Control of network structure in emulsion crosslinking copolymerization

A kinetic model for network structure development during crosslinking copolymerization of vinyl and divinyl monomer is proposed. The model calculations suggest that polymer networks synthesized by free-radical copolymerization are, in general, inhomogeneous at least on a microscopic scale. By application of the same kinetic parameters as those for bulk polymerizations, it was found that the crosslinking density of the polymers formed in the earlier stages of polymerization is very high in emulsion polymerizations and polymer networks tend to be highly heterogeneous. Homogeneous networks cannot be formed even under Flory's simplifying assumptions for vinyl/divinyl copolymerization in emulsion polymerizations. The present kinetic model can be used to find semi-batch policies to control the network structure, and semi-batch policies were used to illustrate the synthesis of homogeneous polymer networks.     

Experimental study of emulsion polymerization with crosslinking

Herein is reported the results of an extensive experimental investigation of the kinetics of emulsion polymerization as affected by crosslinking in the polymer particles. The model monomer system, methyl methacrylate (MMA) and ethylene glycol dimethacrylate (EGDMA), was chosen for this study due to its earlier comprehensive investigation in bulk polymerization. Standard recipes with sodium dodecylsulfate (SDS) as anionic emulsifier and potassium persulfate (KPS) as initiator were used for the batch emulsion polymerizations. Results, which clearly show the effect of crosslinking on the kinetics, are discussed in detail. These include swellability of polymer particles by monomer; polymer particle nucleation rates, below and above the critical micelle concentration (CMC); average number of radicals per particle; and gel-sol levels. It was found advantageous to use electron spin resonance (ESR) to follow radical concentrations during crosslinking in polymer particles. © 1997 John Wiley & Sons, Inc. J Appl Polym Sci 66: 935–957, 1997     

Emulsion copolymerization of alpha-methylstyrene and styrene

Fast copolymerizations of styrene and alpha-methylstyrene can be achieved in emulsion systems where free-radical reactions in the bulk or solution are inefficient. The Smith–Ewart–Gardon theory of emulsion polymerization was developed for homopolymerizations but should extend to this copolymerization since the particular comonomers meet the basic assumptions of this model. Sodium lauryl sulfate surfactant provided faster initial polymerization rates, but steady-state conversions were faster with potassium laurate, especially at higher alpha-methylstyrene contents. This is ascribed to acceleration of potassium persulfate decomposition by the former soap. Monomer concentration in the polymerizing particles was constant during steady reaction rates. The rate of volume growth of particles during this interval was generally as predicted by theory. The number of particles and particle sizes could be predicted well if allowance was made for initiator wastage reactions. The observed average number of radicals per particle appeared to be 0.5. Analysis of the composition of monomer droplets and proton NMR analyses of copolymer compositions provided independent confirmations that the present emulsion copolymerization was consistent with the terminal copolymerization model.     

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     

Study of different types of monomer emulsion feedings to semibatch emulsion polymerization reactors

Semibatch emulsion polymerization processes with a monomer emulsion feed are of great importance in both academia and industry. Monomer emulsion feeds can be applied to semibatch reactors using either a stream of an emulsified monomer or two streams of a neat monomer feed and an aqueous solution of an emulsifier. The effect of the feeding policy on the rate of polymerization and on the secondary particle formation was studied for a seeded semibatch emulsion polymerization of styrene. When a single-stream monomer emulsion feed is applied to a semibatch process, the monomer-swollen micelles formed in the feed might become the locus of initiation upon entering the reaction vessel. Under the conditions of this study, the application of monomer emulsion feed in either one stream or two streams did not result in secondary particle formation. The incoming monomer-swollen micelles were disintegrated to supply emulsifier molecules for the stability of growing particles, before they can capture radicals and become polymer particles. The rate of polymerization was found to be independent of the way that the monomer emulsion feed is added. In the absence of nitrogen, the rate of polymerization decreased more appreciably for the monomer emulsion feed, due to the oxygen dissolved in the emulsified monomer. The number of particles, however, was not affected by the purging policy. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 2472–2477, 2001     

外交联功能型丙烯酸乳液涂料的制备

为了制备常温外交联水性丙烯酸乳液涂料,提高其涂层的交联密度和综合性能,首先以丙烯酸酯类为主要单体,十二烷基磺酸钠、辛烷基酚聚氧乙烯醚和烷基二苯醚二磺酸钠为复合乳化剂,用核壳乳液聚合的方法合成具有外交联特性的水性丙烯酸功能乳液.然后用聚酰胺环氧氯丙烷(PAE)外交联剂对乳液进行交联改性.研究结果表明:胶膜的交联度、硬度、...     

