Flower-like polyacrylonitrile (PAN)
particles have shown
promising
performance for numerous applications, including sensors, catalysis,
and energy storage. However, the detailed formation process of these
unique structures during polymerization has not been investigated.
Here, we elucidate the formation process of flower-like PAN particles
through a series of in situ and ex situ experiments. We have the following
key findings. First, lamellar petals within the flower-like particles
were predominantly orthorhombic PAN crystals. Second, branching of
the lamellae during the particle formation arose from PAN’s
fast nucleation and growth on pre-existing PAN crystals, which was
driven by the poor solubility of PAN in the reaction solvent. Third,
the particles were formed to maintain a constant center-to-center
distance during the reaction. The separation distance was attributed
to strong electrostatic repulsion, which resulted in the final particles’
spherical shape and uniform size. Lastly, we employed the understanding
of the formation mechanism to tune the PAN particles’ morphology
using several experimental parameters including incorporating comonomers,
changing temperature, adding nucleation seeds, and adjusting the monomer
concentration. These findings provide important insights into the
bottom-up design of advanced nanostructured PAN-based materials and
controlled polymer nanostructure self-assemblies.