Thin Layer Copolymerization of Methyl methacrylate and Butyl acrylate in Concentrated Emulsion

Summary In this study, stable concentrated emulsions of methyl methacrylate and butyl acrylate (MMA-BA) were first prepared using sodium dodecyl sulfate/cetyl alcohol (SDS/CA) as composite surfactants and polyvinyl alcohol (PVA) as liquid film reinforcer. A novel polymerization method, thin layer copolymerization of the concentrated emulsion was subsequently carried out with benzoyl peroxide/N, N’-dimethyl phenylamine (BPO/DMA) as redox initiators at low temperature. The effects of the thickness and area of the thin layer, the outside temperature, as well as environment of the polymerization on the amount of volatilization of water and monomer in the system were investigated. It has been found that the liquid film reinforcers and the polymerization environment were responsible for the polymerization stability. In addition, the conversion-time relationships of the thin layer polymerization and the tube polymerization, as well as the effect of polymerization environment on the polymerization rate were also investigated. The size and distribution of particle diameter and morphology of latex particles were determined with transmission electron microscope (TEM).     

Concentrated emulsion copolymerization of butyl acrylate and vinyl acetate initiated by a redox initiator at lower temperature

The concentrated emulsion copolymerization of butyl acrylate and vinyl acetate with an ammonium persulfate/sodium hydrogen sulfate mixture as a redox initiator, with a sodium dodecyl sulfate/cetyl alcohol mixture as a compound surfactant, and with poly(vinyl alcohol) as a liquid film reinforcer was carried out at lower temperature. In less than 3 h, the polymerization conversion was greater than 95%. The effects of the surfactant, the initiator, the volume fraction of the monomer, and the temperature on the stability of the concentrated emulsion, the kinetic process, and the average size of the latices were examined. The morphology of the polymer particles was observed by transmission electron microscopy, and the average size and distribution of the particle diameter were measured by photon correlation spectroscopy. The kinetic equation was R_p = k[M]^0.38[I]^0.89[E]^?0.80 at 30°C (where R_p is the polymerization rate, [I] is the initiator concentration, [M] is the monomer concentration, and [E] is the concentration of the compound surfactant), and the apparent activation energy was 22.69 kJ/mol. The thin‐layer polymerization of the concentrated emulsions, which enabled the removal of the heat of polymerization, was performed first. In comparison with test‐tube polymerization, thin‐layer polymerization provided a more regular morphology of the polymer particles. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 570–576, 2004     

Concentrated emulsion polymerization of methyl methacrylate/butyl acrylate initiated by a redox system

Stable concentrated emulsions of methyl methacrylate/butyl acrylate were prepared with sodium dodecyl sulfate and cetyl alcohol as the compound surfactant and poly(vinyl alcohol) as the major reinforcer of the liquid film. With a redox system based on benzoyl peroxide/N,N′‐dimethyl phenylamine introduced into the concentrated emulsions, polymer particles with different shapes and sizes were obtained by initiation of the polymerization at low temperatures. We investigated the kinetic behaviors of concentrated emulsion polymerization and drew linear regression diagrams of its time–conversion curves in a constant rate phase (conversions ranged from 20 to 70%), and the experimental results show that the variation of the concentrations of the compound surfactant and initiator, the categories of reinforcers of the liquid film, the temperatures, and so on were responsible for the polymerization stability and the polymerization rate. Finally, the kinetics equation and activation energy of the initiator were obtained. The particle size and distribution of particle diameters of latex particles were determined by photon correlation spectroscopy. The determination results reveal that concentrations of the compound surfactant, polymerization temperatures, and so on affected the shape and size of the polymer particles greatly. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 1695–1701, 2005     

Radical/Addition polymerization silicone hydrogels with simultaneous interpenetrating hydrophilic/hydrophobic networks

Transparent silicone hydrogels with interpenetrating hydrophilic/hydrophobic networks were simultaneously synthesized on the basis of the radical polymerization of the methacrylic monomer of 3‐methacryloxypropyl tris(trimethylsiloxy) silane (TRIS)/N,N‐dimethylacrylamide (DMA) and the addition polymerization of hydroxyl‐grafted polysiloxane (HPSO)/isophorone diisocyanate. The curing temperature was set at 80°C by a differential scanning calorimetry study. The polymerization process was studied by in situ Fourier transform infrared spectroscopy. The results indicate that the curing time was about 4.5 min, and the addition polymerization had a faster rate than radical polymerization. Then, the radical polymerization rate increased rapidly, and this led to instant curing. The interpenetrating polymer network (IPN) silicone hydrogels were characterized by swelling kinetics and dynamic mechanical thermal analysis. The results show that all of the hydrogels reached swelling equilibrium at about 4 h in water, and the IPN silicone hydrogels with a hydrophobic network of HPSO indicated a slower water transport than that of the copolymerization hydrogel of DMA and TRIS. The hydrophobic network was finely dispersed in the hydrophilic network, and the increasing hydrophobic network of HPSO decreased the glass‐transition temperature of the IPN silicone hydrogels. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41399.     

