility of the oligoradicals and hydrocarbon in the medium, the shape of the particles changed with changing the polarity of the medium. With decreasing the polarity of the medium, solubility of the oligoradicals in the medium increases and bigger polymer domains form on the surface of PS particles which can absorb higher amounts of decane. All of these can contribute to an increase in volume reduction after extraction of PEHMA/decane, resulting in various particle shapes. Further decreasing in polarity of the medium leads to an increase in the solubility of decane in the medium and decreasing the absorbed amount of decane by PS particles and PEHMA domains, resulting in lower volume reduction after evaporation of decane.     

The morphology of composite polymer particles produced by multistage soapless seeded emulsion polymerization

 Composite polymer particles which contain poly(methyl methacrylate) (PMMA) and polystyrene (PS) components (PMMA/PS composite particle) were synthesized by the method of multistage soapless seeded emulsion polymerization. In this study, the process of multistage soapless seeded emulsion polymerization included two-stage polymerization, three-stage polymerization or four-stage polymerization. The morphologies of the PMMA/PS composite particles were studied. The kinetic factor was the main force to control the morphology of the linear PMMA–PS composite particles which were synthesized by the method of two-stage reaction. Both the kinetic factor and the thermodynamic factor decide the morphology of the linear composite particles which were synthesized by the method of either three-stage or four-stage reaction. However, the thermodynamic factor cannot influence the morphology of the PMMA/PS composite particles with a cross-linked structure which were synthesized by the method of three-stage reaction. The cross-linked composite polymer particles had the morphology of a multilayer structure, which showed that the polymer layers accumulated in their order of production. Received: 9 January 2001 Accepted: 14 June 2001     

Revisiting the synthesis of a well-known comb-graft copolymer stabilizer and its application to the dispersion polymerization of poly(methyl methacrylate) in organic media

Polymeric stabilizers are an essential ingredient for the dispersion polymerization of poly(methyl methacrylate) (PMMA) in nonpolar media. In this contribution, we focus on the synthesis of an amphipathic copolymer consisting of pendant poly(12-hydroxystearic acid) (PHS) chains grafted to an insoluble PMMA backbone. This type of steric stabilizer is well established and capable of producing spherically shaped, monodisperse PMMA colloids. Unfortunately, the comb-graft copolymer is not available commercially; furthermore, the multistep synthesis of the desired stabilizer has proven challenging to reproduce. We discuss the practical matter of preparing PHS-graft-PMMA, and report specific techniques developed over several years in our lab. Gel permeation chromatography, mass spectroscopy, and end group analysis of the stabilizer and the precursor macromonomer reveal important, previously unreported details about the chemical synthesis. Our protocol is reproducible and resulted in the production of low polydispersity PMMA particles.