Preparation of micron-size monodisperse polymer particles by seeded polymerization utilizing the dynamic monomer swelling method

Utilizing a new type of monomer swelling method, 6.1 m-size monodisperse polymer particles were prepared by seeded polymerization. 1.8 m-size monodisperse polystyrene (PS) seed particles (1.8 m in size) were prepared by dispersion polymerization in ethanol-water (80/20, v/v) medium in the presence of poly(acrylic acid) as stabilizer with 2,2-azobisisobutyronitrile as initiator. The PS seed dispersion was mixed with ethanol-water (60/40, v/v) solution dissolving styrene (S) monomer, benzoyl peroxide as initiator, and poly(vinyl alcohol) as stabilizer. By slow, continuous, dropwise addition of water with a micro feeder into the mixture, the PS particles absorbed the many S monomers, which were separated from the medium and swelled from 1.8 m to 8.4 m while keeping the monodispersity high. We named this procedure the dynamic swelling method. Then, the seeded polymerization of the absorbed S monomer was carried out in the presence of NaNO₂ as water-solube inhibitor.Part CXXII of the series Studies on Suspension and Emulsion.     

Preparation of micron-size monodisperse polymer microspheres having crosslinked structures and vinyl groups

Micron-size monodisperse polymer microspheres having crosslinked structures therein and vinyl groups thereon were prepared by seeded copolymerization of styrene and divinylbenzene with 2,2-azobisisobutyronitrile as initiator in ethanolwater medium in the presence of 2.1-m monodisperse polystyrene seed particles produced by dispersion polymerization. The optimum conditions of the seeded copolymerization for producing the microspheres with good monodispersity and colloidal stability were determined.Part CXXI of the series Studies on Suspension and Emulsion.     

Micron-sized monodispersed polymer particles produced by seeded polymerization for the dispersion of high swelling of polymer particles with a large amount of monomer

 Micron-sized monodispersed polystyrene (PS)/poly(n-butyl methacrylate) composite particles were produced as follows. First, 1.77 μm-sized monodispersed PS seed particles produced by dispersion polymerization were dispersed in ethanol/water (1/2, w/w) medium dissolving poly(vinyl alcohol) as a stabilizer. n-Butyl methacrylate (BMA) monomer dissolving benzoyl peroxide initiator was emulsified in ethanol/water (1/2, w/w) solution of sodium dodecyl sulfate as emulsifier with ultrasonic homogenizer, and the BMA monomer emulsion was mixed with the PS seed emulsion. The PS seed particles absorbed with a large amount of BMA (about 150 times weight of the seed particles) for 2 h to about 10 μm in diameter while keeping good monodispersity and BMA droplets disappeared finally. The seeded polymerization was carried out at 70 °C after a certain amount of water was added to depress the redissolving of BMA from the swollen particles into the medium by raising from room temperature to the polymerzation temperature. Received: 21 February 1996 Accepted: 4 September 1996     

Morphology of micron-sized monodispersed composite polymer particles produced by seeded polymerization for the dispersion of highly monomer-swollen polymer particles

 Monodispersed polystyrene (PS)/poly(n-butyl methacrylate) (PBMA) composite particles having 9.4 μm in diameter were produced by seeded polymerization for the dispersion of highly n-butyl methacrylate (BMA)-swollen PS particles, and their morphologies were examined. The highly BMA-swollen PS particles (about 150 times the weight of the PS seed particles) were prepared by mixing monodispersed 1.8 μm-sized PS seed particles and 0.7 μm sized BMA droplets prepared with an ultrasonic homogenizer in ethanol/water (1/2, w/w) medium at room temperature. After NaNO₂ aqueous solution as inhibitor was added in the dispersion, the seeded polymerization was carried out at 70 °C. In an optical microscopic observation, one or two spherical high contrast regions which consisted mainly of PS were observed inside PS/PBMA composite particles. In the PS domain, there were many fine spherical PBMA domains. Such morphologies were based on the phase separation of PS and PBMA within the homogeneous swollen particles during the seeded polymerization. Received: 04 June 1997 Accepted: 27 August 1997     

