The effect of carboxylic monomers on surfactant-free emulsion copolymerization

A study was made of the effect of carboxylic monomers on the surfactant-free emulsion polymerization of styrene and styrene–butadiene. Acid monomers, such as acrylic acid, methacrylic acid, and itaconic acid, were shown to play a critical role in particle formation and particle stabilization in such systems. In the emulsion polymerization of styrene, methacrylic acid forms particles more efficiently than acrylic acid. This difference is attributed to the more hydrophobic nature of the methacrylic monomer which allows it to diffuse more rapidly to the particle surface where it acts to prevent agglomeration. The ability of carboxyl groups to orient at the particle–water interface was studied by acid–base and soap titrations of carboxylated styrene–butadiene latices. The polymerization of itaconic acid onto the particle surface of a styrene–butadiene latex produces a surface carboxyl density much higher than is obtainable with classically adsorbed surfactants. This result is used to explain the greater stability of carboxylated versus noncarboxylated emulsion polymers. During the polymerization of styrene–butadiene latices, carboxyl groups dervied from methacrylic acid are shown to be buried more deeply into the particle as compared to carboxyls derived from the more hydrophilic acrylic acid which orient more at the particle–water interface.     

Monosize polystyrene latices carrying functional groups on their surfaces

In this study, monosized polystyrene (PS) latices were prepared by dispersion polymerization of styrene in isopropanol-water media using poly(acrylic acid) (PAA) as a steric stabilizer and 2,2′-azobisizobutyronitrile (AIBN) as an initiator. The effects of initiator and stabilizer concentrations, alcohol/water and monomer/dispersion medium ratio on the polymerization kinetics, and the size and monodispersity of PS latices were experimented with in a stirred reactor system. Monosize PS beads in the size range of 1.0–3.0 μm were obtained. The PS latex obtained in the first step having a diameter of 2.3 μm were used as the seed latex, and styrene/acrylate monomers, acrylic acid (AA), 2-hydroxyethyl methacrylate (HEMA), and dimethylaminoethyl methacrylate (DMAEMA) were copolymerized onto the PS latex particles. The incorporation of functional groups to the surface and bulk structure of PS was confirmed by IR, FTIR, XPS, and zeta potential measurements. © 1994 John Wiley & Sons, Inc.     

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     

Effect of carboxylic monomers on acid distribution in carboxylated polystyrene latices

A study was made of the effect of carboxylic monomers, such as itaconic acid, acrylic acid, and methacrylic acid, on the relative distribution of acid in the aqueous serum phase to that on the latex surface to that buried in the particle of carboxylated polystyrene latices prepared by emulsion polymerization. The relative acid distribution of the carboxylated latices was determined by the conductometric titration method of Hen. Effect of carboxylic monomer levels and latex particle size on acid distribution ratio are given. It is shown that itaconic acid, being the most hydrophilic and having the least solubility in styrene, tends to distribute itself in favor of the aqueous serum phase, while acrylic acid, which has limited solubility in styrene and being sufficiently hydrophilic, tends to prefer the particle surface predominantly. Methacrylic acid, being the most hydrophobic of the three carboxylic monomers studied and having good solubility in styrene, is shown to be concentrated inside the particle core. The observed results are compared with other similar findings in the literature and analyzed in the light of accepted mechanisms for emulsion polymerization of carboxylated styrene systems.     

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     

油气田固井专用羧基丁苯胶乳的合成

以丁二烯、苯乙烯(St)为主要单体,引入不饱和羧酸、磺酸盐等作为功能性单体,采用复合乳化体系,以乳液聚合方式合成出油气田固井专用羧基丁苯胶乳。试验结果表明:最适宜的合成条件是w(复合乳化剂)=1.5%～2.0%、m(丁二烯)∶m(St)=(45～65)∶(55～35)、w(不饱和功能单体)=2.5%～3.5%(相对于总单体而言)、w(不饱和磺酸盐功能单体)=0.20%～1.00%、w(调节剂)=0.45%、m(烃)∶m(水)=100∶(120～130)、在(75±3)℃条件下聚合且w(过硫酸盐)=0.5%～0.6%;在最佳合成条件下制取的羧基丁苯胶乳,完全满足固井施工的要求。     

