Effect of the carboxylic acid monomer type on the emulsifier‐free emulsion copolymerization of styrene and butadiene

Carboxylated styrene–butadiene rubber latexes were prepared through the emulsifier‐free emulsion copolymerization of styrene and butadiene with various carboxylic acid monomers. The effects of various carboxylic acid monomers on the particle formation process were investigated. The type of carboxylic acid monomer strongly affected the particle nucleation. The number of particles and thus the polymerization rate increased with the increasing hydrophobicity of the carboxylic acid monomers. There was a significant difference in the polymerization rate per particle. The results showed that particle nucleation and growth were dependent on the hydrophilic nature of the carboxylic acid monomers. The average particle diameter of the carboxylated styrene–butadiene rubber latexes in the dry state was obtained through some calculations using direct measurements of the average particle diameter in the monomer‐swollen state by a dynamic light scattering technique. Several parameters, such as the polymerization rate, number of latex particles per unit of volume of the aqueous phase, and polymerization rate per particle, were calculated. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2007     

Emulsifier‐minor emulsion copolymerization of BA‐MMA‐St‐MAA (or AA)‐N‐MA

A novel emulsion polymerization technique referred to as emulsifier‐minor emulsion polymerization was achieved by the copolymerization of methyl methacrylate, butyl acrylate, and styrene (MMA‐BA‐St) with a combination of water‐soluble ionic monomers [methacrylic acid (MAA) or acrylic acid (AA)] and nonionic monomers (N‐methylol acrylamide). In the technique, water‐soluble monomers play a crucial role in the stabilization of the latex particles as they can be bound to the particle surface and form a hydrate protective layer, which exhibits steric and/or electrostatic effects to prevent particle coagulation. The minor but over its critical micelle concentration emulsifier sodium alkylated diphenyl ether disulfonate (DSB) results in the nucleation of particles mainly by the micelle nucleation mechanism and thus determines the polymerization rate, the particle size, and the number. The film water resistance of the latices can be improved, and the foaming capacity of can be lowered by using technique instead of conventional emulsion polymerization. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 2923–2929, 2004     

中空聚合物微球的制备——种子及核乳胶粒的制备

为了制得具有中空结构的聚合物微球,首先以十二烷基苯磺酸钠(SDBS)为乳化剂,在其用量低于CMC的条件下,进行甲基丙烯酸甲酯(MMA)、甲基丙烯酸(MAA)和丙烯酸丁酯(BA)的乳液聚合,制备了带羧基的种子乳胶粒.然后采用MMA、MAA和二乙烯基苯为单体进行种子乳液聚合,制备了轻度交联的带羧基的核乳胶粒.该核乳胶粒经过核-壳乳液聚合和适当的碱处理工艺就可成为具有中空结构的聚合物微球.采用粒度仪测定了乳胶粒的直径及其分布,采用TEM对乳胶粒结构形态进行了表征.研究了种子及核乳胶粒制备过程中单体加料方式、乳化剂用量及羧基单体种类等因素对聚合稳定性、乳胶粒直径及其分布以及最终的中空聚合物微球结构形态的影响,确定了制备种子及核乳胶粒的最佳工艺条件.在制备种子阶段,SDBS用量为单体总量的0.5%,采用一次性加入单体的进料工艺;在核乳胶粒制备阶段,以MAA为羧基单体,所有单体采用"饥饿式"加料,半连续补加乳化剂并使乳化剂用量为核单体总量的0.15%时可保持聚合稳定性并保证无新乳胶粒生成.     

Preparation of monodispersed hollow polymer particles by seeded emulsion polymerization under low emulsifier conditions

In a low emulsifier system, the MMA‐BA‐MAA copolymer emulsions were prepared as seed latices and the seeded emulsion polymerization of MMA‐MAA‐DVB was consequently carried out to prepare carboxylated core particles. The hydrophobic shell was then synthesized onto the core using styrene, acrylonitrile, and divinylbenzene as comonomers. The hollow latex particles were obtained by alkalization treatment of the core‐shell latex particles. The effects of the feeding rate of monomer mixture, contents of emulsifier SDBS and crosslinking agent DVB, and ratio of the monomers during the core stage and shell stage on the morphology and volume expansion of the latex particles were investigated. The results show that the monodispersed hollow latex particles with large size can be obtained when the feeding rate is 0.1 g/min, SDBS content is 0.15 and 0.2 wt % during the core stage and shell stage, respectively, DVB contents are 1% during the preparation of shell copolymers, and the monomer ratio of the core particle to shell layer is 1 : 8. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 98: 1505–1510, 2005     