Production of micron-sized, monodisperse composite polymer particles having epoxy groups by seeded dispersion polymerization

 Micron-sized, monodisperse polystyrene (PS)/glycidyl methacrylate–divinylbenzene copolymer core/shell composite particles having epoxy groups in the shells were produced by seeded dispersion copolymerization of glycidyl methacrylate and divinylbenzene in an ethanol/water medium with 1.65-μm-sized, monodisperse PS seed particles. By chemical modifications of epoxy groups with sodium hydrogensulfite and dimethylamine, composite polymer particles having sulfonate and dimethylamino groups, respectively, in the shells were prepared. Received: 13 September 2000 Accepted: 31 January 2001     

Production of submicron-sized multihollow polymer particles by alkali/cooling method

Submicron-sized styrene-methacrylic acid copolymer particles, which were produced by emulsion copolymerization, were changed to those having multihollow structure by treating stepwise the emulsion as follows. First alkali treatment was carried out at higher temperature than the glass transition temperature and subsequently the emulsion was cooled by keeping it at room temperature. This was named alkali/cooling method. The effects of methacrylic acid content, pH, time and temperature in the alkali treatment on the formation of multihollow structure were clarified.Part CLV of the series Studies on suspension and emulsion     

Monodisperse porous polymer particles: Formation of the porous structure

Monodisperse porous styrene-divinylbenzene copolymer particles were prepared via seeded emulsion polymerization using a mixture of linear polymer (polystyrene seed) and non-solvent as inert diluent. Experimental evidence was presented to describe the mechanism of formation of porous polymer particles during the copolymerization and solvent extraction stages, in which porosity was a consequence of phase separation in the presence of diluents. Pore structure formation was investigated by changes in copolymerization kinetics, gel content, crosslinking density, particle morphology, surface area, pore volume, and pore size distribution. The process of copolymerization was presented, based on the concepts of production, agglomeration, and fixation of the interior gel microspheres of polymer particles. A portion of linear polymer used as diluent was found to participate in the network structure while the porous matrix was built-up. The influence of the removal of the linear polymer from the matrix pores during the solvent extraction process on the porous structure was also discussed.     

Influences of the locations of monomer and initiator in the seeded polymerization systems on the morphologies of micron-sized monodispersed composite polymer particles

Three kinds of micron-sized monodispersed polystyrene (PS)/poly(n-butyl methacrylate) (PBMA) composite particles (PS/BMA=2/1, wt. ratio) were produced by two kinds of seeded polymerizations ofn-butyl methacrylate (BMA) in the presence of about 2 m-sized monodispersed PS particles, and their morphologies were examined. One was produced by a seeded dispersion polymerization where almost monomers and initiators exist in an ethanol/water (1/1, w/w) medium. The others two were produced by seeded polymerizations utilizing the dynamic swelling method, where almost monomers exist in the PS seed particles, with 2,2-azobisisobutyronitrile initiator in the monomer-swollen particles and with 2,2-azobis [2-(2-imidazolin-2-yl)propane] initiator in an ethanol/water (1/5, w/w) medium. In the former polymerization, the produced composite particles had a core-shell structure consisting of a PS-core and a PBMA-shell, whereas in the latter two polymerizations, they had a POO (Polymeric Oil-in-Oil) structure consisting of a PS-matrix and many PBMA-domains, regardless of the location of initiator in the systems. From these results, it is concluded that the location of BMA monomer in the seeded polymerization systems with micron-sized monodispersed PS seed particles greatly affects the morphologies of produced PS/PBMA composite particles.Part CLI of the series Studies on Suspension and Emulsion     

Micron-sized,monodisperse, snowman/confetti-shaped polymer particles by seeded dispersion polymerization

Snowman/confetti-shaped, micron-sized, monodisperse composite particles were prepared by seeded dispersion polymerizations of n-butyl methacrylate (nBMA) with 1.28 and 2.67 m-sized polystyrene (PS) seed particles, respectively, in an ethanol/water (80/20, w/w) medium. These nonspherical composite particles consisted of one or several poly(nBMA) protuberances on the surfaces of the spherical PS particles.Part CCLXII of the series Studies on Suspension and Emulsion     

