A method is developed to enable emulsion polymerization to be performed under RAFT control to give living character without the problems that often affect such systems:  formation of an oily layer, loss of colloidal stability, or loss of molecular weight control. Trithiocarbonate RAFT agents are used to form short stabilizing blocks from a water-soluble monomer, from which diblocks can be created by the subsequent polymerization of a hydrophobic monomer. These diblocks are designed to self-assemble to form micelles. Polymerization is initially performed under conditions that avoid the presence of monomer droplets during the particle formation stage and until the hydrophobic ends of the diblocks have become sufficiently long to prevent them from desorbing from the newly formed particles. Polymerization is then continued at any desired feed rate and composition of monomer. The polymer forming in the reaction remains under RAFT control throughout the polymerization; molecular weight polydispersities are generally low. The number of RAFT-ended chains within a particle is much larger than the aggregation number at which the original micelles would have self-assembled, implying that in the early stages of the polymerization, there is aggregation of the micelles and/or migration of the diblocks. The latexes resulting from this approach are stabilized by anchored blocks of the hydrophilic monomer, e.g., acrylic acid, with no labile surfactant present. Sequential polymerization of two hydrophobic monomers gives completely novel core−shell particles where most chains extend from the core of the particles through the shell layer to the surface.

A new method is described, based on living amphipathic random macro-RAFT copolymers, which enables the efficient polymeric encapsulation of both inorganic and organic particulate materials via free-radical polymerization. The mechanism for this new approach is examined in the context of the polymer coating of zirconia- and alumina-coated titanium dioxide particles and its breadth of application demonstrated by the coating of organic phthalocyanine blue pigment particles. The particulate materials were first dispersed in water using a macro-RAFT copolymer as a stabilizer. Monomer and water-soluble initiator were then added to the system, and the monomer polymerized to form the coating. If nucleation of new polymer particles in the aqueous phase was to be avoided, it was found necessary to use a macro-RAFT copolymer that did not form micelles; within this constraint, a broad range of RAFT agents could be used. The macro-RAFT agents used in this work were found not to transfer competitively in the aqueous phase and therefore did not support growth of aqueous-phase polymer. Successful encapsulation of particles was demonstrated by TEM. The process described enables 100% of the particles to be encapsulated with greater than 95% of the polymer finishing up in the polymeric shells around the particles. Moreover, the coating reaction can be carried out at greater than 50% solids in many cases and avoids the agglomeration of particles during the coating step.

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