A New Heterogenization Technique for Single‐Site Polymerization Catalysts

Summary: Silica‐supported single‐site catalysts show limitations with respect to catalyst homogeneity and maximum metal content. A novel emulsion‐based catalyst heterogenization concept is described, which allows these limitations to be overcome. The method produces catalyst particles with an inherently perfect spherical shape and unique intra‐ and inter‐particle homogeneity. The catalyst particles are very compact and have a low surface area. Video microscopic studies confirm that the improved catalyst homogeneity leads to a more uniform polymerization behavior on a single particle level. The catalysts contain significantly more complex, compared to silica‐supported catalyst systems, which leads to correspondingly higher catalyst activities. No differences, in terms of the mass‐transfer kinetics of these low‐porosity catalysts, compared to porous catalyst systems have been observed.

Electron microscopy image of self‐supported single‐site catalyst prepared by the emulsion‐based method.     

In‐Line Monitoring and Control of Conversion and Weight‐Average Molecular Weight of Polyurethanes in Solution Step‐Growth Polymerization Based on Near Infrared Spectroscopy and Torquemetry

Summary: It is well known that the weight‐average molecular weight ( ) is strictly dependent on conversion in step‐growth polymerizations performed in batch and that the is very sensitive to impurities and molar imbalance. This makes the work of controlling a non trivial job. In this paper a new methodology is introduced for in‐line monitoring and control of conversion and of polyurethanes produced in solution step‐growth polymerizations, based on near‐infrared spectroscopy (NIRS) and torquemetry. A calibration model based on the PLS method is obtained and validated for monomer conversion, while the weight‐average molecular weight is monitored indirectly with the relative shear signal provided by the agitator. Control procedures are then proposed and implemented experimentally to avoid gelation and allow for maximization of . The proposed monitoring and control procedures can also be applied to other step growth polymerizations.

Proposed control scheme.     

Behavior of Active Sites in a Changing,Supported Metallocene Catalyst Particle: Modeling Monomer Transport and Kinetics

Summary: Support‐catalyst‐polymer particles composed of millions of microparticles arranged in cells and having silica nuclei covered with metallocene‐methyl alumoxane (MAO) active sites are studied to analyze cell participation during polymerization. Main variables are the changing particle morphology and the kinetic‐diffusion effects determining local monomer availability during residence time. The phenomena were studied by means of a mathematical model used to produce a set of predictions for particles polymerizing ethylene in a toluene slurry continuous stirred tank reactor (CSTR) under various operating conditions. This information is employed to predict the micro‐ and macroparticle behavior in situations designed to explore catalyst activities, monomer availabilities and reactor conditions. Kinetic constants and concentrations range from reference values up to 6 times these figures, with reactor temperatures between 323 and 353 K and particle Reynolds numbers on a 1 to 10 relative scale. Heat transfer and temperature elevation during polymerization are predicted, with no relevant overheating observed. Morphology changes, in the form of density profiles inside the support‐catalyst‐polymer particle, are monitored with time, and their interaction with transport and reaction phenomena analyzed. Increasing catalyst activity alone may not produce proportional raises in yield; it appears more efficient to improve the monomer availability instead. High catalyst activity may produce monomer depletion at inner cells delaying their fragmentation and decreasing local polymer‐production.

Cell density vs. time for cells located at the exterior, at the center and at half the radius of the macroparticle.     

Spherical Pseudo‐Inverse Opal Silica with Pomegranate‐Like Polymer Microparticles as Templates

Spherical silica particles with pseudo‐inverse opal structure are synthesized by using pomegranate‐like polymer microparticles as templates. A micro‐dispersion polymerization occurring in the suspended monomer droplets in the presence of a silica precursor leads to the formation of nearly monodisperse polymer sub‐particles of about 1 µm size, randomly‐packed within a 30–100 µm polymer particle. The polymerization is followed by an acid‐catalyzed reaction that induces formation of silica in the interstices between the sub‐particles within a polymer particle. Spherical PIOS particles are eventually produced by selectively removing the polymer template by pyrolysis. The PIOS particles show large specific surface areas with unique pore geometry and pore size distribution.