The preparation of uniform polystyrene latices by true emulsion polymerization

Conventional emulsion polymerization of styrene produces some polydispersion in particle sizes in the latex. By carrying out a one-stage polymerization of finely emulsified monomer droplets of styrene formed in a mixture of methanol and water, it is possible to prepare stable latices of polystyrene in which the particles are perfectly uniform in size. The polymer has a relatively low molecular weight, but it is more stable to fragmentation by surfactant solutions than polystyrene prepared by conventional emulsion polymerization, the molecular weight of which is greater. The surface charge density of the particles is higher than that of particles produced by emulsion polymerization, and this probably accounts for the stability of the dispersion during polymerization and of the latex.     

High solids content emulsions. IV. Improved strategies for producing concentrated latices

A new means of producing high solids content latices with low viscosity is presented. The replacement of water‐soluble initiators that decompose to give charged free radicals is shown to perturb the stability of highly concentrated latices. Their replacement by an oil‐soluble initiator during particle growth, then by an activated, water‐soluble system to remove residual monomer has been shown to help significantly reduce the number of stable particles generated by homogeneous nucleation. Latices with 73% (v/v) solids have been produced with a bimodal particle size distribution (PSD) consisting of 900 and 110 nm particles. The viscosity of these latices can be as low as 300 mPa s^?1 at 20 s^?1. Despite the presence of water‐soluble monomers, excellent control over the evolution of the PSD allows one to obtain highly reproducible results. In addition, latices produced with the new initiator system have a much lower water uptake and their viscosity is much less sensitive to changes in pH than is the case for latices produced using standard emulsion polymerization techniques. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1935–1948, 2002; DOI 10.1002/app.10514     

Preparation and characterization of polysiloxane–polyacrylates composite latices and their film properties

Gamma‐ray induced seeded emulsion polymerization of methyl methacrylate and butyl acrylate was carried out in the presence of a polymerizable polysiloxane seed latex, obtained by ring‐opening copolymerization of octamethyl cyclotetrasiloxane (D₄) and tetramethyl tetravinyl cyclotetrasiloxane (VD₄), catalyzed by dodecylbenzene sulfonic acid (DBSA). A series of polysiloxane seed latices with different molecular weights, vinyl contents and particle sizes was used. The conversion–time curve showed that the polymerization rate was accelerated significantly by the seed latex. The obtained composite latices also showed good storage stability, mechanical stability and high electrolyte resistance ability. By using transmission electron microscopy (TEM), the morphology of the composite latex particles was found to display a quite uniform fine structure. The graft polymerization reactions between the polymerizable polysiloxane and the acrylates were confirmed by Fourier‐transform infrared spectroscopy (FT‐IR) and the graft efficiencies were also studied. The influence of seed content, molecular weight, vinyl content of the polysiloxane and seed latex particles size on the mechanical performance, water absorption ratio, surface properties and transparency of the latex films was also investigated. It was found that the seed content and particles size greatly affect the mechanical performance, water absorption ratio and transparency of the latex films. Copyright © 2005 Society of Chemical Industry     

Preparation and properties of alkoxysilane/butyl acrylate/methyl methacrylate copolymer latices

The incorporation of alkoxysilanes into latex systems is of major interest in the field of colloidal science. Two kinds of vinyl‐containing alkoxysilanes, methacyloxypropyltrimethoxyl silane and vinyltriethoxysilane, were copolymerized with butyl acrylate and methyl methacrylate by seeded emulsion polymerization, and copolymer latices were obtained. The morphologies of the latex particles were characterized with transmission electron microscopy. Dynamic light scattering showed that the particle size increased and the particle size distributions of all the copolymer latex particles were alike with increasing amounts of organosilane. The effects of the organosilane content on the morphology of the particles, the rheology, and the swelling properties were also investigated. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