Production of micron-sized monodispersed polymer particles by seeded polymerization for the dispersion of highly monomer-swollen particles prepared with submicron-sized polymer seed particles utilizing the dynamic swelling method

For the purpose of extending the size range of polymer seed particles used in “dynamic swelling method” (DSM), first it was verified theoretically that the submicron-sized polymer particles produced by emulsion polymerization can also absorb a large amount of monomer by DSM in both equilibrium and kinetic control states. Next, on the basis of the theoretical results, experimentally about 2.6 μm-sized styrene-swollen polystyrene (PS) particles were prepared utilizing DSM in the presence of 0.64 μm-sized monodispersed PS seed particles produced by emulsifier-free emulsion polymerization. Moreover, 2.5 μm-sized monodispersed PS particles were produced by the addition of cupric chloride as a water-soluble inhibitor to depress the by-production of submicron-sized PS particles in the seeded polymerization at 30°C with 2,2′-azobis(4-methoxy-2,4-dimethylvaleronitrile) initiator. © 1998 John Wiley & Sons, Inc. J. Polym. Sci. A Polym. Chem. 36: 2513–2519, 1998     

Morphologies of micron-sized monodispersed composite polymer particles having crosslinked structures produced by seeded polymerizations

Three kinds of micron-sized monodispersed polystyrene (PS)/ poly(styrene - divinylbenzene) composite particles were produced by two kinds of seeded copolymerizations of styrene (S) and divinylbenzene (DVB) (PS seed/ (S+DVB)=2/1, wt. ratio; S/DVB=1/1, molar ratio) in the presence of about 2 μm-sized monodispersed PS particles, and their morphologies were examined. One was produced by a seeded dispersion copolymerization where almost monomers and initiators exist in an ethanol/water (12.6/4.0, w/w) medium. The others two were produced by seeded copolymerizations with the dynamic swelling method where almost monomers exist in the monomer-swollen particles using 2, 2'-azobisisobutyronitrile in monomer-swollen PS seed particles or using 4, 4'-azobis (4-cyanopentanoic acid) in an ethanol/water (7/43, w/w) medium. In the former polymerization, the produced composite particles had a high dense crosslinked shell, whereas in the latter two polymerizations, they did the comparatively homogeneous crosslinked structures.     

Production of micron-sized monodispersed composite polymer particles by seeded polymerization utilizing the dynamic swelling method

 In order to develop the seeded polymerization technique utilizing the dynamic swelling method (DSM) proposed by authors for the production of micron-sized mono-dispersed “composite” polymer particles consisting of two kinds of polymers, the seeded polymerization for the dispersion of ethyl methacry-late (EMA)-swollen PS particles prepared utilizing DSM was carried out. Monodispersed PS/poly(ethyl methacrylate) (PEMA) composite particles having 7 μm in diameter were produced by the addition of NaCl to lower the solubility of EMA in medium and by the addition of CuCl₂ as a water-soluble inhibitor to depress the by-production of submicron-sized PEMA particles. Received: 16 July 1996 Accepted: 10 October 1996     

Effect of polymer composition on the production of cationic multihollow polymer particles by the stepwise acid/alkali method

The effect of the polymer composition on the formation of multihollow structures formed within submicron-sized styrene–butyl acrylate–dimethylaminoethyl methacrylate terpolymer particles by the “acid/alkali method” proposed by the authors was examined. The cationic particles were produced by seeded emulsion terpolymerization with 2,2′-azobis(2-amidinopropane) hydrochloride initiator. The dimethylaminoethyl methacrylate content and the glass-transition temperature of the terpolymer greatly affected the formation of the multihollow structure. Received: 3 December 1998 Accepted in revised form: 4 February 1999     

Release of toluene from micron-sized, monodispersed, cross-linked, hollow polymer particles

The release behavior of toluene from the hollow-inside, micron-sized, monodispersed, cross-linked, polystyrene/polydivinylbenzene composite particles which had various cross-linking densities and shell thicknesses was examined. The hollow particles were produced by seeded polymerization utilizing the dynamic swelling method which we proposed in 1991. In comparison with that from hollow-free particles, there was a clear difference. The cross-linking density and shell thickness of the hollow composite particles did not affect the release rate in the former period, but did it in the latter one. Received: 2 February 2000/Accepted: 30 August 2000     