Free-radical transport from latex particles

A rate constant for the diffusion of monomer radicals from latex particles is derived using the transport equations describing the generation, diffusion, and reaction of monomer radicals within the particles. Calculations for styrene emulsion polymerization show that this “desorption constant” accounts for nonuniform distribution of monomer radicals within the particle while some previously published theories do not. The difference in the desorption constant calculated with the model derived in this work and the “uniform concentration” models could be an order of magnitude when diffusivity of monomer radicals in the particles is small. The monomer radical transport theory is extended to emulsion copolymerization. Desorption rate constants accounting for nonuniform distribution of monomer radicals are derived for emulsion copolymerization.     

Kinetic study of emulsion copolymerization of ethyl methacrylate/lauryl methacrylate in propylene glycol,stabilized with poly(ethylene oxide)–block–polystyrene–block–poly(ethylene oxide) triblock copolymer

The kinetics of emulsion copolymerization of ethyl methacrylate (EMA)/lauryl methacrylate (LMA) in propylene glycol is very similar to the emulsion copolymerizations of water‐soluble monomers in water because of the high solubility of EMA/LMA in propylene glycol. The initial rate of polymerization depends only on initiator concentration and is not affected by either monomer concentration or stabilizer concentration. The overall rate of polymerization is only slightly dependent on monomer concentration and stabilizer concentration and is independent of initiator concentration. The final particle number density increases with increasing amount of stabilizer and decreases with increasing monomer concentration. The total surface area increases with stabilizer concentration and is not governed by either initiator concentration or monomer concentration. Homogeneous nucleation is the dominant mechanism of particle nucleation, as shown by the kinetic data on seeded polymerization and monomer partition behavior. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 1691–1704, 2001     

Synthesis and kinetics of microgel in inverse emulsion polymerization of acrylamide

The kinetic behavior is studied in inverse emulsion polymerization of acrylamide. The polymerization rate in a micelle is proportional to the monomer concentration and the effective average radical concentration. When concentrations of monomer and radical are too low to proceed the polymerization only, some finite final conversion is obtained. The micelles of various sizes have different effective average radical concentrations at the same monomer concentration. Therefore, the polymerization rate and the final conversion are different for various sized micelles. The minimum amounts of emulsifier required to get stable state during reaction is 10 and 7 wt% (based on oil phase) in toluene and n-heptane systems, respectively. Phase inversion is observed with the increase of viscosity during polymerization. The final latex coagulates obviously in the toluene system even with 10 wt% of emulsifier, however, it can be improved more in the n-heptane system with 10 wt% of emulsifier. The crosslinking agent which copolymerizes with the monomer was supposed to remain in the interface of micelles. Such interfacial copolymerization not only hardens particles but improves the stability of the system also, therefore avoiding coagulation among particles. An increase in the content of crosslinking agent leads to a more uniform size of final particles. The microgel added in the alkyd resin decreases the drying time. The greater the amount of microgel added, the shorter the drying time.     

Heterogeneities during the formation of poly(sodium acrylate) hydrogels

Summary In situ fluorescence and light scattering techniques were used to study the formation of heterogeneities during the free-radical crosslinking polymerization of sodium acrylate (NaAc) in the presence of N,N'-methylene(bisacrylamide) (BAAm) as a crosslinker. Pyranine was used as a fluorescence probe in the experiments. The reactions were carried out at room temperature and at a monomer concentration of 20.6 w/v% in water. It was found that the gel forming system became turbid at the start of the reaction; continuing polymerization and crosslinking reactions turned the opaque gels into slightly opaque and finally transparent gels. Two peaks were observed both in the scattered and emitted light intensities versus the reaction time plots. The first peak corresponds to the formation and growth of the phase separated domains whereas the second peak reflects the macrogelation point in the reaction system. Received: 14 June 1999/Revised version: 10 October 1999/Accepted: 10 October 1999     

聚合工艺对室温交联丙烯酸乳胶漆性能的影响

研究了无皂、微皂和常规二种乳液聚合工艺对以双丙酮丙烯酰胺(DAAM)为交联单体、己二酰肼为固化剂的室温交联丙烯酸乳胶漆性能的影响。研究表明：采用常规乳液聚合涂膜的光泽较高，而采用无皂和微皂乳液聚合涂膜的耐水性较好，涂料的起泡性较低。     

Effects of cyclization and electrostatic interactions on the termination rate of macroradicals in free-radical crosslinking copolymerization