乳液聚合成核阶段的模拟与分析

建立了乳液聚合成核阶段的Monte Carlo模型，并用计算机对一个体积为10^-17m^3的微型反应器中苯乙烯的乳液聚合进行了模拟。以计算机生成随机数作为自由基被胶束和乳胶粒捕获的几率，模拟了在微型反应器中每一个自由基的生成、被胶束或乳胶粒捕获的过程以及每一个乳胶粒的生成及增长过程。通过对每一个乳胶粒在增长过程中各参数的统计计算，研究了乳液聚合成核阶段诸参数(乳胶粒数目、乳胶粒直径与粒径分布、单体转化率、聚合反应速率等)与乳化剂浓度[S]及引发剂浓度[I]的关系。结果表明，苯乙烯的乳液聚合体系中乳胶粒数目与[S]^0.5996[I]^0.4016成正比：在成核阶段乳胶粒直径分布先变宽后变窄，乳液聚合过程中乳胶粒直径分布有自动变窄的趋势；成核阶段持续时间t12与[S]^0.60[I]^0.60成正比，成核阶段结束时的单体转化率X12与[S]^1.20[I]^0.20成正比。     

Study on the preparation and properties of styrene–butyl acrylate–silicone copolymer latices

Copolymer latices of styrene–butyl acrylate–silicone were prepared using a semicontinuous addition process and batch and monomer emulsion addition processes. The results showed that a stable latex with narrow particle size dispersion and a high monomer conversion can be obtained only by the semicontinuous addition process. The simultaneous free‐radical and ionic copolymerization mechanisms were discussed. 3‐Methacryloyloxypropyl trimethoxysilane in this work was used as a coupling agent to form a chemical bond between vinyl polymer and polysiloxane. It was found that the copolymerization reaction and the properties of latex and latex film were obviously influenced by silicone content. When the silicone content was less than 25 wt %, copolymerization proceeded readily and a stable latex could be prepared. With increasing silicone content, monomer conversion, latex stability, film hardness, and tensile strength decreased, whereas the water resistance and impact strength increased. Results of Soxhlet extraction, silicon analysis, and dynamic mechanical properties of latex polymer confirmed the occurrence of copolymerization. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 3194–3200, 2001     

Size control of polystyrene beads by multistage seeded emulsion polymerization

Micron‐sized monodisperse crosslinked polystyrene (PS) beads have been prepared by a multistage emulsion polymerization using styrene monomer, divinylbenzene crosslinking agent, and potassium persulfate initiator in the absence of emulsifier. In the first stage of the reaction, the lower the reaction temperature, the larger the bead size obtained. In the later stages of the reaction, the particle size is increased with the initiator concentration and monomer content. Particle nucleation of the preexisting polymer seed of 0.7–0.8 μm in diameter is prepared at 60°C, then the monodisperse crosslinked PS beads > 2 μm are synthesized up to the third stage of the reaction. As the particle size grows, the number of free radicals in the growing particles increases, and the conversion of the next stage is continuously increased. The reaction mechanism is suggested that the continuous polymerization be conducted due to the diffusion of monomer into the preexisting particles to induce spherical beads in the later stages of the reaction. Otherwise, phase separation or the formation of protrusion by the capture of free radicals will be taking place. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 71: 2259–2269, 1999     

Particle nucleation in emulsion copolymerization containing multifunctional monomers

Characteristic features of particle nucleation and growth in the emulsion copolymerization of styrene and multifunctional monomers such as ethylene glycol dimethacrylate and divinylbenzene were investigated. It was found that in these emulsion copolymerization systems the rate of polymerization per particle decreased drastically with an increase in the content of the multifunctional monomer in the initial monomer feed, and the number of polymer particles produced, on the other hand, increased corresponding to the decrease in the rate of polymerization per particle. The increase in the number of polymer particles produced was explained on the basis of Smith-Ewart theory, which predicts that the number of polymer particles produced would increase inversely proportional to the 0.4 power of the volumetric growth rate per particle, that is the rate of polymerization per particle during the interval of particle formation (Interval I). It was pointed out that the decrease in the rate of polymerization per particle in Interval I would be due mainly to a decrease in the monomer concentration in the polymer particles which was caused by crosslinking networks of the resultant polymer.     

