TEMPO-mediated styrene miniemulsion polymerizations were conducted at varying particle sizes (∼50, 90, and 180 nm) to study possible effects of compartmentalization. Polymerizations were initiated using a TEMPO-terminated polystyrene macroinitiator that also acted as costabilizer for the miniemulsion. A bulk polymerization was conducted as a control. Conversion, molecular weight distribution, and the chain livingness were measured to assess the effects of particle size. Decreasing particle size resulted in lower rates of polymerization; after 6 h of polymerization, conversions were 59% for ∼180 nm particles and 43% for ∼50 nm particles. More importantly, large differences in the polymer chain livingness were observed, with smaller particles exhibiting superior livingness at equivalent conversions. Minor effects were also observed on molecular weight; decreasing particle size resulted in higher M n at a specified conversion, signifying lower chain concentrations in smaller particles.

While miniemulsion polymerization has proven to be well‐suited for conducting living/controlled radical polymerizations, emulsion polymerizations have proven to be far more challenging. Ab initio emulsion polymerizations, in which monomer droplets are present during polymerization, have thus far not been successful with TEMPO‐mediated polymerizations, as a result of colloidal instability and coagulum formation. By selectively inhibiting polymerization in the monomer droplets, it is demonstrated that droplet polymerization is responsible for the formation of large (>1 µm) particles that can lead to coagulum formation. Furthermore, we show that coagulum‐free latexes can be produced using a TEMPO‐mediated ab initio emulsion polymerization by suppressing droplet polymerization.

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