Polymer encapsulation of surface-modified carbon blacks using surfactant-free emulsion polymerisation

Polymer encapsulations of two different grades of water-dispersible, surface-sulfonated carbon black, Sterling-4620 with an aggregate size of 260 nm and Black Pearls-800 (BP-800) with an aggregate size of 45.7 nm, were carried out using surfactant-free emulsion polymerisation of butyl acrylate, methyl methacrylate and allyl methacrylate. High levels of initiator were required because carbon black acts as an efficient radical trap. Although polymerisation in the presence of Sterling-4620 proceeded satisfactorily using ammonium persulfate (APS), the much larger specific surface area of BP-800 inhibited polymerisation with APS and the sodium salt of 4,4′-azobis(4-cyanopentanoic acid), a non-oxidising initiator, was necessary for effective polymerisation in the presence of BP-800. Several polymer-encapsulated Sterling-4620 and BP-800 products were prepared successfully using different amounts and compositions of polymer, and have been characterised using solvent extraction, pyrolysis, thermogravimetry, infrared spectroscopy, transmission electron microscopy, differential scanning calorimetry and dynamic mechanical thermal analysis.