Preparation of micron-sized, monodispersed, anomalous polymer particles by utilizing the solvent-absorbing/releasing method

 About 2-μm-sized polystyrene (PS) particles having uneven surfaces were prepared by a posttreatment in which toluene-swollen PS particles were thrown into a methanol bath to release toluene therefrom rapidly. The posttreatment was named the “solvent-absorbing/releasing method”. The PS particle had large dents at the surface. The size of the dents was changed by the conditions of the posttreatment. Received: 3 August 1999/Accepted: 1 March 2000     

Preparation of micron-sized, monodispersed, “onion-like” multilayered poly(methyl methacrylate)/polysterene composite particles by reconstruction of morphology with the solvent-absorbing /releasing method

Micron-sized, monodispersed, “onion-like” multilayered poly(methyl methacrylate) (PMMA)/polystyrene (PS) (1/1, w/w) composite particles were prepared by the solvent-absorbing/releasing method (SARM). The viscosity within toluene-swollen composite particles, the release rate of toluene therefrom, the PMMA/PS ratio, and the kind of solvent had great influences on the reconstruction of the morphology of the PMMA/PS composite particles by the SARM. From these results, the conditions for the preparation of the multilayered composite particles by the SARM are clarified. Received: 28 September 2000 Accepted: 27 October 2000     

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     

Influence of particle diameter on the morphology of micron-sized, monodispersed composite polymer particles produced by seeded polymerization for the dispersion of highly monomer-swollen polymer particles

 Micron-sized, monodispersed polystyrene (PS)/poly (n-butyl methacrylate) (PBMA) composite particles, in which the PS domain(s) were dispersed in a PBMA continuous phase, were produced by seeded polymerization for dispersions of n-butyl methacrylate (BMA) swollen PS particles in a wide range of PS/BMA ratios in the presence of NaNO₂ as a water-soluble inhibitor. Moreover, in order to change the diameter of the composite particles at same PS/BMA ratio, PS/PBMA (1/150 w/w) composite particles were produced using five kinds of PS particles in a range of diameters from 0.64 to 3.27 μm as seeds. The percentages of the PS/PBMA composite particles having double and triple and over PS domains, which were thermodynamically unstable morphologies, increased with the increase in the diameter of BMA swollen PS particles. There was a clear influence of the size of the swollen particles on the morphology of the PS/PBMA composite particles produced. Received: 30 September 1999/Accepted: 18 April 2000     

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     

Effect of graft polymer on the formation of micron-sized,monodisperse, "onion-like" alternately multilayered poly(methyl methacrylate)/polystyrene composite particles by reconstruction of morphology with the solvent-absorbing/releasing method

Some factors contributing to the formation of an alternately multilayered structure of micron-sized, monodisperse poly(methyl methacrylate) (PMMA)/polystyrene (PS) (1/1, w/w) composite particles by reconstruction of the morphology with the solvent-absorbing/releasing method (SARM) were discussed. The original composite particles, which were produced by seeded dispersion polymerization (SDP) of styrene, had a core–shell structure. When PS/PMMA (1/1, w/w) composite particles produced by SDP of methyl methacrylate were treated by the SARM with toluene, the reconstructed morphology of the composite particles was not the multilayered structure but a hemisphere (or core–shell). The PS/PMMA composite particle contained less than 10 wt% PMMA- g-PS. On the other hand, the PMMA/PS composite particles contained about 40 wt% graft polymer. The graft polymer would exist at the interfaces of the alternate multilayers and decrease their interfacial energy. This was the main reason why the alternately multilayered structure was constructed by the SARM, though the total interfacial area between PMMA and PS layers in the multilayered particle is much larger than that of the hemisphere (or core–shell).     

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.     

Production of micron-sized, monodisperse, transformable rugby-ball-like-shaped polymer particles

Micron-sized, monodisperse, “rugby-ball-like” polymer particles were produced by seeded polymerization for the dispersion of (divinylbenzene/vinylbiphenyl/xylene)-swollen polystyrene particles prepared by utilizing the dynamic swelling method which the authors proposed in 1991. The shape of the composite polymer particle was reversibly transformed between a rugby-ball-like shape and a spherical one by absorbing/releasing toluene. Received: 24 January 2001/Accepted: 18 April 2001     

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     

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     

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     

Influence of viscosity within polymerizing particle on the morphology of micron-sized,monodisperse composite polymer particles produced by seeded polymerization for the dispersion of highly monomer-swollen polymer particles

Micron-sized, monodisperse polystyrene (PS)/poly( n-butyl methacrylate) (PBMA) composite particles, in which PS domain(s) were dispersed in a PBMA continuous phase, were produced by seeded polymerization for the dispersion of highly n-butyl methacrylate (BMA)-swollen PS particles (PS/BMA=1/150, w/w) using various concentrations of benzoyl peroxide as initiator in the absence/presence of sodium nitrite (NaNO ₂) as a water-soluble inhibitor. The percentages of the composite particles having double, triple and over PS domains, which were thermodynamically unstable morphologies, increased with a rapid increase of viscosity within the polymerizing particle.     