Influence of the swelling state of seed polymer particles with monomer on the morphology of micron-sized monodispersed composite polymer particles produced by seeded polymerization utilizing the dynamic swelling method

 Micron-sized mono-dispersed polystyrene (PS)/poly(n-butyl methacrylate) (PBMA) composite particles (PS/PBMA=2/1 by weight) having a heterogeneous structure in which many fine PBMA domains dispersed in a PS matrix near the particle surface were produced by seeded polymerization of n-butyl methacrylate (BMA) of which almost all had been absorbed by 1.8 μm-sized monodispersed PS seed particles utilizing the dynamic swelling method. The morphology was varied by changing the PS/BMA ratio and polymerization temperature. It was concluded that the swelling state of 2 μm-sized BMA-swollen PS particles in the seeded polymerization process is one of the important factors to control the morphology of the composite particles. Received: 27 November 1996 Accepted: 21 March 1997     

Production of submicron-size monodisperse polymer particles having aldehyde groups by seeded aldol condensation polymerization

Submicron-size monodisperse polystyrene/polyglutaraldehyde composite particles having aldehyde groups at the surfaces were produced by seeded aldol condensation polymerization of glutaraldehyde in the presence of polystyrene particles prepared by emulsifier-free emulsion polymerization. This technique is expected to be useful for the production of size-controlled polymer particles having aldehyde groups.Part CXXXVI of the series Studies on Suspension and Emulsion     

The dissolution of ionized water-insoluble carboxylated polymer particles in the nonionic emulsifier solution

It was found that 276 nm-sized styrene-butyl acrylate-methacrylic acid terpolymer (P(S-BA-MAA)) (50.4/40.9/8.7, molar ratio) particles produced by emulsifier-free emulsion polymerization dissolved in a polyoxyethylene nonylphenylether nonionic emulsifier aqueous solution at pH values above 11 and above 25°C resulted in polymer microemulsion. The weight-average diameter of P(S-BA-MAA) microparticles in the solution was 31 nm, which was measured by dynamic light scattering spectroscopy. Such a dissolution of the particles was not observed in the absence of the emulsifier.Part CXLI of the series Studies on Suspension and Emulsion.     

Production of submicron-sized multihollow polymer particles having high transition temperatures by the stepwise alkali/acid method

Submicron-sized multihollow styrene-methacrylic acid (92.6/7.4, molar ratio) copolymer particles having high transition temperature above 100°C were produced by using the stepwise alkali/acid method proposed by the authors. The original particles were prepared by emulsion copolymerization of styrene and methacrylic acid. The effects of pH, temperature and time in the alkali treatment process as the first step on the multihollow structure were clarified under the same acid treatment conditions.Part CLII of the series Studies on Suspension and Emulsion     

Production of multihollow polymer particles by the stepwise alkali/acid method IV. Acid treatment process

The effects of pH, temperature and time in the acid-treatment process on the multihollow structure formed within submicron-sized monodispersed polymer particles by the stepwise alkali/acid method proposed by the authors were examined in detail. The original particles were produced by emulsifier-free emulsion terpolymerization of styrene, butyl acrylate, and methacrylic acid. It was clarified that the number and the size of hollows per particle were drastically changed by the acid treatment conditions as well as those in the alkali treatment process.Part CXLV of the series Studies on Suspension and Emulsion     

Control of hollow size of micron-sized monodispersed polymer particles having a hollow structure

Micron-sized monodispersed cross-linked polymer particles having one hollow in the inside were produced by seeded polymerization for the dispersion of (toluene/divinylbenzene)-swollen PS particles prepared utilizing the dynamic swelling method which the authors proposed. In order to control the hollow size, the weight ratio of toluene/PS was changed in the range of 520. The hollow size increased with an increase in the weight ratio. Even if benzene and xylene were used in place of toluene, similar hollow particles were produced, though the hollow size was affected by their solubility in water.Part CLIII of the series Studies on Suspension and Emulsion