Modelling secondary particle formation in emulsion polymerisation: application to making core-shell morphologies

A simple model for particle formation in surfactant-free emulsion polymerisation [Macromol. Symp. 92 (1995) 13; Emulsion polymerization: a mechanistic approach, 1995], with extension to allow for induced decomposition of initiator, is explored. The object is to find conditions for secondary particle formation, especially to find conditions under which it would be possible to grow core-shell particles of vinyl acetate in styrene, and vice versa; core -shell particle formation requires that secondary particle formation be avoided. The system is described by homogeneous nucleation: a radical generated in the aqueous phase will either enter a latex particle, undergo termination, or grow in the aqueous phase until it becomes the nucleus of a new particle. The simplified kinetic description contains only easily specified parameter values and requires minimal computational resources. The model implies that secondary particle formation is suppressed by decreasing seed radius, by increasing solids content, and by starved-feed conditions; seed radius is by far the most influential, while monomer-catalysed initiator decomposition has negligible effect. The model predicts that new particle formation will be rampant when vinyl acetate is polymerised in the presence of large polystyrene particles (implying that large core-shell polystyrene/poly(vinyl acetate) (PS/PVAc) particles cannot be obtained in this way), but that there should be relatively little secondary particle formation when styrene is polymerised in the presence of large PVAc particles (implying that large core-shell PS/PVAc particles can be created by inverse core-shell polymerisation). The model was also used to estimate the particle numbers expected in ab initio, surfactant-free styrene and vinyl acetate systems. The model explains why such styrene systems give large, monodisperse particles, whereas such vinyl acetate systems give much smaller particles. Comparison of predictions of the model with those of more sophisticated treatments suggests that model contains the kinetic events which are most essential in determining the rate of particle formation, and thus is sufficient for stating whether or not massive secondary nucleation will occur. (C) 2002 Elsevier Science Ltd. All rights reserved.