A novel method for encapsulation of a liquid crystal in monodisperse micron-sized polymer particles

Liquid crystals (LCs) encapsulated in monodisperse micron-sized polymer particles were prepared to control the size and size distribution of LC droplets in polymer-dispersed LCs. The poly(methyl methacrylate) (PMMA) seed particles were swollen with the mixture of liquid crystal, monomers (methyl methacrylate and styrene) and initiator by using a diffusion-controlled swelling method. A single LC domain was produced by the phase separation between PMMA and LC through polymerization. The optical microscopy and scanning electron microscopy showed that the particles are highly monodisperse with core–shell structure. Moreover, monodisperse LC core domains were confirmed from polarized optical microscope observations. The final particle morphology was influenced by the cross-linking of the seed particle. When linear PMMA particles, which are not cross-linked, were used as a seed, the microcapsules were distorted after annealing for a few days; however, in the case of cross-linked PMMA particles, the core–shell structure was sustained stably after annealing. Received: 22 November 2000 Accepted: 12 March 2001     

Synthesis of temperature-sensitive micron-sized monodispersed composite polymer particles and its application as a carrier for biomolecules

 Temperature-sensitive micron-sized monodispersed composite polymer particles were prepared by seeded copolymerization of dimethylaminoethyl methacrylate and ethylene glycol dimethacrylate with 1.77 μm-sized monodispersed polystyrene seed particles. The change in surface property at temperature above and below 35 °C was examined by differential scanning calorimetry, trypsin activity and the adsorption/ desorption behaviors of low molecular weight cationic emulsifier as well as biomolecules. Received: 6 August 1997 Accepted: 16 January 1998     

Estimation of surface morphology of composite polymer particles prepared by the stepwise heterocoagulation method with ζ-potential measurement

 Core-shell composite polymer particle was prepared by the stepwise heterocoagulation of cationic small polymer particles (SPs) onto an anionic large polymer particle (LP), following heat treatment at temperatures which were higher than glass transition temperature (T _g=18 °C) of SP. At pH 9 ζ-potential of the hetero-coagulated particle (HP) was negative, but it changed to positive by the heat treatment and increased with the treatment time and finally attained to that of SP. The treatment time to attain the ζ-potential of SP became short by elevating the treatment temperature. This indicates that during the heat treatment, SP continued to melt on the surface of LP and finally formed a continuous shell. Received: 3 September 1997 Accepted: 29 October 1997     

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     

Preparation and thermodynamic stability of micron-sized, monodisperse composite polymer particles of disc-like shapes by seeded dispersion polymerization

Micron-sized, monodisperse composite polymer particles having "disc-like" and "polyhedral" shapes were prepared by seeded dispersion polymerization of 2-ethylhexylmethacrylate (EHMA) with 2.67-mum-sized polystyrene (PS) seed particles in methanol/water media in the presence of droplets of various saturated hydrocarbons and evaporation of the hydrocarbon after the polymerization. Such nonspherical shapes were based on the volume reduction due to the evaporation. The primary factors influencing the particle shape seemed to be the absorption rate of the hydrocarbon into the resulting PS/poly(EHMA)/hydrocarbon composite particles during the polymerization, which affected the viscosities and the volumes of the PS and poly(EHMA) phases. It was found that the morphological development during the polymerization was retarded at "hamburger-like" morphology, which is a precursor of the disc-like particle, although this morphology is a thermodynamically metastable state.     

Agitation requirement for synthesis of micron-sized monodisperse polymer particles in soap-free polymerization method

Single-stage polymerization recently proposed for producing micron-sized polymer particles in aqueous media by Gu, Inukai and Konno (2002) was carried out under the control of agitation with styrene monomer, an amphoteric initiator, 2,2′-azobis [N-(2-carboxyethyl)-2-methylpropionamidine] tetrahydrate and a pH buffer NH₃/NH₄Cl at a monomer concentration of 1.1 kmol/m³ H₂O, an initiator concentration of 10 mol/m³ H₂O and a buffer concentration of [NH₃] = [NH₄Cl] = 10 mol/m³ H₂O. In the polymerizations, impeller speed was ranged from 300 to 500 rpm to satisfy complete dispersion of the monomer phase and not to introduce the gas phase from the free surface. Polymerization experiments under steady agitation indicated that impeller speed was an important factor for size distribution of polymer particles. An increase in impeller speed promoted particle coagulation during the polymerization to enlarge the average size of polymer particles but widen the size distribution. To produce polymer particles with narrow size distribution, stepwise reduction in impeller speed was examined in the polymerization experiments. It was demonstrated that this method was more effective than the steady agitation. The impeller speed reduction could produce highly monodisperse particles with an average size of 2 μm and a coefficient of variation of size distributions of 2.2% that was much smaller than typical monodispersity criterion of 10%.     

Preparation of polystyrene/poly(methyl methacrylate) composite particles having a dent

Nonspherical polystyrene (PS)/poly(methyl methacrylate) (PMMA) composite particles having a dent were prepared by releasing toluene from PS/PMMA/toluene droplets dispersed in a poly(vinyl alcohol) aqueous medium. An ex-centered PS-core/PMMA-shell morphology, in which a part of the PS core contacted with the aqueous medium and toluene partitioned more in the PS core than in the PMMA shell, was formed in the polymers/toluene droplet in the process of phase separation therein with releasing toluene. The volume of the dent became bigger with an increase in the PS content and in the toluene content partitioned in the PS core.Part CCLXI 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