Incorporation of nonionic emulsifiers inside particles in emulsion polymerization: mechanism and methods of suppression

Data-Driven Prediction of Janus/Core-Shell Morphology in Polymer Particles: A Machine-Learning Approach

The majority of research on Janus particles prepared by solvent evaporation-induced phase separation technique uses models based on interfacial tension or free energy to predict Janus/core-shell morphology. Data-driven predictions, in contrast, utilize multiple samples to identify patterns and outliers. Using machine-learning algorithms and explainable artificial intelligence (XAI) analysis, we developed a model based on a 200-instance data set to predict particle morphology. As model features, simplified molecular input line entry system syntax identifies explanatory variables, including cohesive energy density, molar volume, the Flory-Huggins interaction parameter of polymers, and the solvent solubility parameter. Our most accurate ensemble classifiers predict morphology with an accuracy of 90%. In addition, we employ innovative XAI tools to interpret system behavior, suggesting phase-separated morphology to be most affected by solvent solubility, polymer cohesive energy difference, and blend composition. While polymers with cohesive energy densities above a certain threshold favor the core-shell structure, systems with weak intermolecular interactions favor the Janus structure. The correlation between molar volume and morphology suggests that increasing the size of polymer repeating units favors Janus particles. Additionally, the Janus structure is preferred when the Flory-Huggins interaction parameter exceeds 0.4. XAI analysis introduces feature values that generate the thermodynamically low driving force of phase separation, resulting in kinetically stable morphologies as opposed to thermodynamically stable ones. The Shapley plots of this study also reveal novel methods for creating Janus or core-shell particles based on solvent evaporation-induced phase separation by selecting feature values that strongly favor a given morphology.

Preparation of Monodisperse Bio-Based Polymer Particles via Dispersion Polymerization

Monodisperse bio-based polymer particles were successfully prepared through the dispersion polymerization of tulip-derived α-methylene-γ-butyrolactone (MBL) in N,N-dimethylformamide/ethanol (7/3, w/w) at 65 °C with poly(vinylpyrrolidone) (PVP) as a colloidal stabilizer. The diameter of the polymer particles was well controlled by changing the composition of the reaction medium or PVP concentration. Furthermore, 100% bio-based poly(MBL) (PMBL) particles were prepared via the dispersion polymerization of MBL in water using hydrolyzed PMBL as a colloidal stabilizer, which was synthesized by hydrolysis of PMBL.

Surfactant-free emulsion polymerization of vinylidene fluoride mediated by RAFT/MADIX reactive poly(ethylene glycol) polymer chains

Vinylidene fluoride (VDF) emulsion polymerization is conducted in the presence of xanthate-end functionalized poly(ethylene glycol)s leading to stable PVDF latexes.

Incorporation Behavior of Nonionic Emulsifiers inside Particles and Secondary Particle Nucleation during Emulsion Polymerization of Styrene

In previous studies, it was found that a large amount of the polyoxyethylene nonylphenyl ether nonionic emulsifier, Emulgen 911 (E911), was incorporated inside polymer particles obtained at the completion of a conventional emulsion polymerization with potassium persulfate as a typical water-soluble initiator. In this study, to understand the incorporation phenomenon in more detail, the incorporation behavior during a batch emulsion polymerization of styrene was investigated. The percentage of E911 incorporated inside polystyrene (PS) particles relative to the total weight of E911 used in the polymerization increased to 18% until 50% conversion and then decreased and levelled off to 13% at 70-80% conversion. A similar incorporation behavior was observed in a seeded emulsion polymerization of styrene, in which E911 was added to an emulsifier-free PS seed emulsion to set the same E911 concentration as the batch emulsion polymerization before swelling of the PS seed particles with styrene at 70 °C for 24 h. These indicate that E911 molecules absorbed once into styrene-swollen PS particles partially exited therefrom into the aqueous medium during the polymerizations. When the E911 concentration in the aqueous medium is kept above the critical micelle concentration for a long period by the repartitioning process of E911 from styrene droplets into styrene-swollen particles via aqueous medium and/or exiting from the styrene-swollen particles into the aqueous medium, secondary particle nucleation continues during the polymerization, resulting in PS particles having a broad size distribution.

Role of Osmotic Pressure for the Formation of Sub-micrometer-Sized, Hollow Polystyrene Particles by Heat Treatment in Aqueous Dispersed Systems †

In a previous article, it was reported that a rather amount of sulfate end-groups as initiator fragment were buried in the inside of polystyrene (PS) particles, which were synthesized by emulsion polymerization with potassium persulfate initiator and nonionic emulsifier and operated to absorb water from the aqueous medium, resulting in hollow particles, when the PS emulsion was treated at higher temperature than the glass transition temperature of PS. In this article, it was clarified that the water absorption is based on the osmotic pressure between the outside (aqueous medium) and inside of the PS particles due to the buried sulfate end-groups.

