Pure Chemical Id., Ltd, Tokyo) as an initiator were used. Pure Chemical Id., Ltd, Tokyo) as polymerizable monomer and 2,2’-Azobis (2,4-dimethylvaleronitrile) (V-65) (Wako. Materials used to prepare the polymer composite particles (PCP) composed of polystyrene and carbon black were as follows. The purposes of this work are to try to prepare the polymer composite particles composed of polystyrene and carbon black with the preparation method presented in this study and to investigate how the operation conditions such as the pouring velocity of poor solvent, the surfactant species and their concentrations and the carbon concentration affect the characteristics of polymer composite particles. Namely, it may be expected that the monomer droplets with the more uniform diameter and with the higher content could be prepared with the phase separation process and then, mass production of polymer composite particles could be performed with conventional suspension polymerization. In this study, it was tried to prepare the polymer composite particles with the more uniform diameter and with the high content of solid powder by using phase separation followed by suspension polymerization. While, the phase separation emulsification method can form the liquid droplets with the uniform diameter by controlling a few experimental conditions such as the pouring velocity of poor solvent and the surfactant species and their concentrations. However, these preparation methods are complex of the operation and not suitable to the mass production. In order to prepare the polymer composite particles with the more uniform diameters by use of the suspension polymerization method, the SPG emulsification method, the microchannel emulsification method and the high pressure homogenization emulsification method have been applied. However, with regard to the uniformity of the polymer composite particle diameters, the suspension polymerization method is well known to prepare the polymer composite particles with the broder diameter distribution. The suspension polymerization method and the mini emulsion polymerization method are suitable to preparing the polymer composite particles containing a lot of solid powder at once, and the soap free polymerization method and the dispersion polymerization method are suitable to preparing the polymer composite particles containing a solid powder particle. The in-situ polymerization method among them is based on the formation of polymer particles while containing solid powder, which is dispersed in monomer or the continuous phase beforehand.įor example, as the typical in-situ polymerization methods, there are the suspension polymerization method, the mini emulsion polymerization method, the soap free emulsion polymerization method and the dispersion polymerization method. Ī lot of approaches have been developed for preparing polymer/solid powder composite particles, such as the in-situ polymerization method, the dry coating method and the physical chemistry method. Polymer/solid powder composite particles have attracted tremendous attention for their potential in improving polymer properties and dispersibility and solvent resistance of solid powder in the organic solvent. The diameters of polymer composite particles increased with the pouring velocity of water and with the weight ratio of carbon black to styrene monomer. The spherical polymer composite particles containing carbon black were prepared with Tween 20 and Tween 80 of nonionic surfactants and the irregular polymer composite particles were prepared with PVA, SDS and Kotamine. Water was poured at the given pouring velocity into ethyl alcohol in which styrene monomer and an initiator were dissolved and carbon black was dispersed beforehand. In the experiment, the surfactant species and their concentrations, the pouring velocity of water and the weight ratio of carbon black to styrene monomer were mainly changed. In order to prepare the polymer composite particles with the more uniform diameter, the styrene monomer droplets containing carbon black were formed with phase separation emulsification in which ethyl alcohol and water were used as the good solvent and the poor solvent for styrene monomer, respectively. It was tried to prepare polymer composite particles composed of polystyrene and carbon black with the phase separation method followed by suspension polymerization. The novel method for preparing the polymer composite particles has been developed.
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