Free‐radical terpolymerization of n‐butyl acrylate/butyl methacrylate/d‐limonene

d ‐Limonene (Lim) is a renewable monoterpene derived from citrus fruit peels. We investigated it for use as part of a more sustainable polymer formulation. The bulk free‐radical terpolymerization of n‐butyl acrylate (BA)/butyl methacrylate (BMA)/Lim was carried out at 80°C with benzoyl peroxide as the initiator. The terpolymerization was studied at various initial BA/BMA/Lim molar ratios, and the products were characterized for conversion, terpolymer composition, molecular weight, and glass‐transition temperature. Lim was observed to undergo a significant degradative chain‐transfer reaction, which greatly influenced the polymerization kinetics. The rate of polymerization, final conversion, and polymer molecular weight were all significantly reduced because of the presence of Lim. Nonetheless, polymers with relatively high weight‐average molecular weights (20,000–120,000 Da) were produced. The terpolymer composition was well predicted with the reactivity ratios estimated for each of the three copolymer subsystems. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42821.     

Interfacial‐initiated seeded emulsion polymerization: preparation of polystyrene/poly(methacrylic acid) core/shell particles in the absence of surfactant

Composite polymer particles with hydrophobic polystyrene (PSt) as the core and hydrophilic poly(methacrylic acid) (PMAA) as the shell were prepared through two‐stage emulsion polymerization without any surfactant. In the first step, narrowly distributed PSt seed particles were prepared by surfactant‐free emulsion polymerization with 2,2′‐azobis(2‐methylpropionamide) dihydrochloride (AMPA) as the initiator. In the second step, hydrophilic PMAA shells were fabricated onto PSt seed particles through redox interfacial‐initiated seeded emulsion polymerization with cumyl hydroperoxide (CHPO)/ferrous sulfate/ethylenediaminetetraacetic acid (EDTA)/sodium formaldehydesulfoxylate (SFS), where the initiation took place mainly at the interface between PSt seed particles and the aqueous medium. The composite particles were characterized with transmission electron microscopy, fourier transform infrared spectroscopy and dynamic light scattering, and the results show that a core/shell structure was successfully built. Hydrodynamic radius (R_h) of the composite particles increased with the amount of polymerized monomers in the seeded emulsion polymerization. Copyright © 2006 Society of Chemical Industry     

Emulsion polymerization of tetrafluoroethylene: effects of reaction conditions on the polymerization rate and polymer molecular weight

The emulsion polymerization of tetrafluoroethylene (TFE) was carried out in a semibatch reactor using a chemical initiator (ammonium persulfate) and a fluorinated surfactant (FC-143). The effects of the reaction condition were investigated though the polymerization rate, molecular weight of polytetrafluoroethylene (PTFE), and stability of the dispersion. The emulsion polymerization of TFE was different from conventional emulsion polymerization. The polymerization rate was suppressed when the polymer particles were significantly coagulated. The polymerization rate increased with operating temperature, surfactant concentration, and agitation speed, due to the enhanced stability of the polymer particles. However, once the parameter value was reached, the rate decreased due to the coagulation of the particles. Stable PTFE dispersion particles were obtained when the surfactant concentration was in the range between 3.48 × 10⁻³ and 32.48 × 10⁻³ mol/liter, which is below critical micelle concentration (CMC). The molecular weight of the PTFE obtained was a function of the surfactant and initiator concentrations, and the polymerization temperature. The molecular weight increased as each parameter decreased. This is against the phenomena observed in a conventional emulsion polymerization. A stable PTFE dispersion polymer having a high molecular weight was obtained by optimizing the reaction conditions. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 73: 777–793, 1999     

Synthesis and characterization of polystyrene/layered double‐hydroxide nanocomposites via in situ emulsion and suspension polymerization

