Engineering the surface patchiness and topography of polystyrene colloids: From spheres to ellipsoids

HYPOTHESIS

Colloidal surface morphology determines suspension properties and applications. While existing methods are effective at generating specific features on spherical particles, an approach extending this to non-spherical particles is currently missing. Synthesizing un-crosslinked polymer microspheres with controlled chemical patchiness would allow subsequent thermomechanical stretching to translate surface topographical features to ellipsoidal particles.

EXPERIMENTS

A systematic study using seeded emulsion polymerization to create polystyrene (PS) microspheres with controlled surface patches of poly(tert-butyl acrylate) (PtBA) was performed with different polymerization parameters such as concentration of tBA monomer, co-swelling agent, and initiator. Thermomechanical stretching converted seed spheres to microellipsoids. Acid catalyzed hydrolysis (ACH) was performed to remove the patch domains. Roughness was characterized before and after ACH using atomic force microscopy.

FINDINGS

PS spheres with controlled chemical patchiness were synthesized. A balance between two factors, domain coalescence from reduced viscosity and domain growth via monomer absorption, dictates the final PtBA) patch features. ACH mediated removal of patch domains produced either golf ball-like porous particles or multicavity particles, depending on the size of the precursor patches. Patchy microspheres were successfully stretched into microellipsoids while retaining their surface characteristics. Particle roughness is governed by the patch geometry and increases after ACH. Overall, this study provides a facile yet controllable platform for creating colloids with highly adjustable surface patterns.

Preparation of asymmetric particles by controlling the phase separation of seeded emulsion polymerization with ethanol/water mixture

Alcohols are discovered for the first time to tune the morphology of poly(vinyl benzyl chloride)-poly(3-methacryloxypropyltrimethoxysilane) (PVBC-PMPS) composite particles through seeded emulsion polymerization within the alcohol/water mixture. Here, monodispersed linear PVBC particles was synthesized through the dispersion polymerization and employed as the seeds. The as-obtained PVBC-PMPS composite particles could be dramatically tuned from core-shell structures to snowman-like particles, to dumbbell-shaped particles, to inverse snowman-like particles when the ethanol content in reaction mixtures is only adjusted within a narrow range. The morphology of fresh PMPS bulges was observed after removing the linear PVBC seeds with N,N'-dimethyl formamide, and their formation mechanism was studied by monitoring the free radical polymerization and sol-gel process of 3-methacryloxypropyltrimethoxysilane. It has been confirmed that the sol-gel kinetics were the main factor on the particles' morphology. In addition, morphologies of PVBC-PMPS particles were also varied by the MPS feeding amount, types of the co-solvent and pH values of alcohol/water mixtures.

Epoxy-acrylic core-shell particles by seeded emulsion polymerization

We developed a novel method for synthesizing epoxy-acrylic hybrid latexes. We first prepared an aqueous dispersion of high molecular weight solid epoxy prepolymers using a mechanical dispersion process at elevated temperatures, and we subsequently used the epoxy dispersion as a seed in the emulsion polymerization of acrylic monomers comprising methyl methacrylate (MMA) and methacrylic acid (MAA). Advanced analytical techniques, such as scanning transmission X-ray microscopy (STXM) and peak force tapping atomic force microscopy (PFT-AFM), have elucidated a unique core-shell morphology of the epoxy-acrylic hybrid particles. Moreover, the formation of the core-shell morphology in the seeded emulsion polymerization process is primarily attributed to kinetic trapping of the acrylic phase at the exterior of the epoxy particles. By this new method, we are able to design the epoxy and acrylic polymers in two separate steps, and we can potentially synthesize epoxy-acrylic hybrid latexes with a broad range of compositions.