Summary: Controlled radical polymerization using RAFT has the potential to make polymers with virtually any desired molecular architecture. For this to be implemented on an industrial scale, it must be performed by polymerization in disperse media. However, simply adding a RAFT agent to a conventional emulsion polymerization recipe leads to a loss of molecular weight control and formation of coagulum, probably because of nucleation in droplets, which is normally an unlikely phenomenon in emulsion polymerizations. Recently, a method has been devised for implementing RAFT in ab initio emulsion polymerization that avoids droplets in the particle formation stage. The molecular weight distribution of the polymer thus formed shows that molecular weight control is maintained throughout the polymerization. A model is developed to predict the particle size formed in this new type of emulsion polymerization. The new methodology enables synthesis of novel dispersions where molecular architecture can be precisely controlled, such as structured core-shell particles.

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