Polystyrene (PS)/ZnAl layered double‐hydroxide (LDH) nanocomposites were synthesized via in situ emulsion and suspension polymerization in the presence of N‐lauroyl‐glutamate surfactant and long‐chain spacer and characterized with elemental analysis, Fourier transform infrared spectrum, X‐ray diffraction (XRD), transmission electron microscopy (TEM), and thermogravimetric analysis. The XRD and TEM results demonstrate that the exfoliated ZnAl–LDH layers were well dispersed at molecular level in the PS matrix. The completely exfoliated PS/LDH nanocomposites were obtained even at the 20 and 10 wt % LDH loadings prepared by emulsion polymerization and suspension polymerization, respectively. The PS/LDH nanocomposites with a suitable amount of LDH showed apparently enhanced thermal stability. When the 50% weight loss was selected as a comparison point, the decomposition temperature of the exfoliated PS/LDH sample prepared by emulsion polymerization with a 5 wt % LDH loading was about 28°C higher than that of pure PS. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 3758–3766, 2006     

Reverse atom transfer radical polymerization of n‐butyl methacrylate in an aqueous dispersed system

Reverse atom transfer radical polymerization (ATRP) of n‐butyl methacrylate (BMA) was conducted in an aqueous dispersed system. The influence of the surfactant, catalyst, reaction time and temperature on the colloidal stability and the control of polymerization was investigated. As a result, using an azo initiator (AIBN), a non‐ionic surfactant (Brij 35) and a hydrophobic ligand (dNbpy) to complex a copper halide, polymers with predetermined molecular weight and low polydispersity were obtained as stable latexes. Copyright © 2004 Society of Chemical Industry     

Reverse atom‐transfer radical polymerization of acrylonitrile catalyzed by FeCl3/iminodiacetic acid

FeCl₃ coordinated by iminodiacetic acid (IMA) was Changed used for the first time as the catalyst in azobisisobutyronitrile‐initiated reverse atom‐transfer radical polymerization (ATRP) of acrylonitrile (AN). An FeCl₃ to IMA ratio of 1:2 not only gave the best control of molecular weight and its distribution but also provided a rather rapid reaction rate. The effects of solvents on the polymerization of AN were also investigated. The rate of the polymerization in N,N‐dimethylformamide (DMF) was faster than in propylene carbonate or toluene. The molecular weight of polyacrylonitrile agreed reasonably well with the theoretical molecular weight in DMF. The rate of polymerization increased with increasing polymerization temperature and the apparent activation energy was calculated to be 54.8 kJ mol⁻¹. The reverse ATRP of AN did not show obvious living characteristics with CuCl₂ instead of FeCl₃. Copyright © 2005 Society of Chemical Industry     

Synthesis and characterization of poly(n‐butyl methacrylate)‐b‐polystyrene diblock copolymers by atom transfer radical emulsion polymerization

Poly(n‐butyl methacrylate) (PBMA)‐b‐polystyrene (PSt) diblock copolymers were synthesized by emulsion atom transfer radical polymerization (ATRP). PBMA macroinitiators that contained alkyl bromide end groups were obtained by the emulsion ATRP of n‐butyl methacrylate with BrCH₃CHCOOC₂H₅ as the initiator; these were used to initiate the ATRP of styrene (St). The latter procedure was carried out at 85°C with CuCl/4,4′‐di(5‐nonyl)‐2,2′‐bipyridine as the catalyst and polyoxyethylene(23) lauryl ether as the surfactant. With this technique, PBMA‐b‐PSt diblock copolymers were synthesized. The polymerization was nearly controlled; the ATRP of St from the macroinitiators showed linear increases in number‐average molecular weight with conversion. The block copolymers were characterized with IR spectroscopy, ¹H‐NMR, and differential scanning calorimetry. The effects of the molecular weight of the macroinitiators, macroinitiator concentration, catalyst concentration, surfactant concentration, and temperature on the polymerization were also investigated. Thermodynamic data and activation parameters for the ATRP are also reported. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 98: 2123–2129, 2005     

Effects of surfactants on acrylonitrile polymerization initiated by a Cr(VI)–cyclohexanone redox system: A kinetic study

The polymerization of acrylonitrile (AN) was kinetically studied with a Cr(VI)–cyclohexanone (CH) redox system as an initiator from 25 to 45° C in the presence of a surfactant. The rate of polymerization and the percentage of the monomer conversion increased as the concentration of the anionic surfactant [sodium dodecyl sulfate (SDS)] increased above its critical micelle concentration. However, the cationic surfactant (cetyltrimethylammonium bromide) reduced the rate considerably at higher concentrations, whereas the nonionic surfactant (TX‐100) had no effect on the rate. The effects of the Cr(VI), CH, AN, and H⁺ concentrations and the ionic strength on the rates were also examined. The presence of 0.015M SDS reduced the overall activation energy of the polymerization by 5.55 kcal/mol with respect to that in the absence of the surfactant. With increasing SDS concentration, the viscosity‐average molecular weight also increased. A suitable mechanistic scheme was proposed for the polymerization process. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 1147–1153, 2004     