Summary Effects of cyclization and ionic group contents on the termination rate of macroradicals formed at zero monomer conversion were investigated. For this purpose, the pregel regime of free-radical methyl methacrylate / ethylene glycol dimethacrylate (MMA/EGDM) and acrylamide / N,N'-methylenebisacrylamide (AAm/BAAm) copolymerization systems was studied by means of the dilatometric technique. To eliminate the chain-length dependent variation of the termination rates, different sets of experiments were carried out each at a fixed monomer and initiator concentration. At low crosslinker contents, the termination rate of zero-conversion macroradicals was enhanced in crosslinking copolymerizations compared to linear polymerization. This is due to the cyclization reactions which reduce the size of the macroradical coils and thus, enhance the termination rates due to the lowering of the thermodynamic excluded volume effect. As the amount of the crosslinker increases, an enhancement in the initial rate of polymerization is observed in all series of experiments, indicating that steric effects on segmental diffusion dominate at high crosslinker contents. The results also indicate a slower rate of termination of ionic macroradicals compared to the non-ionic radicals of the same molecular weight and points the significance of the thermodynamic excluded volume effect on rising the ionic group content. Received: 15 December 1997/Accepted: 13 February 1998     

Winsor I-like (micro)emulsion polymerization of styrene initiated by oil-soluble initiator

Batch emulsion polymerization of styrene initiated by an oil-soluble initiator and stabilized by non-ionic emulsifier (Tween 20) has been investigated. The rate of polymerization vs. conversion curve shows the two non-stationary rate intervals typical for the non-stationary-state polymerization. This behavior is a result of the continuous particle nucleation and the decrease of monomer concentration at the reaction loci with increasing conversion. The initial increase of the polymerization rate is attributed to the increase of particle number and the polymerization proceeding under the monomer-saturated condition—the Winsor I-like (micro)emulsion polymerization. The decrease of the polymerization rate is the result of the depressed transfer of monomer from the monomer reservoir to the reaction loci. Above 50 °C the monomer emulsion separates into two phases: the upper transparent monomer phase and the lower blue colored (microemulsion) phase. The polymerization mixture consists of the microdroplets (act as the reaction loci) and large degradable monomer droplets (act as the reservoir monomer and emulsifier). The continuous release of emulsifier from the monomer phase and the microdroplets induce the continuous particle nucleation up to high conversion. The initial formation of large particles results from the agglomeration of unstable growing particles and monomer droplets. The size of large (highly monomer-swollen) particles decreases with conversion and they merge with the growing particles at ca. 40-50% conversion. The coarse initial emulsion transformed during polymerization to the fine (semitransparent) polymer emulsion as a result of the continuous particle nucleation, the shrinking of highly monomer-swollen polymer particles and the depletion of monomer droplets. The low overall activation energy of polymerization is mainly ascribed to the decreased barrier for entering radicals into the latex particles with increasing temperature.     

Recalculation of the monomer reactivity and experimental differences in emulsion and microemulsion copolymerizations of partially water‐soluble monomers

On the basis of the copolymerization data for the emulsion and microemulsion polymerizations of ethyl acrylate and methyl methacrylate, the monomer concentrations at the copolymerization loci were calculated, with the assumption that the sum of their concentrations at the polymerization loci was equal to unity. The equivalency of the locus and feed concentrations, as for styrene, was invalid because of the partial water solubility of both the monomers. Consequently, the locus concentration rather than the initial feed concentration was used to recalculate the monomer reactivity at the actual site of polymerization, and this was called the true reactivity ratio. The apparent reactivity ratios for emulsion and bulk polymerizations were different, whereas those for microemulsion and bulk polymerizations were similar. This difference was attributed to the mode of polymerization in the emulsions and microemulsions, leading to different copolymer compositions for similar initial feed concentrations. This was verified experimentally from the thermal properties and particle size distribution measurements. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 2802–2810, 2002     

Structure and swelling of poly(acrylic acid) hydrogels: effect of pH, ionic strength, and dilution on the crosslinked polymer structure

The network formation of crosslinked polymer hydrogels made via a free radical polymerization mechanism is significantly influenced by the polymerization conditions. In particular, the crosslinked structure of ionic networks like poly(acrylic acid) copolymers is affected by the monomer concentration, the pH, and ionic strength during the polymerization. In this work experimental data as well as theoretical analysis are used to investigate how these factors control the degree of crosslinking and primary cyclization during the network formation of multifunctional monomers. It was found that the amount of water present during the polymerization increases primary cyclization rates, and this change affects the subsequent swelling behavior of the acrylic acid hydrogel. The effects of ionic strength and pH on the network structure are interrelated. An increase in the pH decreases the degree of primary cyclization while an increase in the ionic strength increases cyclization. To investigate further the effect of pH, a cationic polymer was formed that contained a monovinyl amine monomer and a novel diamine crosslinking agent synthesized in our laboratory. The combined effect of the ionizing backbone chain and crosslinking agent cause the degree of primary cyclization in this material to be extremely sensitive to the pH during polymerization. This result confirms the significant role of pH on the network formation in ionic materials.     

