Bulk polymerization of styrene in the presence of polybutadiene. The use of bifunctional initiators

This work experimentally and theoretically investigates the use of bifunctional initiators in the synthesis of high-impact polystyrene (HIPS). The experimental design involved a series of nonisothermal bulk polymerizations of styrene (St) in the presence of polybutadiene (PB). The performance of three commercial initiators [2,5-dimethyl −2,5 bis(2-ethylhexanoyl peroxy] hexane or L–256; 2,5 bis(benzoyl peroxy) hexane or L–118; and ethyl 3,3 di(t-butyl peroxide) butirate or L–233] were compared to the performance of a standard monofunctional initiator (terbutylperoctoate or TPBO), and to the blank case (i.e., without initiator). From samples taken along the prepolymerization period, the phase inversion point and the 30% conversion point were estimated. For the final product, the free polystyrene (PS) molecular weights and the St grafting efficiency were measured. A mathematical model was developed that predicts the evolution of the MWDs for the free PS the residual PB, and the graft copolymer, together with the chemical composition distribution for the total graft copolymer. Compared to the monofunctional case, the L–256 initiator induces phase inversion and rubber grafting at low conversions. Also, it shortens the prepolymerization times by around 38%, without affecting the molecular characteristics of the final product. L–118 also shortens prepolymerization time with respect to TBPO; but is not as effective as L–256 or TBPO in promoting rubber grafting. At the polymerization end, the final molecular characteristics are practically independent of the initiator type because most of the polymerization in induced by monomer initiation. Due to its slow decomposition rate, the L–233 initiator is less effective that TBPO for reducing prepolymerization times and for promoting phase inversion. © 1996 John Wiley & Sons, Inc.     

Polymerization of styrene in the presence of polybutadiene: determination of the molecular structure

This work experimentally and theoretically determines the molecular macrostructure of the polymer mixture that is developed (at relatively low conversions) in a solution polymerization of styrene (St) in presence of polybutadiene (PB). The reaction was carried out at 70°C in a batch‐stirred tank reactor. From samples taken along the reaction, the three polymeric components of high‐impact polystyrene (HIPS) (i.e., polystyrene  PS , residual PB, and graft copolymer) were first separated from each other by solvent extraction. Then, the graft copolymer was ozonized to isolate the St branches. The molecular weight distributions (MWDs) of the total HIPS, the three HIPS components, and the grafted St branches were determined by the size exclusion chromatography (SEC). For the graft copolymer and the total HIPS, the variation of the St mass fraction with molecular weights was also determined by SEC. All measurements were compared with theoretical estimates, and a reasonable agreement is observed. For the theoretical estimates, the mathematical model of Estenoz, D. A.; Valdez, E.; Oliva, H. M.; Meira, G. R. (J Polym Sci 1996, 59, 861) was extended to compare the MWD of the St branches with the MWD of the free PS. For the sought experimental conditions, these two distributions had very similar results but in a bulk industrial process, larger discrepancies are to be expected. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 74: 1950–1961, 1999     

Deformation mechanism of polystyrene toughened with sub‐micrometer monodisperse rubber particles

Core–shell polybutadiene‐graft‐polystyrene (PB‐g‐PS) rubber particles with different ratios of polybutadiene to polystyrene were prepared by emulsion polymerization through grafting styrene onto polybutadiene latex. The weight ratio of polybutadiene to polystyrene ranged from 50/50 to 90/10. These core‐shell rubber particles were then blended with polystyrene to prepare PS/PB‐g‐PS blends with a constant rubber content of 20 wt%. PB‐g‐PS particles with a lower PB/PS ratio (≤70/30) form a homogeneous dispersion in the polystyrene matrix, and the Izod notched impact strength of these blends is higher than that of commercial high‐impact polystyrene (HIPS). It is generally accepted that polystyrene can only be toughened effectively by 1–3 µm rubber particles through a toughening mechanism of multiple crazings. However, the experimental results show that polystyrene can actually be toughened by monodisperse sub‐micrometer rubber particles. Scanning electron micrographs of the fracture surface and stress‐whitening zone of blends with a PB/PS ratio of 70/30 in PB‐g‐PS copolymer reveal a novel toughening mechanism of modified polystyrene, which may be shear yielding of the matrix, promoted by cavitation. Subsequently, a compression‐induced activation method was explored to compare the PS/PB‐g‐PS blends with commercial HIPS, and the result show that the toughening mechanisms of the two samples are different. Copyright © 2006 Society of Chemical Industry     

