Synthesis of monodisperse, large scale and high solid content latexes of poly(n-butyl acrylate) by a one-step batch emulsion polymerization

Seeded emulsion polymerization and agglomerating method were well-known techniques for the production of polymeric latexes with large particle size and high solid content. Obtaining latexes with monodisperse and particle size above 300 nm scale, however, was time-consuming and difficult by means of these methods. Here, stable, monodisperse latexes with the controlled particle diameter (55–650 nm) and high solid content (60 wt%) were synthesized via one-step in batch emulsion polymerization. Experimental investigations show that the particle size increased with decreasing emulsifier concentrations and increasing monomer/water ratios or electrolyte concentrations. The latex particle coagulation was considered as the dominant particle formation and growth method, which could be proved by the evolutions of particle number as well as dimension against conversion. Latex particle coagulation occurred if the particle surface covered ratio dropped between the critical surface covered ratio (θcrit = 0.59) and the lowermost surface covered ratio (θlow = 0.38). In addition,θcrit and θlow were increased with electrolyte concentrations.