Particle Nucleation in High Solids Miniemulsion Polymerization

The nucleation mechanisms in high solids content semicontinuous miniemulsion polymerization was investigated using as case study a silicone−acrylic system. Batch polymerization of the miniemulsion used as initial charge of the reactor was studied. Semicontinuous processes using both miniemulsion feeding and neat monomer feeding were considered. Strategies to maximize the extent of droplet nucleation and to minimize the formation of polymer particles by homogeneous nucleation were discussed.