     

Compatibilization of Poly(propylene)/Polyamide 6 Blends with Functionalized Poly(propylene)s Prepared with Metallocene Catalyst

Summary: Propylene was copolymerized with 10‐undecen‐1‐ol using dimethylsilanylbis(2‐methyl‐4‐phenyl‐1‐indenyl)zirconium dichloride as catalyst and MAO and TIBA as cocatalysts. Comonomer incorporations from 0.1 to 0.9 mol‐% (0.5 to 3.6 wt.‐%) were obtained. These hydroxyl functionalized copolymers were applied as compatibilizers to PP/PA6 blend with a composition of 70/30. For comparison, hydroxyl functionalized polyethylene prepared with metallocene catalyst and commercial MAH grafted ethylene butyl acrylate (E/BA/MAH) and poly(propylene) (PP‐g‐MAH) were also used as compatibilizers. Effects of the compatibilizers on morphology and mechanical and thermal properties of the blends were studied. Enhanced adhesion between the blend components was observed in morphology and dynamic mechanical studies. Although improvement in toughness was not as pronounced as expected, there were indications that the hydroxyl functionalized propylene copolymers prepared with metallocene catalysts could serve as a new type of compatibilizer in polymer blends.

SEM micrograph (5 000×) of an PP/PA6/PP‐co‐OH4 blend.     

Steady‐State Model for Olefin Polymerization With a Two‐Site Vanadium Catalyst in a Continuous Stirred‐Tank Reactor

Summary: In this study, a process for continuous EP(D)M production is examined and a mechanistic kinetic model is developed to explain the behavior exhibited by this vanadium‐catalyzed solution polymerization process. The catalyst system without promoter and without hydrogen, produces polymer with bimodal molecular weight distributions (MWDs), while the addition of catalyst promoter causes an order of magnitude increase in catalyst productivity and eliminates the higher‐MW component in the MWD. The addition of hydrogen also precludes bimodal MWDs, regardless of the presence of promoter. In all cases, the polymerization rate has a zero‐order rather than a first‐order response to monomer concentration. The zero‐order response of polymerization rate to monomer concentration is described using a mechanism of monomer coordination to form a stable complex prior to insertion. The bimodal MWDs at high monomer feeds (corresponding to low monomer conversion), in the absence of catalyst promoter and hydrogen, are explained by a two‐site type catalyst model in which both monomer insertion and the formation of the second‐site type occur after the monomer forms a stable coordinated complex with the first catalyst site type. The model reconciles the molecular weight development with these seldom‐discussed features of vanadium catalysis.

Propylene acting as a coordinating ligand at a coordinatively unsaturated vanadium catalyst site (adapted from ref.^[7]).     

A Novel Process for Ultrasound‐Induced Radical Polymerization in CO2‐Expanded Fluids

Summary: A strong viscosity increase upon polymerization hinders cavitation and subsequent radical formation during an ultrasound‐induced bulk polymerization. In this work, ultrasound‐induced radical polymerizations of methyl methacrylate (MMA) have been performed in CO₂‐expanded MMA in order to reduce the viscosity of the reaction mixture. For this purpose, the phase behavior of CO₂/MMA systems has been determined. With temperature oscillation calorimetry, the influence of CO₂ on the viscosity and on the reaction kinetics of ultrasound‐induced polymerizations of MMA has been studied. In contrast to polymerizations in bulk, this technique shows that a low viscosity is maintained during polymerization reactions in CO₂‐expanded MMA. As a consequence, a constant or even increasing polymerization rate is observed when pressurized CO₂ is applied. Moreover, the ultrasound‐induced polymer scission in CO₂‐expanded MMA is demonstrated, which appears to be a highly controlled process. Finally, a preliminary sustainable process design is presented for the production of 10 kg/h pure PMMA (specialty product) in CO₂‐expanded MMA by ultrasound‐induced initiation.

Process flow diagram of the ultrasound‐induced polymerization of MMA in CO₂‐expanded MMA.     

