Influence of solvent contents on the rubber-phase particle size distribution of high-impact polystyrene

High-impact polystyrene (HIPS) was prepared by the bulk or low-solvent polymerization of styrene in the presence of dissolved rubber and characterized to measure the dispersed particle size of the rubber phase. Before preparation, the prepolymerization time was established by measuring the evolution of particle size distribution of the dispersed phase as a function of reaction time. The measurement technique by laser light scattering was found to be efficient enough not only to lead to the right prepolymerization time but also to predict rubber-phase particle size distribution. Polymerization experiments were then conducted to investigate the effect of solvent contents on the particle size distribution of the rubber phase, in which ethylbenzene was introduced as a solvent at levels of 0, 3, 10, and 15%. As the solvent content increased, the size of rubber-phase particles initially increased, reaching a maximum, and then decreased. It is speculated that a decrease in the molecular weight of the matrix, a decrease in the viscosity ratio between polybutadiene to polystyrene phases, and a change in rubber morphology all contributed to the change in the rubber particle size of HIPS. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 3672–3679, 2003