On Particle Size Distributions in Catalytic Chain Transfer Emulsion Polymerization: Chain-Extension and the Use of Derived Macromonomers as Reactive Surfactants in Emulsion Polymerization.

Catalytic chain transfer emulsion polymerization (CCTP) and subsequent chain extension via reversible addition-fragmentation chain transfer (RAFT) were used to synthesize amphiphilic macromonomers (MM), in the form of polymer latexes. The macromonomers consisted of two blocks whose first was a random copolymer of methacrylic acid and methyl methacrylate, at 35:65 mol:mol, while the second block was n-butyl methacrylate P[(MAA-co-MMA)-block-PBMA]. The block copolymer colloids were disintegrated and micellized upon addition of ammonia. The resulting nanosized polymer dispersions were used as reactive surfactants in the emulsion polymerization of n-butyl methacrylate. For this, a dual stage slow-fast monomer feed profile was used. The final polymer latexes were in the sub-100 nm range for the particle diameter at 30% w/w total polymer content. The emphasis of the work is to discuss and find an explanation for the observed particle size distributions in the three consecutive emulsion polymerization steps. The particle size distribution of the ω-unsaturated macromonomer latex synthesized by CCTP emulsion polymerization was found to be much broader than expected. This discrepancy is attributed to an extended particle nucleation period. The chain extension step in the macromonomer latex preparation showed considerable secondary nucleation. The presence of water-soluble macromonomer species from the CCTP emulsion polymerization step assured that control of chain growth persisted. The use of the amphiphilic macromonomers as reactive surfactants in the form of a nanosized aggregate seed dispersion showed that the average particle diameter could be tuned and that the molecular weight distributions could be regulated, when monomer starved conditions were used in the emulsion polymerizations.