Shedding light on the different behavior of ionic and nonionic surfactants in emulsion polymerization: from atomistic simulations to experimental observations

Although surfactants are known to play a vital role in polymerization reactions carried out in dispersed media, many aspects of their use are poorly understood, perhaps none more so than the vastly different action of ionic and nonionic surfactants in emulsion polymerization. In this work, we combine experimental measurements of emulsion polymerization of styrene with atomistic molecular dynamics simulations to better understand the behavior of surfactants at monomer/polymer-water interfaces. In a batch emulsion polymerization of styrene, the nonionic surfactant Disponil AFX 1080 leads to two nucleation periods, in contrast to the behavior observed for the ionic surfactant SDS. This can be explained by the absorption of the nonionic surfactant into the organic phase at the early stages of the polymerization reaction which is then released as the reaction progresses. Indeed, we find that the partition coefficient of the surfactant between the organic phase and water increases with the amount of monomer in the former, and preferential partitioning is detected to organic phases containing at least 55% styrene. Results from molecular dynamics simulations confirm that spontaneous dissolution of the non-ionic surfactant into a styrene-rich organic phase occurs above a critical concentration of the surfactant adsorbed at the interface. Above this critical concentration, a linear correlation between the amount of surfactant adsorbed at the interface and that absorbed inside the organic phase is observed. To facilitate this absorption into a completely hydrophobic medium, water molecules accompany the intruding surfactants. Similar simulations but with the ionic surfactant instead did not result in any absorption of the surfactant into a neat styrene phase, likely because of its strongly hydrophilic head group. The unusual partitioning behavior of nonionic surfactants explains a number of observable features of emulsion polymerization reactions which use nonionic surfactants and should help with future development of processes for improved control over polymerization.

Water Absorption Behavior of Polystyrene Particles Prepared by Emulsion Polymerization with Nonionic Emulsifiers and Innovative Easy Synthesis of Hollow Particles

Submicrometer-sized raspberry-like polystyrene (PS) particles, which were prepared by emulsion polymerization with polyoxyethylene nonylphenyl ether nonionic emulsifier (Emulgen 910, HLB 12.2) and potassium persulfate initiator, contained 8.5 vol % (relative to the particle) of water and 5.5 wt % (relative to PS) of Emulgen 910 in the inside. The water absorption decreased the glass transition temperature of the PS particles dispersed in an aqueous medium. The wt % (relative to PS) of the incorporated Emulgen 910 increased with increasing initial Emulgen 910 concentration in the emulsion polymerization, but the wt % (relative to the total Emulgen 910 used) of the incorporated Emulgen 910 was constant at approximately 50% independent of the initial concentration. The vol % (relative to particle) of water increased to 46% by heat treatment at 90 °C for 24 h, which was based on further water absorption, and resulted in spherical hollow particles, where the amount of the incorporated Emulgen 910 remarkably decreased in a short treatment and then remained almost constant during the heat treatment. After another 24 h treatment, the percentage of nonhollow particles increased gradually, which was based on the escape of the water domain together with Emulgen 910 from the inside of the particles. On the other hand, spherical PS particles prepared by emulsifier-free emulsion polymerization did not contain water in the inside and were not changed to hollow ones by a similar heat treatment. From these results, an innovative easy method to synthesize hydrophobic hollow PS particles is proposed.

Hollow particles are produced by the burying of sulfate end-groups inside particles prepared by emulsion polymerization of styrene with potassium persulfate as initiator in the absence/presence of a nonionic emulsifier

We resolved the longtime enigma in emulsion polymerization of styrene with K₂S₂O₈ by showing the fact that hollow polystyrene particles were successfully prepared by heat treatment in the emulsion state.

Synthesis of multi-hollow clay-armored latexes by surfactant-free emulsion polymerization of styrene mediated by poly(ethylene oxide)-based macroRAFT/Laponite complexes

We report the RAFT-mediated synthesis of Laponite-armored latexes by surfactant-free emulsion polymerization.

Incorporation of nonionic emulsifier inside carboxylated polymer particles during emulsion copolymerization: influence of methacrylic acid content

The influence of the methacrylic acid (MAA) content (0-10 mol %) on the incorporation of polyoxyethylene nonylphenyl ether (Emulgen 911, HLB 13.7) nonionic emulsifier inside polymer particles during emulsion copolymerization of styrene (S) and MAA was investigated. The amount of incorporated emulsifier after centrifugal washing with 2-propanol to remove adsorbed emulsifier from the surfaces was directly measured by gel permeation chromatography (GPC) and (1)H NMR. The level of incorporation increased with increasing MAA content and reached 74% of the total amount of emulsifier at 10 mol % MAA. At lower MAA contents (0-3 mol %), the particle size distribution was bimodal because of formation of new particles by secondary nucleation. However, only limited secondary nucleation occurred at higher MAA contents (6-10 mol %), and monodisperse particles were thus obtained.