Miniemulsion and conventional emulsion copolymerization of styrene and butadiene: A comparative kinetic study

The kinetics of conventional and miniemulsion copolymerizations of styrene and butadiene were compared using the Mettler RC1 calorimeter. A two‐step homogenization procedure was applied to obtain miniemulsions of these monomers with hexadecane as the costabilizer. The results indicated that the miniemulsion polymerizations proceeded mainly by nucleation in the monomer droplets, while in the conventional emulsion polymerizations, particle formation occurred by a combination of micellar and homogeneous nucleation. The overall rate of miniemulsion polymerization was faster than the corresponding conventional emulsion system if the surfactant concentration was below the critical micelle concentration (cmc) and slower if the surfactant concentration was above the cmc. The homogenization process is important for making stable miniemulsion systems, but had no effect on the conventional emulsion system (without hexadecane), most likely because of the second stage addition of the butadiene monomer. The dependencies of the rate of polymerization (heat of reaction) and number of particles on the surfactant concentration differed for the two types of polymerization systems. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 2304–2312, 2006     

Carboxyl-stabilized emulsion polymers

An emulsion polymerization process is reported for the production of high-solids, surfactant-free styrene/butadiene latices. With this procedure latices require no surfactants, for stabilization is built into the emulsion particles by means of copolymerized acid monomers. This “pH variable” method is a two-step, batch-on-batch polymerization. In the first step, all the ingredients are present in the reaction mixture; however, only enough styrene and butadiene is added to reach a low solids content. This step, carried out at low pH, produces a carboxylated seed latex. On raising the pH of this low-solids emulsion, the copolymerized carboxyl groups ionize, and the now highly charged latex particles provide an expedient locus for the generation of stable, highsolids latices. Neutralizing the carboxyl groups of the seed latex before adding the remaining monomers induces the highly hydrophilic carboxyl anions to remain on the surface of the latex particle, nearer to the aqueous environment of the surrounding media. Hence, the maximum stabilization capacity of the acid monomers is utilized. The process was evaluated to ascertain the effects of the following variables: the particle size and solids content of the first step, the nature of the base used to raise the pH, the pH of the dispersion prior to the second step, and the effect of the acid monomer on the latex stability.     

Miniemulsion copolymerization of styrene and butyl acrylate initiated by redox system at lower temperature: Reaction kinetics and evolution of particle‐size distribution

The kinetics of the miniemulsion copolymerization of styrene (St) and butyl acrylate (BA) initiated by redox initiators, (NH₄)₂S₂O₈/NaHSO₃, at lower temperature (45°C) was studied. The polymerization rate in miniemulsion copolymerization is lower than that of the corresponding conventional emulsion copolymerization. In regard to the rate of polymerization, the initiator concentration plays a more important role in miniemulsion copolymerization than in conventional emulsion polymerization, while the surfactant concentration has a more important role in conventional emulsion polymerization than in miniemulsion polymerization. These are attributed to their different nucleation mechanisms, which are the same as those found in the miniemulsion polymerization carried out at higher temperatures. While by eliminating nucleation via micelle and ensuring against homogeneous nucleation, miniemulsion polymerization can be carried out by the sole nucleation mechanism—monomer droplet nucleation—at lower temperature. Because of this, the particles become narrower during the polymerization and, finally, monodisperse polymer particles are obtained. The result of the particle numbers indicated that a continuous nucleation will cease at about 60% conversion. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 73: 315–322, 1999     

Effect of emulsifier type on the copolymerization of styrene and acrylic acid

In this work we report the emulsion copolymerization of styrene and acrylic acid using a cationic (cetyltrimethylammonium bromide or CTAB) or an anionic (sodium dodecylsulfate or SDS) emulsifier. Latexes were stable and monodisperse with spherical particles of ～100 nm for the CTAB latex and of ～70 nm for the SDS latex. However, a random copolymer was produced with CTAB whereas a “blocky” copolymer was obtained with SDS. Here we propose a mechanism to explain these structural differences in terms of the relative reactivities of styrene and acrylic acid and of their initial location and distribution in the SDS and CTAB emulsions.     

