| Miniemulsion polymerization has become increasingly popular among researchers since it can provide significant advantages over conventional emulsion polymerization in certain cases, such as production of high-solids, low-viscosity latexes with better stability and polymerization of highly water-insoluble monomers. Miniemulsions are relatively stable oil (e.g., monomer) droplets, which can range in size from 50 to 500 nm, and are normally dispersed in an aqueous phase with the aid of a surfactant and a costabilizer. These droplets are the primary locus of the initiation of the polymerization reaction. Since particle formation takes place in the monomer droplets, theoretically, in miniemulsion systems the final particle size can be controlled by the initial droplet size. The miniemulsion preparation process typically generates broad droplet size distributions and there is no complete treatment in the literature regarding the control of the mean droplet size or size distribution. This research aims to control the miniemulsion droplet size and its distribution.;In situ emulsification, where the surfactant is synthesized spontaneously at the oil/water interface, has been put forth as a simpler method for the preparation of miniemulsions-like systems. Using the in situ method of preparation, emulsion stability and droplet and particle sizes were monitored and compared with conventional emulsions and miniemulsions. Styrene emulsions prepared by the in situ method do not demonstrate the stability of a comparable miniemulsion. Upon polymerization, the final particle size generated from the in situ emulsion did not differ significantly from the comparable conventional emulsion polymerization; the reaction mechanism for in situ emulsions is more like conventional emulsion polymerization rather than miniemulsion polymerization. Similar results were found when the in situ method was applied to controlled free radical polymerizations (CFRP), which have been advanced as a potential application of the method. Molecular weight control was found to be achieved via diffusion of the CFRP agents through the aqueous phase owing to limited water solubilities.;The effects of adsorption rate and energy on the droplet size and size distribution of miniemulsions using different surfactants (sodium lauryl sulfate (SLS), sodium dodecylbenzene sulfonate (SDBS), Dowfax 2A1, Aerosol OT-75PG, sodium n-octyl sulfate (SOS), and sodium n-hexadecyl sulfate (SHS)) were analyzed. For this purpose, first, the dynamics of surfactant adsorption at an oil/water interface were examined over a range of surfactant concentrations by the drop volume method and then adsorption rates of the different surfactants were determined for the early stages of adsorption. The results do not show a direct relationship between adsorption rate and miniemulsion droplet size and size distribution. Adsorption energies of these surfactants were also calculated by the Langmuir adsorption isotherm equation and no correlation between adsorption energy and miniemulsion droplet size was found.;In order to understand the mechanism of miniemulsification process, the effects of breakage and coalescence processes on droplet size distributions were observed at different surfactant concentrations, monomer ratios, and homogenization conditions. A coalescence and breakup mechanism for miniemulsification is proposed to explain the size distribution of droplets. The multimodal droplet size distribution of ODMA miniemulsions was controlled by the breakage mechanism. The results also showed that, at a surfactant concentration when 100% surface coverage was obtained, the droplet size distribution became unimodal. |
