Synthesis of nearly micron-sized particles by soap-free emulsion polymerization of methacrylic monomer using an oil-soluble initiator

Methacrylic monomer was used in soap-free emulsion polymerization in order to obtain a stable dispersion containing particles of the polymerized monomer. 2,2′-Azobis(2-methylpropionitrile) (AIBN) or 1,1′-azobis(1-acetoxy-1-phenylethane) (OT_AZO-15) were used as the radical initiator. Although particles with a size of about 1.0 μm were obtained when using methyl methacrylate as the monomer and AIBN as the initiator, the particles did not exhibit good dispersion stability. When OT_AZO-15, which has phenyl rings, was used as the initiator, the monomer phase solidified instead of forming particles in the aqueous phase. Benzyl methacrylate (BMA) monomer, which contains a phenyl ring, was polymerized using AIBN. Negatively charged particles with a size of 0.90 μm were formed. These particles exhibited good dispersion stability probably because of the pi electrons of the phenyl ring in the BMA monomer. The method in this study allows the synthesis of nearly micron-sized particles without surfactant, organic solvent, and electrolyte.