Nylon 6‐Polyesteramide Block Copolymers (NBC) and NBC/Phenolic Resin Composites, 1

Summary: A series of NBC/phenolic resin composites, containing 0, 1, 3, 5 or 7 wt.‐% of a powdered phenolic resin of different particle diameter, was prepared by the reaction injection molding (RIM) process. It was determined by SEM analysis that there exists a strong interaction between particles and matrix and that such interaction occurs through hydrogen‐type bonds as determined by FTIR analysis. According to the results it is thought that the glass transition temperature of the NBC/phenolic resin composites depends on two competing factors: the rigidity promoted by the hard solid filler and the flexibility imparted by the nylon 6 amorphous phase, whose proportion becomes more important with increasing amounts of phenolic resin particles. The elastic and flexural moduli of the NBC were improved by the addition of phenolic resin confirming the reinforcing effect of this filler. On the contrary, the impact strength diminishes with increasing amounts of phenolic resin, although this property is strongly dependent on the particle diameter.

SEM micrograph of the nylon 6‐polyesteramide block copolymer (80/20).     

Radiation‐Induced Graft Copolymerization of Styrene into Tetrafluoroethylene‐Hexafluoropropylene‐Vinylidene Fluoride (THV) Terpolymer Films

The objective of this work was to investigate the influence of irradiation conditions on grafting of styrene into tetrafluoroethylene‐hexafluoropropylene‐vinylidene fluoride (THV) terpolymer films. Stress–strain measurements, infrared spectroscopy and electron paramagnetic resonance spectroscopy have been used to characterize the pre‐irradiated polymer films regarding tensile strength, elongation at break, changes in the chemical structure and concentration of trapped radicals, respectively. Main‐chain scissions associated with the formation of carbonyl end groups and end‐chain double bond structures have been identified to be the reason for a moderate deterioration of the mechanical properties of the pre‐irradiated films. The yield of grafting has been found to be influenced by THV grade, irradiation temperature and concentration of cross‐linker.

     

Synthesis and Characterization of Biodegradable Poly(ε‐caprolactone)‐Polyglycolide‐Poly(ethylene glycol) Monomethyl Ether Random Copolymer

Summary: Poly(ε‐caprolactone)‐polyglycolide‐poly(ethylene glycol) monomethyl ether random copolymers were synthesized from ε‐caprolactone (ε‐CL), glycolide (GA) and poly(ethylene glycol) monomethyl ether (MPEG) using stannous octoate as catalyst at 160 °C by bulk polymerization. The copolymers with different composition were synthesized by adjusting the weight ration of reaction mixture. The resultant copolymer with a weight ratio (10:15:75) of MPEG2000, GA, and CL was characterized by IR, ¹H NMR, GPC and DSC. The new biodegradable copolymer has potential for medical applications since it is combined with properties of PCL, PGA and MPEG.

     

Preparation of Nano‐Polyethylene Fibers and Floccules by Extrusion Polymerization Under Atmospheric Pressure Using the SBA‐15‐Supported Cp2ZrCl2 Catalytic System

Summary: Nano‐polyethylene fibers and floccules were prepared under atmospheric pressure via ethylene extrusion polymerization in suit, using the SBA‐15‐supported Cp₂ZrCl₂ catalytic system. The major morphology units in the samples were fibers and floccules. The diameter of the single nano‐fibers was 120–200 nm. The single nano‐fibers could aggregate to form fiber aggregates and bundles. The number of PE floccules increased with extension of polymerization time, while the melting point of PE with nano‐fibers was little higher than that of common polyethylene.

SEM micrograph of the nano‐polyethylene fibers produced at a polymerization time of 60 min: micro‐fibers and floccule surface morphologies.     

