Synthesis and characterization of new flame-retardant microspheres by dispersion polymerization of pentabromobenzyl acrylate

New flame-retardant nano/micro particles of sizes ranging between 0.06 ± 0.01 and 1.70 ± 0.23 μm were formed by dispersion polymerization of the pentabromobenzyl acrylate monomer (PBBA) in methyl ethyl ketone as a continuous phase. The effect of various polymerization parameters, e.g., monomer concentration, initiator type and concentration, stabilizer concentration and crosslinker monomer concentration, on the size, size distribution and polymerization yield of the produced poly(pentabromobenzyl acrylate) particles has been elucidated. Poly(pentabromobenzyl acrylate)/polystyrene (PPBBA/PS) nano/micro blends of the contents of different PPBBA particles were prepared by mixing the PPBBA particles with a PS solution in methylene chloride, followed by evaporation of the methylene chloride from the mixture. The thermal stability of these blends was also studied.