Exploring the limits of emulsion polymerization of styrene for the synthesis of polymer nanoparticles

Suspensions of polymer nanoparticles in water (latices) with average particle diameters between 20 and 80 nm were synthesized by batch emulsion polymerization of styrene using sodium dodecyl sulphate (SDS) as surfactant and potassium persulphate (KPS) as initiator. The influence of surfactant concentration, initiator concentration, monomer concentration, and reaction temperature on the final average particle diameters and size distributions of the latices were studied. The number of particles generated was proportional to the 0.56 power of the emulsifier concentration and to the 0.37 power of the initiator concentration in the whole concentration range which was observed. Furthermore, the final number of particles was dependant on the reaction temperature to the 2.06 power. With these correlations the average particle number as well as the average particle size could be estimated, and the results were in good agreement (+/- 6%) with the experimental values. A reduction of the monomer/water ratio from 1:5 to 1:20 yielded smaller particle diameters, while leaving the particle number unaffected. The lower particle size limits for monomer ratios of 1:10 and 1:15 were estimated with diameters of about 18 and 16 nm.