Synthesis and characterization of micrometer-sized homo and composite polyacrylonitrile particles of narrow size distribution on the basis of single-step swelling of uniform polystyrene template microspheres

Polyacrylonitrile/polystyrene micrometer‐sized composite particles of narrow size distribution were prepared by a single‐step swelling of uniform polystyrene template microspheres with emulsion droplets of methylene chloride containing the monomer acrylonitrile and the initiator benzoyl peroxide. Methylene chloride was then evaporated carefully, followed by polymerization of acrylonitrile at 70 °C within the shrunken template particles. Polymerization of acrylonitrile also occurred at the particles' surface due to the interaction of surface polyacrylonitrile oligoradicals with acrylonitrile dissolved in the aqueous phase. Uniform polyacrylonitrile particles of higher surface area were formed by dissolving the template polystyrene polymer of the composite particles. Surface and bulk characterization of the particles were performed by methods such as FTIR, elemental analysis, TGA‐DSC, XRD, XPS, advancing contact angle, light microscope, SEM and cross‐sectional TEM. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 4847–4861, 2004 A single‐step swelling process of uniform micron‐sized polystyrene particles has been used to prepare uniform polystyrene/polyacrylonitrile composite particles and polyacrylonitrile particles of controlled properties. Cross‐sectional TEM photomicrographs are enclosed.