Statistical design strategies to optimize properties in miniemulsion polymerization of methyl methacrylate

PMMA particles were synthesized by a miniemulsion polymerization method using hexadecane as costabilizer and sodium dodecyl sulfate as surfactant. Full factorial experimental design incorporating the linear regression analysis of the experimental values was used to illustrate the usefulness of this technique in miniemulsion polymerization studies. The effect of initiator concentration, costabilizer concentration, surfactant concentration, sonication time and amplitude, and their interactions on the particle size were identified. Costabilizer and surfactant concentrations influence both particle size individually whereas initiator concentration influences particle size via its interactions with the costabilizer and the surfactant. Sonication parameters influence also greatly the particle size. Two mathematical models were established, and have demonstrated the capability of predicting particle diameter from the synthesis conditions with a precision of 1–2 nm over a range from 75 to 180 nm.