Initiator Systems Effect on Particle Coagulation and Particle Size Distribution in One-Step Emulsion Polymerization of Styrene

Particle coagulation is a facile approach to produce large-scale polymer latex particles. This approach has been widely used in academic and industrial research owing to its higher polymerization rate and one-step polymerization process. Our work was motivated to control the extent (or time) of particle coagulation. Depending on reaction parameters, particle coagulation is also able to produce narrowly dispersed latex particles. In this study, a series of experiments were performed to investigate the role of the initiator system in determining particle coagulation and particle size distribution. Under the optimal initiation conditions, such as cationic initiator systems or higher reaction temperature, the time of particle coagulation would be advanced to particle nucleation period, leading to the narrowly dispersed polymer latex particles. By using a combination of the Smoluchowski equation and the electrostatic stability theory, the relationship between the particle size distribution and particle coagulation was established: the earlier the particle coagulation, the narrower the particle size distribution, while the larger the extent of particle coagulation, the larger the average particle size. Combined with the results of previous studies, a systematic method controlling the particle size distribution in the presence of particle coagulation was developed.