Chemical Kinetics,Simulation, and Thermodynamics of Glycolytic Depolymerization of Poly(ethylene terephthalate) Waste with Catalyst Optimization for Recycling of Value Added Monomeric Products

Reaction of poly(ethylene terephthalate) (PET) waste powder with ethylene glycol (EG) was carried out in a batch reactor at 1 atm pressure and at various temperatures ranging from 100–220 °C at the intervals of 10 °C. Particle size from 50–512.5 μm, reaction time from 30–150 min, amount of catalyst from 0.001–0.009 mol, and type of catalysts required for glycolysis of PET were optimized. To increase the PET weight (%) loss, various external catalysts were introduced during the reaction at different reaction parameters. Depolymerization of PET was increased with reaction time and temperature. Depolymerization of PET was decreased with increase in the particle size of PET. Reaction rate was found to depend on concentrations of liquid ethylene glycol and ethylene diester groups in the polyester. Analyses of value added monomeric products (DMT and EG) as well as PET were undertaken. Yields of monomers were agreed with PET conversion. A kinetic model was proposed and simulated, and observed consistent with experimental data. Comparisons of effect of various amounts of catalysts and type of catalysts on glycolysis rate were undertaken. Dependence of the rate constant on reaction temperature was correlated by Arrhenius plot, which shows activation energy of 46.2 kJ/mol and Arrhenius constant of 99 783 min^?1.

Arrhenius plot of the rate constant of glycolysis at 1 atm pressure for 127.5 μm PET particle size (KZA = rate constant using zinc acetate as a catalyst, KMA = rate constant using manganese acetate as a catalyst).     

Influence of Screw Speed on Electrical and Rheological Percolation of Melt‐Mixed High‐Impact Polystyrene/MWCNT Nanocomposites

The influence of screw speed on the electrical and rheological percolation of HIPS/MWCNT composites prepared via melt mixing was investigated. Microscopic examination of these composites using POM, FESEM and HRTEM revealed optimum MWCNT dispersion was achieved at intermediate screw speeds. On addition of MWCNTs to HIPS, the electrical conductivity of HIPS increased by up to 12 orders of magnitude. At screw speeds up to 100 rpm an electrical percolation of 1–3 wt.‐% was achieved. This increased to 3–5 wt.‐% when the screw speed was increased to 150 rpm. The onset of a rheological percolation was detected for an MWCNT loading of 5 wt.‐%, irrespective of screw speed employed. An up‐shift in the Raman G‐band of 24 cm^?1 was observed, implying strong interfacial interaction between HIPS and MWCNTs.

     

Novel Poly(N‐isopropylacrylamide)‐graft‐poly(vinylidene fluoride) Copolymers for Temperature‐Sensitive Microfiltration Membranes

In the present work, we report on the synthesis and characterization of poly(vinylidene fluoride) (PVDF) with N‐isopropylacrylamide (NIPAAM) polymer side chains from molecular graft copolymerization in solution. The copolymer can be readily cast into temperature‐sensitive microfiltration (MF) membranes by the phase inversion technique. The copolymer approach to membrane fabrication allows a much better control of the physicochemical nature of the membrane pores through the variation in graft concentration, membrane casting temperature and concentration of the membrane casting solution.

     

Production of Narrow‐Size‐Distribution Polymer‐Pigment‐Nanoparticle Composites via Electrohydrodynamic Atomization

Near‐monodisperse, size‐controllable, poly(methyl methacrylate)‐pigment nanoparticle composites were produced using electrohydrodynamic atomization (EHDA). The geometric mean diameters of the composite particles were in the 0.91 to 1.90 µm‐diameter range with geometric standard deviations of approximately 1.05 to 1.12. Increasing the polymer volume fraction and liquid flow‐rate resulted in an increase in the diameter of the composite particles, which agreed well with droplet scaling relations for EHDA. The results here demonstrate that EHDA can be used for polymer‐nanoparticle‐composite production and as an alternative to conventional inkjet printing.

     

Flexible Use of Single‐Screw Extruders through Multiple‐Process Optimization

Using general‐purpose screws to process different types of material offers considerable cost advantages over special‐purpose screws. Designing screws of this type is generally a difficult task, since modifications to different aspects of the geometry can run counter to each other in some cases. Optimization software is thus of particular benefit here. For this reason, a program was developed for the optimization of general‐purpose screws. A central feature of this program is an appraisal system for the computer‐aided evaluation of single‐screw simulations. The performance of the software was verified on the basis of actual extrusion experiments.

