Particle encapsulation and composite particle formation via in-situ polymerization in scCO2

I&EC 54

Baohua Yue1, Jun Yang2, Yulu Wang1, Chien-Yueh Huang3, Rajesh Dave4, and Robert Pfeffer3. (1) Department of Chemistry and Environmental Science, New Jersey Institute of Technology, 161 Warren Street, Newark, NJ 07102, (2) New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, (3) Otto H. York Department of Chemical Engineering, New Jersey Institute of Technology, Newark, NJ 07102, (4) Department of Mechanical Engineering, New Jersey Institute of Technology, Newark, NJ 07102
In this work, a new approach was employed for production of polymeric nanocomposite and fine particle encapsulation via in-situ polymerization in scCO2. Silica nanoparticles were synthesized and modified with MPS as filler material. Copolymerization of grafted MPS with MMA in scCO2 produced micron-sized composite particles. Silica nanopartricles were shown well dispersed in the PMMA matrix. Depending on experimental conditions such as silica to PMMA ratio and surfactant concentration, final product morphologies from individual composite particles to large agglomerates were obtained. This process was also employed for encapsulation of larger micron-sized particles such as Dechlorane crystals. It provides an alternative to the SAS type processes, as the new method renders uniform coating layers with complete coverage and controllable thickness, owing to the initial homogeneity of dispersed reactants and operation conditions that affect the kinetics of polymerization-induced phase separation. The coating morphologies showed strong dependence on the polymer to particle ratio: from smooth thin-film coating to surface aggregations of fine polymer particles; the effect of various reaction parameters was also studied. Results on other particles and polymers demonstrated potential industrial applications of this technique.