Preparation and characterization of poly(styrene-co-butyl acrylate)-encapsulated single-walled carbon nanotubes under ultrasonic irradiation

Polymeric composite materials filled with single-walled carbon nanotubes (SWNTs) have attracted much attention, but successful applications of such composites require uniform dispersion of SWNTs in the polymeric matrix and the strong SWNTs-polymer interface interaction. In this paper, chemical modification combined with ultrasonically initiated in situ polymerization was successfully employed to prepare poly(styrene-co-butyl acrylate)/single-walled carbon nanotubes composites [P(St-BA)/SWNTs]. The whole procedure contained two steps: in the first step, 3-(trimethoxy)-propylmethacrylate-silane (silane-coupling agent, KH570), a kind of polymerizable vinyl monomer, was grafted onto the surface of SWNTs, forming KH570-g-SWNTs by reacting KH570 with hydroxyl groups on the surface of SWNTs, which was proved by combination of FTIR and XPS results. Due to the presence of polymerizable KH570 on the surface of SWNTs, this provides a basis for the next stage of polymerization to prepare polymer-encapsulated SWNTs composites. In the second step, an ultrasonically initiated in situ emulsion polymerization of monomer styrene (St) and n-butyl acrylate (BA) proceeded in the presence of KH570-g-SWNTs. Consequently, P(St-BA)/SWNTs composite emulsion was obtained. TEM confirmed that SWNTs were coated with the obtained polymer. FTIR and XPS further showed that even after 72 h of soxhlet extraction with boiling toluene, there were still unextracted polymers in P(St-BA)/SWNTs composite, indicating strong interaction between the polymer and carbon nanotubes. Finally, a mechanism for formation of polymer-encapsulated SWNTs through ultrasonically initiated in situ emulsion polymerization was proposed. This study could provide a new way to resolve the problems of the dispersion, stabilization, and compositing of SWNTs with polymer matrix and prepare polymer/SWNTs composites.