Preparation and properties of core [poly(styrene‐n‐butyl acrylate)]–shell [poly(styrene–methyl methacrylate–vinyl triethoxide silane)] structured latex particles with self‐crosslinking characteristics

Structured latex particles with a slightly crosslinked poly(styrene‐n‐butyl acrylate) (PSB) core and a poly(styrene–methacrylate–vinyl triethoxide silane) (PSMV) shell were prepared by seed emulsion polymerization, and the latex particle structures were investigated with Fourier transform infrared, thermogravimetric analysis, differential scanning calorimetry, transmission electron microscopy, and dynamic light scattering. The films that were formed from the structured core (PSB)–shell (PSMV) particles under ambient conditions had good water repellency and good tensile strength in comparison with films from structured core (PSB)–shell [poly(styrene–methyl methyacrylate)] latex particles; this was attributed to the self‐crosslinking of CH₂?CH? Si(OCH₂CH₃)₃ in the outer shell structure. The relationship between the particle structure and the film properties was also investigated in this work. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 1824–1830, 2006     

Synthesis of polystyrene latex via emulsion polymerization with poly(vinyl alcohol) as sole stabilizer

Compared with low molecular surfactants, poly(vinyl alcohol) (PVA) could afford latexes with particular tackiness as an important property for various applications. However, until now, except for some highly reactive monomers, most of monomers including styrene seldom use PVA as protective colloid in emulsion polymerization. In this work, we used oil‐soluble initiator, 2,2′‐azobisisobutyronitrile, to accelerate the copolymerization of styrene and divinyl benzene in PVA protected colloids and synthesize polystyrene (PS) latex within 50 min at 70 °C successfully. The reaction system could remain stable even at the monomer‐to‐water ratio as high as 1:4, and the polymerization in pseudo‐micelles or latex particles was always dominant. The adjustment of the size of the PS latex in the range from 70 to 100 nm was facilely achieved by changing the polymerization temperature, the addition of PVA, or the monomer‐to‐water ratio. This method was also exploited to synthesize poly(styrene‐co‐methyl methacrylate) and poly(styrene‐co‐4‐chlorostyrene) latexes, indicating prospects in applications with the advantages of high capacity and broad applicability. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45111.     

Monodisperse polymer beads as packing material for high-performance liquid chromatography. Synthesis and properties of monidisperse polystyrene and poly(methacrylate) latex seeds

The effects of initiator concentration, ionic strength of polymerization medium, polymerization temperature, and monomer/water phase ratio on particle size, particle size distribution and molecular weight of the resulting polymers prepared by an emulsifier-free emulsion polymerization of styrene, methyl methacrylate and glycidyl methacrylate have been studied. Optimal conditions for preparation of uniformly sized polystyrene particles larger than 1 μm have been found. An attempt to synthesize monodisperse particles of similar size from methacrylate monomers and crosslinked particles has failed. It is shown that the swelling ability of “non-activated” latex particles does not exceed 70 fold increase in the volume and strongly depends on the size of the original particles.     

2‐Hydroxyethylmethacrylate carrying uniform porous particles: preparation and electron microscopy

Uniform macroporous particles carrying hydroxyl groups have been obtained in the size range 3–11.5 µm by seeded polymerization. For this purpose, uniform polystyrene particles in the size range 1.9–6.2 µm were used as seeds. The seed particles were successively swollen by dibutyl phthalate (DBP) and a monomer mixture comprising styrene, 2‐hydroxyethylmethacrylate (HEMA) and a crosslinker. Two different crosslinkers, divinylbenzene (DVB) and ethylene glycol dimethacrylate (EGDMA), were tested. Size distribution properties together with bulk and surface structures of the particles have been characterized by both scanning and transmission electron microscopy. While EGDMA provides uniform particles with a non‐porous surface, DVB produces uniform particles having a highly porous surface and interior. The comparison of FTIR and FTIR‐DRS spectra shows that the HEMA concentration is higher on the particle surface than within the particle interior. Seed latex size and monomer/seed latex ratios are identified as the most important variables affecting the final particles. Different seed latexes have been tried; the result is that highly macroporous particles with a sponge‐like pore structure both on the surface and in the particle interior have been obtained by use of the seed latex with the largest particles and the lowest molecular weight. An increase in the HEMA feed concentration leads to final particles with a non‐porous surface and a crater‐like porosity in the particle interior. The average pore size significantly decreases with increasing DBP/seed latex and monomer/seed latex ratios. © 2001 Society of Chemical Industry     

