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There are several ways to make polystyrene.One of the earliest methods of industrial production is to make transparent PS sheet by suspension polymerization and impact-resistant PS sheet by bulk and suspension polymerization.The styrene monomer is mixed with almost equal volume of water, and the surfactant is added to stir the styrene monomer into suspended droplets, which are finally polymerized into hard beads.An initiator is added to the reaction to accelerate and terminate the reaction.Finally, the polystyrene beads are extruded into pellets.
The same method is used to prepare the developable polystyrene, except that a foaming agent (typically pentane) is added during the impregnation process.The method of anti-impact polystyrene is to dissolve rubber in styrene and conduct bulk polymerization (make styrene and PS sheet react below the phase transition point, add water and surfactant to make it into suspension, add no agent to terminate the reaction, and then dry the bead, extrude and cut the bead.At present, continuous bulk polymerization is mostly adopted in production. In this production process, styrene (to make transparent PS sheet material) or styrene – rubber solution (to make impact-resistant PS sheet material) should undergo continuous reaction before reaching the optimal conversion rate, and then stripping off the unreacted components for granulation.