Seeded dispersion polymerization of MMA using submicron PMMA particles as seed: a mechanistic study

Micron-size poly(methyl methacrylate) (PMMA) particles having a narrow particle size distribution were prepared by seeded dispersion polymerization of methyl methacrylate (MMA) using submicron PMMA particles as seed. The processes of particle aggregation and nucleation were controlled by the initial seed size, initial seed number, and initiator concentration, determining the formation of the mature particles and the number (N ((final))) and size of the final particles. It was found that N ((final)) was equal to the number of particles produced in the absence of seed (N ((ab initio))) when the initial number of seed particles (N ((initial))) was less than N ((ab initio)). When N ((initial)) was greater than N ((ab initio)), N ((final)) was equal to k x N ((initial)), where the value of k was a function of seed size and initiator concentration. k increased with seed size and was less than 1 at high initiator concentrations (0.52 and 1.00 %), while at low initiator concentrations (0.23 and 0.30 %), a maximum value of k was found for a 198 nm seed size. k could be greater than unity in some cases.