Effects of stirring prior to starting emulsion polymerization of styrene with nonionic emulsifier on particle formation and its incorporation

Emulsion polymerization of styrene with a nonionic emulsifier (polyoxyethylene nonylphenyl ether, E911) and potassium persulfate as initiator was carried out at different stirring rates (240–500 rpm) at 70 °C, which was started by the addition of initiator after stirring for 100 min at 70 °C. Resulting polystyrene (PS) particles at 240 rpm were 70-nm-sized, spherical particles and incorporated only 5 wt.% of total E911. On the other hand, particles at 500 rpm were 1-μm-sized, nonspherical particles, which were formed by coagulation of small particles, and incorporated above 70 wt.% of E911 in the inside. Before starting emulsion polymerization, E911 and styrene, respectively, transferred from an aqueous phase to a styrene phase and from the styrene phase to the aqueous phase (water and micelles) faster at 500 rpm than 240 rpm. At 240 rpm, there were a lot of almost empty micelles (ca. 5 nm) in the aqueous phase, on the other hand at 500 rpm, 70 wt.% of total E911 transferred to the styrene phase and the micelles were swollen with much monomer (ca. 40 nm) even if the number was smaller. Stirring prior to starting the emulsion polymerization greatly affected partitionings of monomer to the aqueous phase and the nonionic emulsifier to the styrene phase, resulting in the differences in the particle formation and the incorporation of the nonionic emulsifier inside PS particles.