Heterogeneous bulk polymerization of styrene in the presence of polybutadiene: Calculation of the macromolecular structure

A mathematical model is presented that simulates the polymerization of styrene in the presence of polybutadiene (PB) for producing high‐impact polystyrene (HIPS) via the heterogeneous bulk process. The model follows the polymerization in two phases; and calculates in each phase the main reaction variables and the molecular structure of the three polymeric components: free polystyrene (PS), unreacted PB, and graft copolymer. Two polymerizations (at 90 and 120°C) were carried out and simulated. The model was validated with measurements of the monomer conversion, the grafting efficiencies, and the average molecular weights. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 99: 3023–3039, 2006     

Styrene–butadiene block copolymer with high cis‐1,4 microstructure

The sequential block copolymerization of styrene (St) and butadiene (Bd) was carried out with an activated rare earth catalyst composed of catalyst neodymium tricarboxylate (Nd), cocatalyst Al(i‐Bu)₃ (Al), and chlorinating agent (Cl). The microstructure, composition, and morphology of the copolymer were characterized by FTIR, ¹H NMR, ¹³C NMR, and TEM. The results show that styrene–butadiene diblock copolymer with high cis‐1,4 microstructure of butadiene units (～ 97 mol %) was synthesized. The cis‐selectivity for Bd units was almost independent on the content of styrene units in the copolymer ranging from 18.1 mol % to 29.8 mol %. The phase‐separated morphology of polystyrene (PS) domains of about 40 nm tethered by the elastomeric polybutadiene (PB) segments is observed. The PS‐b‐cis‐PB copolymer could be used as an effective compatilizer for noncompatilized binary PS/cis‐PB blends. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Toughness and morphology of radiation‐crosslinked natural rubber modified polystyrene

γ‐Radiation vulcanized natural rubber (RVNR)/phase transfer/suspension polymerization technique was used to prepare high‐impact polystyrene (HIPS) in bead form. The high notched Izod impact resistance of HIPS based on RVNR was observed and compared with that of unmodified PS. The impact resistance of HIPS based on RVNR was further enhanced by addition of 10% of polystyrene‐block‐polyisoprene‐block‐polystyrene copolymer. A mesh structure of all crosslinked rubber particles containing polystyrene and long crazes in HIPS were observed under electron microscopy. Copyright © 2003 Society of Chemical Industry     

Nanocomposites based on high impact polystyrene/silver nanoparticles: Effect of silver nanoparticles concentration on the reaction evolution,morphology, and impact strength

Nanocomposites based on high impact polystyrene (HIPS) and silver nanoparticles (AgNPs) were synthesized via in situ bulk‐suspension polymerization adding a colloidal suspension of AgNPs in styrene from the beginning of the reaction. The concentrations of AgNPs in the final nanocomposites were 0, 0.025, 0.10, and 1.0 wt%. The rate of polymerization and free radicals concentration were found to decrease with increasing AgNPs concentration. For nanocomposites with 0.025 and 0.10 wt% of AgNPs, the phenomenon of phase inversion (PI) during the mass polymerization occurred within the same range as that for the blank HIPS. Further, the impact strength of these nanocomposites did not present any changes as compared to the blank HIPS. However, there was no sign of the PI phenomenon in the case of 1.0 wt% of AgNPs, due to a decrease in the amount of free and graft polystyrene onto the rubber chain as the free radicals concentration diminishes with an increase in AgNPs. In this case the impact strength doubles the values of the blank HIPS due to the presence of a interpenetrated polymer network of crosslinked grafted rubber and polystyrene (PS) instead of the formation of a defined morphology. POLYM. ENG. SCI., 2011. © 2011 Society of Plastics Engineers     

Novel methods for synthesis of high‐impact polystyrene with bimodal distribution of rubber particle size