水泥改性用丁苯胶乳的合成

采用种子乳液聚合法制备了丁苯共聚物/水泥复合材料专用丁苯胶乳,考察了复合乳化剂体系、种子胶乳用量、极性单体种类、聚合温度及加料方式等对乳胶粒尺寸及其分布和胶乳稳定性等的影响。结果表明,在小粒径种子体存在下,分批加乳化剂的加料方式是合成水泥专用丁苯胶乳的有效途径之一,平均粒径小且粒径分布窄的丁苯胶乳具有较好的稳定性。采用复合乳化剂体系、添加少量带极性的第三单体等可以较好地提高丁苯胶乳的化学和机械稳定性。     

Preparation and characterization of imidazole‐functionalized microspheres

The preparation of imidazole‐functionalized latex microspheres by a two‐stage emulsion copolymerization process and their characterization are reported on. Emulsifier‐free emulsion copolymerization of styrene (St) and 1‐vinyl imidazole (VIMZ) exhibited bimodal particle size distributions caused by secondary homogeneous nucleation process. However, secondary nucleation can be avoided by using cetyltrimethylammonium bromide (CTAB) as a stabilizer at a concentration below its cmc (critical micelle concentration). This would result in the formation of monodisperse latex particles. The final particle size diameter depended on the concentration of CTAB as well as the amount of VIMZ. To control the amount of the functional imidazole groups on the latex particle surfaces, independent of the latex diameters, without secondary nucleation of particles, the seeded emulsion copolymerization of styrene and VIMZ was explored as a second‐stage polymerization at different concentrations and ratios of monomers in the presence of the previously prepared monodisperse poly(styrene‐co‐1‐vinyl imidazole) seed latex particles. The concentration of imidazole functional groups on the surface of the latex particles could also be varied through the rearrangement of hydrophilic imidazole groups by varying the second‐stage monomer addition process such as the utilization of monomer‐swollen seed particles or a shot addition of monomers. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 120:5753–5762, 2006     

High solids content emulsions. III. Synthesis of concentrated latices by classic emulsion polymerization

Two different methods of producing bi‐ and trimodal latices of a mixture of methyl methacrylate, butyl acrylate, and small amounts of acrylic acid were tested. It is shown that a combination of concentrating blends of seed particles by semibatch reaction, followed by a nucleation of small particles plus a second semibatch phase allowed us to obtain stable latices with solids contents over 65% and viscosities of below 2500 mPa s^?1 with little coagulum formation. The key parameter in determining latex stability, coagulum formation, and viscosity appears to be the the particle size distribution, and especially its modification attributed to secondary nucleation. Because it is not possible to eliminate water‐soluble monomers from the polymerization recipe, secondary (homogeneous) nucleation must be minimized by careful addition of the free‐radical initiator and choice of monomer feed flow rates. The nucleation of the third population in the trimodal latices is best accomplished with a mixed surfactant system because renucleation by anionic surfactant alone leads to detrimental changes in the particle size distribution (PSD) resulting from excessive flocculation of particles. In addition, it was found that the viscosity of the final products was not sensitive to small changes in the ionic strength of the latex, although neutralization to a pH of 6 effectively doubles the final latex viscosity. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1916–1934, 2002; DOI 10.1002/app.10513     

Latex produced with carboxylic acid comonomer for waterborne coatings: Particle morphology variations with changing pH

Carboxylic acid comonomers are often added to latex formulations to improve colloidal stability and to help control the physical structure of composite (core-shell type) particles. We have performed a systematic study of the incorporation of methacrylic acid (MAA) within styrene/butyl acrylate copolymer seed latices, and determined the eventual effect on the morphology of the composite particles when using a second-stage monomer that is either polar (MMA) or nonpolar (BMA). These latices have been produced in batch and semibatch reactions in the pH range of 3–7. At low pH, the MAA groups are not ionized, but at the higher pH they may be nearly completely ionized. Here, we report that for batch reactions carried out within the above pH range, the latex particle morphologies of the PMMA second-stage systems change dramatically with increasing pH, while those for the PBMA system do not change at all. These results show that one cannot easily generalize the effect of acid comonomers on the morphology of composite latex particles, as this depends upon the choice of the copolymers in the latex and the process characteristics of the polymerization reaction. Presented at the 82nd Annual Meeting of the Federation of Societies for Coatings Technology, on October 27–29, 2004, in Chicago, IL.     