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。     

PVC modification through polymerization of a monomer absorbed in porous suspension‐type PVC particles

In‐situ polymerization is the polymerization of one monomer in the presence of another polymer. It can be performed by sequential emulsion polymerization, or by reactions in the melt, in the solid phase, or in solution. The current report describes two methods to obtain poly(vinyl chloride) (PVC) modification through polymerization of a monomer absorbed in commercial porous suspension‐type PVC particles. The generated modified PVC products differ significantly in their structure and properties. The first approach includes absorption of a monomer/peroxide solution within porous suspension‐type PVC particles, followed by polymerization/crosslinking in the solid state at 80°C in an aqueous stabilizer‐free dispersion. The monomer/crosslinker pairs selected are styrene/DVB (divinyl benzene), methylmethacrylate/EGDMA (ethylene glycol dimethacrylate), butyl acrylate/EGDMA, and ethylhexyl acrylate/EGDMA. The influence of composition and nature of the polymerizing/crosslinking constituents on the modified PVC particle structure was studied by microscopy methods, porosity measurements, and dynamic mechanical behavior (DMTA). The level of molecular grafting between PVC and the modifying polymer was determined by solvent extraction experiments. This work shows that the different monomers used represent distinct courses of monomer transport through the PVC particles. The characteristics of the modified PVC particle indicate that the polymerization/crosslinking process occurs in both the PVC bulk, i.e., within the walls constituting a particle, and in the PVC pores. No indication of chemical intermolecular interaction within the modified PVC particles was found. In the second approach, a solution of monomer, initiator, and a crosslinking agent is absorbed in commercial suspension‐type porous PVC particles, thus forming a dry blend. This dry blend is subsequently reactively polymerized in a twin‐screw extruder at an elevated temperature, 180°C, in the molten state. The properties of the reactively extruded PVC/PMMA blends are compared with those of physical blends at similar compositions. Owing to the high polymerization temperature, short‐chain polymers are formed in the reactive polymerization process. Reactively extruded PVC/PMMA blends are transparent, form single‐phase morphology, have a single T_g, and show mechanical properties comparable with those of the neat PVC. The resulting reactively extruded PVC/PMMA blends have high compatibility. J. Vinyl Addit. Technol. 10:109–120, 2004. © 2004 Society of Plastics Engineers.     

RADICAL DESORPTION IN EMULSION POLYMERIZATION OF VINYL ACETATE

In the present paper a model equation for calculating the radical desorption rate constant,k_0,in the emulsion polymerization of vinyl acetate was suggested and the various parameters forevaluating k_0 were determined.Effects of reaction temperature,emulsifier concentration,initiator con-centration,monomer conversion and phase ratio on k_0 were studied.It indicates that the desorptionof radicals from latex particles to aqueous phase must be taken into account in the modelling ofemulsion polymerization for the monomers with higher hydrophilicity such as vinyl acetate.     

Survey of preparation techniques of monodispersed microspheres of glycidyl methacrylate and its derivatives

This article describes the preparation of monodispersed microspheres of glycidyl methacrylate, 2-hydroxyethyl methacrylate, and triethylene glycol dimethacrylate by radical polymerization. The initial stage of the polymerization reaction began in the liquid phase. As the polymerization proceeded, a nuclear polymer chain of microspheres was generated from soluble oligomeric radicals and then solidified from the liquid phase. The radius of the microspheres was controlled by polymerization parameters, such as monomer concentration, polymerization time, and the kind of polymerization solvent. A small number of thin platelike substances may be produced by the anisotropy of the two-dimensional monomer added to the oligomeric radicals. The monodispersed microspheres were achieved through the use of the following: (1) a fluorinated tube in which the polymerization reaction proceeded; (2) a monomer concentration of about 1 mol/L; (3) a higher concentration of crosslinking regeant than used commercially; (4) the prevention of the occurrence of polymer microsphere aggregation; (5) pouring the solution mixtures into a large amount of cooled acetone after the polymerization reaction; and (6) the use of a low-temperature purification process and centrifugation at low temperature. This article describes the mechanism of microsphere formation and growth by solution polymerization. © 1995 John Wiley & Sons, Inc.     

一种丙烯酸改性乳化环氧树脂的制备与研究

提供了一种制备改性环氧树脂乳液的新方法,以丙烯酸酯类为聚合性单体,加入环氧树脂,利用乳液聚合方法制成了环氧树脂含量达50％的丙烯酸酯改性环氧树脂乳液。通过测试交联度,证明环氧树脂确实参与了聚合反应。同时,还对乳化剂、功能性单体以及环氧树脂含量对乳液稳定性、产品收率、吸水性以及各项力学性能的影响问题进行了研究,得出：丙烯酸对环氧树脂的聚合交联起到了决定性的作用,丙烯酰胺的引入大大提高了乳液的稳定性和力学性能,环氧树脂含量越多产品性能越接近纯环氧树脂,聚合应采用阴、非离子复合乳化剂。