Dual-seeded dispersion polymerization: Effect of different polymerization conditions on the shape of the produced particles

Abstract

Dual-seeded dispersion polymerization (DSDP) of 2-ethylhexyl methacrylate with polystyrene (PS) and poly(methyl methacrylate) (PMMA) seed beads in the presence of saturated hydrocarbon droplets followed by evaporation of the hydrocarbon was studied. The effect of various polymerization conditions including initiator type and content, stabilizer type and concentration, and different hydrocarbon’s content on the shape of the obtained particles was investigated. The increase of concentration of 2,2'-azobis(isobutyronitrile) (AIBN) had no effect on the shape of the produced almond-shell-like PS particles, although it contributes in the formation of associated composite particles along with larger poly(2-ethylhexyl methacrylate) (PEHMA) beads produced by secondary nucleation. The experimental results showed that other initiators led to the formation of stable golf-ball-like PMMA particles as well as PS ones with symmetric shape. The type of stabilizer did not affect the shape of the particles. This observation suggests that unique almond-shelllike PS particles can be produced through a stabilizer-free DSDP process. The lowering of the concentration of hydrocarbons with long alkyl chains yielded stable disc-like PMMA particles. The formation of functional almond-shell-like particles by using light hydrocarbons was another interesting finding of this research.