Nucleation mechanism and morphology of polystyrene/Fe3O4 latex particles via miniemulsion polymerization using AIBN as initiator

In this study, oil‐based magnetic Fe₃O₄ nanoparticles were first synthesized by a coprecipitation method followed by a surface modification using lauric acid. Polystyrene/Fe₃O₄ composite particles were then prepared via miniemulsion polymerization method using styrene as monomer, 2,2′‐azobisisobutyronitrile (AIBN) as initiator, sodium dodecyl sulfate (SDS) as surfactant, hexadecane (HD) or sorbitan monolaurate (Span20®) as costabilizer in the presence of Fe₃O₄ nanoparticles. The effects of Fe₃O₄ content, costabilizer, homogenization energy during ultrasonication, and surfactant concentration on the polymerization kinetics (e.g., conversion), nucleation mechanism, and morphology (e.g., size distributions of droplets and latex) of composite particles were investigated. The results showed that at high homogenization energy, an optimum amount of SDS and hydrophobic costabilizer was needed to obtain composite particles nucleated predominately by droplet nucleation mechanism. The morphology of the composite particles can be well controlled by the homogenization energy and the hydrophobicity of the costabilizer. The magnetic composite particles can be made by locating Fe₃O₄ inside the latex particles or forming a shell layer on their PS core surface depending on the aforementioned polymerization conditions. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Preparation and properties of polydimethylsiloxane/polyacrylate composite latex initiated by 60Co γ‐ray irradiation

In this study, polydimethylsiloxane (PDMS)/polyacrylate composite polymer latex was synthesized via polymerization of the acrylate monomer in the presence of vinyl‐containing PDMS seeded latex. The polymerization was initiated by ⁶⁰Co γ‐ray irradiation. The morphology of the PDMS/polyacrylate composite polymer latex was a core–shell structure with PDMS as the core and polyacrylate as the shell. There was an interpenetration layer between the PDMS core and the polyacrylate shell. The composition of the vinyl‐containing PDMS and the PDMS/polyacrylate composite latex were investigated with NMR and Fourier transform infrared spectroscopy, respectively. The effect of irradiation dose on the seeded emulsion polymerization conversion is discussed. Finally, the mechanical properties of latex film, such as water‐absorption ratio, tensile strength, pendulum hardness, and heat‐decomposed temperature, were tested. The results showed that the mechanical properties of the PDMS/polyacrylate film were remarkably improved when compared to the polyacrylate film. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 2732–2736, 2003     

Modeling for primary radical desorption in miniemulsion polymerization initiated by oil‐soluble initiator

Primary radical (PR) desorption in the miniemulsion polymerization initiated by oil‐soluble initiator was investigated. Both the aqueous phase inhibition experiments and the theoretical predictions, which combined the two film theory and aqueous phase mass balance, were performed to evaluate the PR desorption process quantitatively. The theoretical predictions agreed well with the experiment results. It was found that the organic phase diffusion, particle size, surfactant layer, aqueous phase resistance, and different initiator type affected the PR desorption. The desorption rate of PR was faster than its reaction rate at the early stage of polymerization, while the former decreased to a comparable level as the latter at the high conversion. PR was prone to desorb in the polymerization and the desorption of PR played a critical role in the miniemulsion polymerization initiated by oil‐soluble initiator. It is concluded that the PR desorption–reabsorption is a process to generate effective radicals in the miniemulsion polymerization initiated by oil‐soluble initiator. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3276–3285, 2014     

Soap‐free emulsion copolymerization of perfluoroalkyl acrylates in the presence of a reactive surfactant

Soap‐free emulsion copolymerization of perfluoroalkyl acrylate (FA)/methyl methacrylate (MMA)/n‐butyl acrylate (n‐BA) was carried out in the presence of sodium 2‐acrylamide‐2‐methyl propanesulfonate (AMPSNa) as a reactive surfactant and potassium persulfate (KPS) as an initiator. An analysis of the effects of concentration of AMPSNa, KPS, FA as well as polymerization temperature on the kinetic features (rate of polymerization) and colloidal characteristics (mean particle diameter, particle disperse index, particle numbers, and surface charge density) was followed. NMR, FTIR, AFM, and fluorine‐selective electrode analysis were used to characterize the composition and morphology of the FA copolymers. Both AFM analysis and contact angle measurements strongly implied that the fluorinated segments migrated to the outmost surface and created films with lower surface energy. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 2438–2444, 2007     