By using in situ prepolymerization and radiation curing, high‐impact polystyrene (HIPS) with a bimodal distribution of the size of the rubber particles (bimodal HIPS) was synthesized in the presence of ultrafine full‐vulcanized powdered styrene–butadiene rubber (UFPSBR) and polybutadiene rubber (BR). TEM photographs indicated that UFPSBR was dispersed uniformly as a single particle with a diameter of about 100 nm. On the other hand, bimodal HIPS with different rubber particle size distributions could also be obtained by blending HIPS and UFPSBR grafting styrene (UFPSBR‐g‐St) with different grafting yields. The bimodal HIPS with the smallest rubber particle size, at about 100 nm, could be prepared by blending the monomodal HIPS containing big rubber particles with polystyrene/UFPSBR. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Influence of core–shell rubber particles synthesized with different initiation systems on the impact toughness of modified polystyrene

Core–shell poly(butadiene‐graft‐styrene) (PB‐g‐PS) rubber particles were synthesized with different initiation systems by emulsion grafting polymerization. These initiation systems included the redox initiators and an oil‐soluble initiator, 1,2‐azobisisobutyronitrile (AIBN). Then the PB‐g‐PS impact modifiers were blended with polystyrene (PS) to prepare the PS/PB‐g‐PS blends. In the condition of the same tensile yield strength on both samples, the Izod test showed that the notched impact strength of PS/PB‐g‐PS(AIBN) was 237.8 J/m, almost 7 times than that of the PS/PB‐g‐PS(redox) blend, 37.2 J/m. From transmission electron microscope (TEM) photographs, using the redox initiators, some microphase PS zones existed in the core of PB rubber particles, which is called “internal‐grafting.” This grafting way was inefficient on toughening. However, using AIBN as initiator, a great scale of PS subinclusion was seen within the PB particle core, and this microstructure increased the effective volume fraction of the rubber phase with a result of improving the toughness of modified polystyrene. The dynamic mechanical analysis (DMA) on both samples showed that the glass transition temperature (T_g) of rubber phase of PS/PB‐g‐PS(AIBN) was lower than that of PS/PB‐g‐PS(redox). As a result, the PB‐g‐PS(AIBN) had better toughening efficiency on modified polystyrene than the PB‐g‐PS(redox), which accorded with the Kerner approximate equation. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 738–744, 2007     

Instability of styrene/polystyrene/polybutadiene/polystyrene‐b‐polybutadiene emulsions that emulate styrene polymerization in the presence of polybutadiene

This article investigates the room temperature demixing of oil‐in‐oil emulsions containing styrene (St), polybutadiene (PB), a St‐butadiene star block copolymer (BC), and two polystyrene (PS) samples of different molecular weights and is a contribution toward a better understanding of the stability/instability of the reaction mixture in a bulk high‐impact polystyrene (HIPS) process close to the phase inversion. Twelve bulk prepolymerizations of St in the presence of PB were emulated, at 10%, 15%, and 20% conversion; and with constant grafting efficiencies. All the blends contained 6% in weight of butadiene units. After stirring the blends for 24 h, the decantation demixing process was monitored along 30 days, with daily measurement of the interface levels after appearance of a clear interface. For some of the isolated phases, their unswollen morphologies were observed by transmission electron microscopy. All the isolated phases exhibited macrophase separation into homopolymer‐ and copolymer‐rich macrodomains with lamellar microdomains. The BC showed a greater affinity toward the PS‐rich phase. The separation of an independent BC‐rich phase in the blends containing the high molar mass PS and at high grafting efficiencies, modifies the idea of the graft‐ or BC molecules located at the interface of large PS‐rich and PB‐rich phases. POLYM. ENG. SCI., 2013. © 2013 Society of Plastics Engineers     

