High solids content film‐forming polystyrene‐co‐(n‐butyl acrylate)] poly(Sty‐co‐BuA)] latexes armored with Laponite clay platelets have been synthesized by soap‐free emulsion copolymerization of styrene and n‐butyl acrylate. The polymerizations were performed in batch in the presence of Laponite and a methyl ether acrylate‐terminated poly(ethylene glycol) macromonomer in order to promote polymer/clay association. The overall polymerization kinetics showed a pronounced effect of clay on nucleation and stabilization of the latex particles. Cryo‐transmission electron microscopy observation confirmed the armored morphology and indicated that the majority of Laponite platelets were located at the particle surface. The resulting nanostructured films displayed enhanced mechanical properties.