Incorporation of disodium alkyl polyoxyethylene ether sulfosuccinate inside styrene droplets: mechanism and its application for preparation of multihollow polymer spheres

Emulsion polymerization of styrene was carried out using two kinds of alkyl polyoxyethylene ether sulfosuccinates as surfactant: disodium cetyl polyoxyethylene (25) ether sulfosuccinate (CPS) and octyl-phenol polyoxyethylene (10) ether sulfosuccinate (OPS). In experiments, the incorporation of CPS or OPS inside styrene droplets and polystyrene particles was clearly observed. Based on this phenomenon, multihollow polymer spheres are prepared in a one-step reaction and this strongly supports the proposed incorporation mechanism. CPS is more effective than OPS during the preparation of multiporous spheres. This difference between the two surfactants mainly contributes to the difference of the length of the EO (polyoxyethylene) group, which can determine the affinity among surfactant, styrene, and water molecules.

Formation of "snowmanlike" polystyrene/poly(methyl methacrylate)/toluene droplets dispersed in an aqueous solution of a nonionic surfactant at thermodynamic equilibrium

"Snowmanlike" polystyrene (PS)/poly(methyl methacrylate) (PMMA) composite particles were prepared by evaporation of toluene from PS/PMMA/toluene droplets dispersed in an aqueous solution of polyoxyethylene nonylphenyl ether surfactant (Emulgen 911). Partitioning experiments revealed that the Emulgen 911 concentration was higher in the droplets than in the aqueous solution during toluene evaporation. As a consequence, the interfacial tensions between the polymer phases (PS and PMMA) and the aqueous phase (gammaP-T/W) were extraordinarily low (approximately 10(-1) mN/m). The interfacial tension between the PS and PMMA phases containing toluene (gammaPS-T/PMMA-T) measured by the spinning drop method was not affected by the presence of Emulgen 911. Based on minimization of the total interfacial free energy at a polymer weight fraction in the toluene droplet of 0.17, the formation of spherical droplets is expected, in agreement with experiment. The subsequent morphology change of the PS/PMMA/toluene droplets from spherical to snowmanlike during toluene evaporation under thermodynamic equilibrium is attributed to (i) the low values of gammaP-T/W, which explains the increase in the interfacial area between the droplets and the aqueous phase, and (ii) the increase in gammaPS-T/PMMA-T with increasing polymer weight fraction.

Preparation of multihollow polymer particles by seeded emulsion polymerization using seed particles with incorporated nonionic emulsifier

Emulsion polymerizations of styrene using poly(oxyethylene) nonylphenyl ether nonionic emulsifier were carried out at different emulsifier and initiator (potassium persulfate, KPS) concentrations to prepare polystyrene (PS) seed particles with incorporated nonionic emulsifier. Seeded emulsion polymerizations of styrene using the PS seed particles with different amounts of incorporated emulsifier were carried out to develop a novel method for the preparation of multihollow particles. When seed particles with a small amount of incorporated emulsifier were used, non-hollow spherical particles were prepared. However, multihollow particles were obtained in the case of seed particles with a large amount of incorporated emulsifier. Moreover, the higher the initiator concentration in the preparation of seed particles, the more effectively were hollow particles prepared. On the basis of the above results, a mechanism for the formation of multihollow structure was suggested.

Effect of stabilizer on formation of "onionlike" multilayered polystyrene-block-poly(methyl methacrylate) particles

The effect of the kind of stabilizers on the formation of "onionlike" multilayered polystyrene-block-poly(methyl methacrylate) (PS-b-PMMA) particles was studied. The release of toluene from PS-b-PMMA/toluene droplets dispersed in aqueous medium resulted in the formation of onionlike multilayered structures in the particles for all stabilizers used. However, the surface composition of the particles was strongly affected by the kind of stabilizer. When sodium dodecyl sulfate (SDS) and poly(vinyl alcohol) (PVA) were used as stabilizers, the surface of the particles was occupied by PMMA phase. On the other hand, in the cases of Emulgen 911 (polyoxyethylene nonylphenyl ether) and Tween 80 (polyoxyethylene sorbitan monooleate) as stabilizers, the PS phase occupied the surfaces. These results for SDS, PVA, and Emulgen 911 are consistent with the surface layer of the PS-b-PMMA particles being occupied by the polymer phase, which gives a lower interfacial tension than that of another phase. However, in the case of Tween 80, interfacial tensions between water and toluene solutions of the polymer showed almost the same values making it impossible to predict the surface polymer phase.

Revisiting the morphology development of solvent-swollen composite polymer particles at thermodynamic equilibrium

Morphology of polystyrene (PS)/poly(methyl methacrylate) (PMMA)/toluene droplets, in which phase separation proceeds, dispersed in SDS aqueous solution was examined. It changed from ex-centered PS-core/PMMA-shell to hemisphere with increasing SDS concentration. At low polymer weight fraction (wp), PS and PMMA phases contained non-negligible amount of PMMA and PS, respectively. The small amount of PS and PMMA in PMMA and PS phases, respectively, affected significantly the interfacial tension between polymer/toluene and aqueous solutions. Interfacial tension between PS and PMMA phases at low wp was measured by the spinning drop method, showing a quite low value ( approximately 10-2 mN/m). Predicted morphology obtained from calculation of minimum total interfacial free energy of the droplets using the interfacial tensions agreed well with the experimental observation.