Poly1‐hexene: New impact modifier in HIPS technology

Poly1‐hexene was prepared using a conventional heterogeneous Ziegler–Natta catalyst and its stereoregularity was characterized using ¹³C‐NMR analysis. New kind of high impact polystyrene (HIPS) was prepared by radical polymerization of styrene in the presence of different amounts of synthesized poly1‐hexene (PH) as impact modifier (HIPS/PH) and compared with conventional high impact polystyrene with polybutadiene (HIPS/PB) as rubber phase. Scanning electron microscopy (SEM) revealed that the dispersion of poly1‐hexene in polystyrene matrix was more uniform compared with it in HIPS/PB. The impact strength of HIPS/PH was 29–79% and 80–289% higher than that in HIPS/PB and neat polystyrene, respectively. FTIR was used to confirm more durability of HIPS/PH samples toward ozonation. To study the effect of rubber type and amount on the T_gs of polystyrene, differential scanning calorimetry was employed. Results obtained from TGA demonstrated higher thermal stability of HIPS/PH sample in comparison with conventional HIPS/PB one. Our obtained results suggest new high impact polystyrene that in all studied aspects has better performance than the conventional HIPS. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43882.     

Graft copolymerization of styrene and acrylonitrile onto EPDM

Acrylonitrile–EPDM–styrene (AES) graft copolymers were synthesized by solution graft polymerization of styrene (St) and acrylonitrile (AN) onto EPDM in an n‐hexane/benzene solvent with benzoyl peroxide (BPO) as an initiator. The structure changes were studied by an FTIR spectrophotometer. The grafting parameters were calculated gravimetrically. The influence of the polymerization conditions, such as the reaction time, concentration of the initiator, EPDM content, and weight ratio of St/AN, on the structure of the products was investigated. It was found that a proper initiator concentration and EPDM content will give a high grafting ratio of the AES resin. The thermal property of the copolymer was studied using programmed thermogravimetric analysis (TGA). The results showed that the copolymer has a better heat‐resistant property than that of ABS, especially for the initial decomposition temperature (T_in) and the maximum weight loss rate temperature (T_max). Also, the mechanism of the graft reaction was discussed. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 428–432, 2002     

Molecular simulation of the effect of graft structure on the miscibility of high‐impact polystyrene blends

High‐impact polystyrene (HIPS) is a kind of thermoplastic with good impact, which is considered to derive from the biphase of microstructure studied with SEM, etc. In this article, the influence of polystyrene (PS)/polybutadiene (PB) graft structure to the behavior of HIPS was studied through molecular simulation. The analysis of Flory‐Huggis parameter χ and radial distribution function (RDF) shows that the blend system of PS/PB has the best miscibility when the mass ratio of PS/PB is 60/40. In the toughening process, however, the graft copolymer PB‐g‐S is formed. For the PS/PB‐g‐S system with the same repeat unit of PS, PB‐g‐S chains with two grafts [PB‐g‐S(G = 2)] are better than PB‐g‐S chains with one graft [PB‐g‐S(G = 1)] in miscibility, which is in accord with the study of Fischer and Hellmann. POLYM. COMPOS., 2012. © 2012 Society of Plastics Engineers     

Architecture of prototype copolymer brushes composed of alternating structure and intramolecular phase separation of side chains in solution

Atom transfer radical polymerization (ATRP) was applied to the synthesis of prototype copolymer brushes composed polystyrene/poly(t‐butyl methacrylate) (PS/PBMA) alternating structure. Dilute solution properties of prototype copolymer brush were investigated by static and dynamic light scattering (SLS and DLS) in tetrahydrofuran (THF). As a result, such prototype copolymer brush composed of short aspect ratio formed a star‐like single molecule in THF. To discuss the intramolecular phase separation of PS/PBMA brushes in solution, we determined the radius of gyration (R_g) and cross‐sectional radius of gyration (R_g,c) of prototype copolymer brush by small‐angle X‐ray scattering (SAXS) using Guinier's plots in THF and styrene. We used styrene as solvent to cancel each other out with the electron density of PS side chains. Both R_g and R_g,c obtained in styrene decreased drastically compared with those obtained in THF. These results indicated strongly that PS and PBMA side chains of prototype brushes formed intramolecular phase separation even in good solvent. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Modification of porous suspension‐PVC particles by stabilizer‐free aqueous dispersion polymerization of absorbed monomers

