Synthesis and characterization of polystyrene-encapsulated laponite composites via miniemulsion polymerization

A novel polystyrene-encapsulated laponite composite system has been developed via a miniemulsion polymerization approach. The encapsulation mechanism and process parameters have been examined in detail using light-scattering, sedimentation analysis, wide-angle-X-ray diffraction (WXRD), and transmission electron microscopy (TEM). The laponite was encapsulated through a miniemulsion polymerization process in which laponite was predispersed in the monomer phase. The stability of both the miniemulsion and the latex depends on initiation loci, premixing procedures, intensity and time of ultrasonification and the surfactants and co-stabilizer used. Hydrophobicity of the laponite clay played a vital role in both the encapsulation of the clay and the stability of the latex. A quaternary ammonium salt, cetyltrimethylammonium bromide (CTAB), was mixed with the clay in the monomer phase prior to emulsification. As a result, the clay particles were hydrophobically modified and were intercalated. The hydrophobicity not only favored the clay dispersions in the oil droplets but also aided the entry of the monomer into the clay's intergalleries during polymerization. Meanwhile, CTAB helped stabilize the system when it was used in conjunction with the nonionic surfactant polyoxyethylene (40) isooctylphenyl ether (TX-405). In this way, the saponite is effectively encapsulated within a polystyrene shell in a stable latex form. More importantly, the polymerization initiated in the intergalleries of the clay effectively expands the clay's platelet array to form an exfoliated structure.