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Particle Nucleation and Growth in the Emulsion Polymerization of Styrene: Effect of Monomer/Water Ratio and Electrolyte Concentration

This work is an extension of previous research results reported by our team (Colloid and Polymer Science 2013, 291: 2385-2398), where large scale and high solid content latexes of poly(n-butyl acrylate) were obtained with the particle coagulation method induced by the electrolyte. However, how to prepare controlled particle size distribution polymer latex has not been studied. Thus, in this study, the effect of the monomer/water ratios and electrolyte concentrations on particle formation and growth methods were studied by following the tracks of the evolutions of particle size, number and distribution as a function of reaction time or conversion. Experimental results showed that the length of time that particle nucleation occurred increased with increasing monomer charged for the systems without electrolyte. A point worthy of attention here is that homogeneous nucleation may occur at high monomer concentrations (30/70, 40/60). However, electrolyte added could be made the nucleation mechanism shift from micellar/homogeneous nucleation to micelle /coagulation nucleation. As a result, the final particle size distribution can be controlled by adding an appropriate electrolyte to regulate the nucleation mechanism. Spherical and uniformly sized particles could be obtained when electrolyte concentration is between 0.2 wt% and 0.4 wt% for water at the high monomer/water ratio (40/60). The effects of electrolyte concentration on nucleation mechanism mainly were expressed by decreasing the solubility of the monomer and interparticle potential, and then preventing homogeneous nucleation and enhancing particle coagulation.