Control of pore generation and pore size in nanoparticles of poly(styrene‐methyl methacrylate‐acrylic acid)

Seeded emulsion polymerization of styrene‐methyl methacrylate‐acrylic acid onto seed latexes of monodisperse particles of poly(styrene‐methyl methacrylate) was conducted with or without divinyl benzene as a crosslinking agent. Experiments revealed that almost no new particles were formed during the second stage of polymerization, and that the seeded latex particles obtained were almost monodisperse. An alkali‐acid treatment was then applied to the seeded latex particles swollen in 2‐butanone. Experimental results indicated that: (1) for uncrosslinked particles, an optimum volume expansion of >50% is reached for a ratio of the swelling agent, 2‐butanone, to polymer (methyl‐ethyl‐ketone/polymer by weight) between 2.0 and 2.9; the volume expansion is much lower outside the above range. (2) For crosslinked particles, the particle volume expansion follows the same pattern, but with smaller values. (3) pH plays an important role in pore generation and volume expansion. Pore generation is optimized by decreasing pH to a value as low as 1.5 during acid treatment, and by keeping pH in the optimum range between 11.98 and 12.20 during alkali treatment. Based on the above observations, a discussion regarding the mechanism of pore generation and particle expansion is provided. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 72: 419–426, 1999     

Chromatographic performance of monodisperse–macroporous particles produced by “modified seeded polymerization.” I: Effect of monomer/seed latex ratio

In this study, the monodisperse–macroporous particles produced by a relatively new polymerization protocol, the so‐called, “modified seeded polymerization,” were used as column‐packing material in the reversed phase chromatography (RPC) of proteins. The particles were synthesized in the form of styrene‐divinylbenzene copolymer approximately 7.5 μm in size. In the first stage of the synthesis, the monodisperse polystyrene particles 4.4 μm in size were obtained by dispersion polymerization and used as the “seed latex.” The seed particles were swollen by a low‐molecular‐weight organic agent and then by a monomer mixture. The monodisperse–macroporous particles were obtained by the polymerization of monomer mixture in the seed particles. In the proposed polymerization protocol, the number of successive swelling stages was reduced with respect to the present techniques by the use of sufficiently large particles with an appropriate average molecular weight as the seed latex. A series of particles with different porosity properties was obtained by varying the monomer/seed latex ratio. The separation behavior of HPLC columns including the produced particles as packing material was investigated in the RPC mode using a protein mixture including albumin, lysozyme, cytochrome c, and ribonuclease A. The chromatograms were obtained with different flow rates under an acetonitrile–water gradient. The theoretical plate number increased and chromatograms with higher resolutions were obtained with the particles produced by using a lower monomer/seed latex ratio. The separation ability of the column could be protected over a wide range of flow rates (i.e., 0.5–3 mL/min) with most of the materials tested. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 607–618, 2004     

Effect of carboxylic acid monomer and butadiene on particle growth in the emulsifier-free emulsion copolymerization of styrene-butadiene-carboxylic acid monomer

Carboxylated styrene-butadiene rubber (XSBR) latexes were prepared by emulsifier-free batch emulsion copolymerization of styrene and butadiene with different types of carboxylic acid monomers (AA, MAA, IA). It was found that the particle growth is dependent on the hydrophilic nature of carboxylic acid monomers. SEM studies showed that N_p is almost constant in the particle growth stage (conversion above 10%). Through some calculations by data obtained from DLS technique, average diameter of monomer swollen polymer particles of all the XSBR latexes at the same conversion of 0.4 was obtained to be 368.91, 174.17 and 437.15 nm for AA, MAA and IA, respectively. Several kinetic parameters related to the particle growth stage such as the average number of growing chain per particle were calculated to be 0.474, 0.370 and 1.685 for AA, MAA and IA, respectively. It was observed that these kinetic parameters increase with increasing average diameter of monomer swollen polymer particles, which is consistent with the emulsion polymerization kinetics. Moreover, results indicated that the polymerization rate per particle or equivalently the average number of the growing chain per particle (particle growth stage) decreases by replacing a part of styrene with butadiene in the emulsion copolymerization recipe of styrene-carboxylic acid monomer.