PBA/PS核壳聚合物的制备及其与PS共混

采用种子乳液聚合方法制备了丙烯酸丁酯/苯乙烯核壳结构聚合物,研究了不同核壳单体质量比对乳液聚合过程的影响.结果表明,单体的总转化率超过98%;假设乳胶粒为球形生长时,乳胶粒理论粒径与实测值基本一致,说明该聚合体系没有明显的二次成核过程.随着核壳单体质量比的增加,低温区(聚丙烯酸丁酯)的玻璃化转变温度变化不大,而高温区(聚苯乙烯)的玻璃化转变温度呈下降趋势,这说明该核壳结构界面存在明显的过渡层.将该乳液聚合物与聚苯乙烯共混,随着核壳单体质量比的增加,共混物的冲击强度呈先增加后降低的趋势,说明该核壳聚合物对聚苯乙烯的增韧存在最佳条件.     

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.     

STUDIES ON SYNTHESIS OF SILICA SOL-ORGANIC POLYMER COMPOSITE EMULSION

An emulsion of polystyrene/poly (butylacrylate-methyl methacrylate acrylic acid) core/shell latex particles (PS/P (BA-MMA-AA)) has been prepared by use of three synthetic methods. The effects of synthetic methods on the distribution of carboxyl groups in latex particles were studied. The results show that the seed emulsion polymerization in which the pre-emulsified monomers were added by dropping method to the second stage is the best technique for obtaining the optimum distribution of carboxyl groups on the surface of the latex particles. Furthermore, by using PS/P (BA-MMA-AA), a type of novel composite emulsion of silica sol-PS/P (BA-MMA-AA) was synthesized with the above method. By observation through transmission EM, the morphology of the latex particles obtained shows that a composite structure has been formed between silica sol particles and organic polymer particles.     

Control of particle size distribution for the synthesis of small particle size high solids content latexes

A polymerization process to synthesize bimodal latexes with maximum particle diameters below 350 nm and solids content above 65 wt% has been developed.The process is based on an iterative strategy to determine the optimal particle size distribution that gives the maximum packing factor for a given range of particle sizes and at a given solids content. The calculated optimal bimodal PSD was experimentally obtained in a seeded semi-continuous emulsion polymerization reaction as follows: in the first step, a polymer seed latex was loaded in the reactor and grown, under monomer starved conditions, until a given particle size. At this point a fraction of the same seed was added to the reactor and the feed was continued until the desired particle size distribution and solids content were achieved. The point at which the seed was added again to the reactor and the amount of seed required were determined by the iterative strategy and depended on the competitive growth rate ratio of large and small particles that is an input for the iterative strategy.Implementation of the solution obtained from the iterative strategy, and for the first time in the open literature, led to the production of a coagulum free and stable bimodal latex with 70 wt% of solids content and particle sizes below 350 nm.     

Preparation of carboxylated polymer emulsion particles in which carboxyl groups are predominantly localized at surface layer by using the seeded emulsion polymerization technique

It was studied how to localize carboxyl groups at the particle surface in a preparation of styrene (S)/butyl acrylate (BA)/methacrylic acid (MAA) polymer emulsion. The relative distribution of carboxyl groups in the emulsion was determined by conductometric titration method: in serum, at surface, and inside particle. By seeded (two-stage) emulsion polymerization that S–BA–MAA terpolymer emulsion was first prepared at low pH and then second stage polymerization of S–BA was continued at high pH, S/BA/MAA polymer emulsion particles in which carboxyl groups are localized predominantly at the surface could be prepared.