Temperature measuring cross for measuring thermal homogeneity.     

Design of a Microfluidic System to Investigate the Mechanical Properties of Layer‐by‐Layer Fabricated Capsules

A microfluidic system was designed, fabricated and implemented to study the behavior of polyelectrolyte capsules flowing in microscale channels. The device contains microchannels that lead into constrictions intended to capture polyelectrolyte microcapsules which were fabricated with the well‐known layer‐by‐layer (LbL) assembly technique. The behavior of hollow capsules at the constrictions was visualized and the properties of the capsules were investigated before and after introduction into the device.

Time series of video frames showing capsules being compressed into a constriction.     

Effect of Silica‐Coated Poly(butyl methacrylate)‐block‐poly(methyl methacrylate) Double‐Shell Particles on the Mechanical Properties of PMMA Composites

Silica nanoparticles with an average diameter of 12 nm are grafted with PBMA‐b‐PMMA double shells through typical sequential ATRP from bromoisobutyrate initiators anchored at the silica surface using an epoxysilane. A commercially available PMMA homopolymer is used for the preparation of composites with unmodified, silane‐modified and double‐shell‐modified silica particles. Good mechanical properties are obtained for silica double shell containing systems. The silica content in double shell particle systems is varied from 0 to 2.5 wt%. A significant improvement in impact properties is observed. The surface‐modified silica particles are characterized by ATR‐FTIR, NMR, GPC, and thermal analyses. TEM analysis is used to analyze the nature of dispersion of particles in the composites.

     

Studies on Hydrotalcite‐Catalyzed Synthesis of Poly(ethylene terephthalate)

Summary: The hydrotalcite‐catalyzed synthesis of PET was studied to clarify the effect of hydrotalcite properties on its catalytic activity. Hydrotalcite was modified by various treatments to tune its activity as a polycondensation catalyst. Hydrotalcite activity was found to decrease upon calcination. However, rehydration of the calcinated hydrotalcite resumed the catalytic activity. The hydrotalcite activity depends on the ratio of magnesium to aluminum cations in its composition, and highest activity occurs at a molar ratio of 2:1. Replacement of the carbonate anions of hydrotalcite by more nucleophilic ones like hydroxide and alkoxide groups resulted in improved catalytic activity. Hydrotalcite has two assembly orders: primary lamination of sheets into plates and secondary agglomeration of plates into particles. Hydrotalcite with larger sheet size showed lower activity. On the other hand, milling of hydrotalcite particles did not affect its activity as it probably enters the reaction on a plate level, which is not affected by milling. Polycondensation resulted in expansion of the hydrotalcite sheets under the effect of formed polymer. Reuse of hydrotalcite after polycondensation followed by depolycondensation resulted in a large activity enhancement.

High‐resolution SEM micrograph of calcinated HT after rehydration.     

UV‐Induced Cross‐Linking of Poly(ethylene oxide) in Aqueous Solution

Summary: Hydrogels of high‐molecular‐weight poly(ethylene oxide) (PEO) have been obtained in situ by applying a very simple procedure that involves UV cross‐linking of PEO in aqueous solution. The efficiency of the photoactivated cross‐linking of thin layers of PEO in aqueous solution in the presence of (4‐benzoylbenzyl) trimethylammonium chloride as a photoinitiator has been determined at room temperature and in a frozen state (?25 °C). It was found that the efficiency varies with the concentration of PEO solution, the molecular weight of PEO, and especially with the temperature. When the UV cross‐linking was performed in the frozen state, porous hydrogels with very high yield of gel fraction (above 90%) and high cross‐linking density were obtained. After drying the hydrogels, films of 50–150 μm thickness were prepared. The films swell extremely fast in water and act as asymmetric membranes.

SEM of a dried PEO hydrogel obtained by UV cross‐linking of an aqueous solution at room temperature.