Aqueous polyacrylate/poly(silicone‐co‐acrylate) emulsion coated fertilizers for slow nutrient‐release application

Waterborne polyacrylate/poly(silicone‐co‐acrylate) emulsions were synthesized to develop coated fertilizers. The effects of the n‐butyl acrylate (BA)/methyl methacrylate (MMA) ratio, vinyltriethoxysilane, and synthesis method on the water resistance, glass‐transition temperature, mechanical properties, and nutrient‐release profiles were investigated. The results show that miniemulsion polymerization with a BA/MMA ratio of 55:45 was the most suitable for slow nutrient‐release applications. Under these conditions, the preliminary solubility rate of the nutrient was about 3%, and the 30‐day cumulative nutrient release was 15% at 25°C. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40369.     

Mass transfer and radical flux effects in dispersed‐phase polymerization of isooctyl acrylate

The kinetics of dispersed phase polymerization of a highly water‐insoluble monomer (isooctyl acrylate) were explored in emulsion, miniemulsion, and microsuspension polymerization. The effects of monomer water solubility and choice of initiator (oil‐ vs. water‐soluble) strongly impact the final product (particle size and molecular weight distribution). For emulsion polymerization, as the surfactant concentration was increased, there was a transition from homogenous to micellar nucleation near the CMC, then a drop in nucleation rate at high surfactant concentration due to insufficient radical flux to support more nucleation. For miniemulsion polymerization, a slow rate of growth of (droplet) nucleation with surfactant concentration was found, followed (at the CMC) by an increase in the rate of nucleation with added surfactant as the mode of nucleation switched to micellar. The conversion‐time kinetics of microsuspensions could be modeled with a bulk polymerization model. IOA is sufficiently insoluble in the aqueous phase that emulsion polymerization may or may not be reaction limited. The presence of a stabilizer such a PAA, the use of an oil‐soluble initiator such as BPO, and the insolubility of IOA in the aqueous phase all push the polymerization locus toward droplet (microsuspension) nucleation and bulk kinetics.© 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 5649–5666, 2006     

Emulsion polymerization of styrene with amphiphilic random copolymer as surfactant: Predominant droplet nucleation

Amphiphilic random copolymer consisting of monomeric units of poly (butyl acrylate) and poly (maleic acid salt) was synthesized and characterized. The emulsion polymerization kinetics of styrene stabilized by this copolymer was investigated. The influencing factors, including polymeric surfactant concentration, initiator concentration and polymerization temperature, were systematically studied. The kinetic data show that the polymerization rate (R_P) increased with the increase of the polymeric surfactant concentration ([S]) and polymerization temperature (T). At the higher [S], droplets nucleation and micelle nucleation coexisted in the polymerization system; at the lower [S], only the droplets nucleation process existed. The polymerization did not follow Smith‐Ewart Case II kinetics. Dynamic light scatter and transmission electron microscope were utilized to measure the sizes and shapes of the particles, respectively. It would be speculated that a kind of large heterogeneous particles with multiple‐active‐sites was formed in the polymerization system. The increasing of R_P with increasing initiator concentration ([KPS]) was rapid at a medium [KPS], but the slowly increasing was observed at a lower or higher [KPS]. It was attributed to the barrier effect of the polymeric surfactant around the monomer droplets. The polymerization activation energy was 60.29 kJ/mol. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Synthesis of well‐defined,functionalized polymer latex particles through semicontinuous emulsion polymerization processes

The design of a semicontinuous emulsion polymerization process, primarily based on theoretical calculations, has been carried out with the objective of achieving overall independent control over the latex particle size, the monodispersity in the particle size distribution, the homogeneous copolymer composition, the concentration of functional groups (e.g., carboxyl groups), and the glass‐transition temperature with n‐butyl methacrylate/n‐butyl acrylate/methacrylic acid as a model system. The surfactant coverage on the latex particles is very important for maintaining a constant particle number throughout the feed process, and this results in the formation of monodisperse latex particles. A model has been set up to calculate the surfactant coverage from the monomer feed rate, surfactant feed rate, desired solid content, and particle size. This model also leads to an equation correlating the polymerization rate to the instantaneous conversion of the monomer or comonomer mixture. This equation can be used to determine the maximum polymerization rate, only below or at which monomer‐starved conditions can be achieved. The maximum polymerization rate provides guidance for selecting the monomer feed rate in the semicontinuous emulsion polymerization process. The glass‐transition temperature of the resulting carboxylated poly(n‐butyl methacrylate‐co‐n‐butyl acrylate) copolymer can be adjusted through variations in the compositions of the copolymers with the linear Pochan equation. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 30–41, 2003