The modification of porous PVC particles by an in‐situ stabilizer‐free polymerization/crosslinking of a monomer/crosslinker/peroxide solution absorbed within the PVC particles is presented. The modifying crosslinked polymers are polystyrene (PS) crosslinked with DVB (divinyl benzene), polymethyl methacrylate (PMMA) crosslinked with ethylene glycol dimethacrylate (EGDMA), and styrene‐MMA copolymer crosslinked with DVB. The modified PVC particles characterization includes polymerization yield, non‐extractables, ¹³C solid‐state CPMAS NMR, porosity measurements and also morphology and dynamic mechanical behavior (DMTA). The levels of nonextractable fractions found and ¹³C solid‐state CPMAS NMR results are indicative of low chemical interaction in the semi‐IPN PVC particles. Particle porosity levels and SEM observations indicate that styrene and MMA mainly polymerize within the PVC particles' bulk and just small amounts in the pores. MMA polymerization in the PVC pores is as crusts covering the PVC pore surfaces, whereas styrene polymerization in the PVC pores is by filling the pores. Dynamic mechanical studies show that tanδ and the storage modulus curves are influenced by the incorporation of PS and XPS but not by the incorporation of PMMA and XPMMA.     

Preparation magnetite core/coated with polystyrene shell hybrid materials via redox interfacial‐initiated emulsion polymerization

In this article, we describe a novel redox interfacial‐initiated micro‐emulsion polymerization (RIEP) to prepare hollow polystyrene microspheres with magnetite nanoparticles (MPs) core and polystyrene (PS) shell (MPs‐PS) under ambient pressure. The emulsion was constituted water‐based magnetic ferro‐fluid as dispersing phase and organic solvent and styrene (St) as continuous phase. Cumene hydroperoxide (CHPO)/iron (II) sulfates (FS) as the redox initiation system, the water‐soluble FS acted as the reducing component and the oil‐soluble CHPO as the oxidant component of the redox initiation system. Therefore, the primary radicals are produced mainly at the oil/water interface to initiate the polymerization of styrene to form polymer shell. The final products thoroughly characterized by X‐ray powder diffraction, Fourier transform infrared spectroscopy, transmission electron microscopy, field‐emission scanning electron microscopy, thermogravimetric analysis, dynamic light scattering, and X‐ray photoelectron spectroscopy, which showed the formation of hollow magnetite/polystyrene nanocomposite microspheres. Magnetic measurements were carried out at room temperature using a vibrating sample magnetometer. The saturation magnetization (M_s), remanent magnetization (M_r) and coercivity (H_c) is 30 emu/g, 15 emu/g and 370 Oe, respectively. The results revealed that the hybrid materials microspheres were super‐paramagnetic. POLYM. COMPOS., 31:1846–1852, 2010. © 2010 Society of Plastics Engineers     

Controlled free radical photopolymerization of styrene initiated by trithiocarbonate

Density functional theory calculations are reported for prediction of the trends in C S bond dissociation energies and atomic spin densities for radicals using S,S′‐bis(α,α′‐dimethyl‐α‐acetic acid) trithiocarbonate (TTCA) and bis(2‐oxo‐2‐phenylethyl) trithiocarbonate (TTCB) as reversible addition fragmentation chain transfer (RAFT) reagents. The calculations predict that the value of the C S bond length (1.865 Å) of TTCA is longer than that (1.826 Å) of TTCB, and TTCA is more effective for the polymerization of styrene (St) compared to TTCB as predicted by density functional theory. In photopolymerizations, pseudo‐first‐order kinetics were confirmed for TTCB‐mediated photopolymerization of St due to the linear increase of ln([M]₀/[M]) up to about 28% conversion, suggesting the living characteristics behavior of the photopolymerization of St in the presence of TTCB. For both TTCA and TTCB the polydispersities change with increasing conversion in the range 1.10–1.45, typical for RAFT‐prepared (co)polymers and well below the theoretical lower limit of 1.50 for a normal free radical polymerization. In addition, the triblock copolymer polystyrene‐block‐poly(butyl acrylate)‐block‐polystyrene (PS PBA PS) was successfully prepared, with very good control over molecular weight and narrow polydispersity (M_w/M_n = 1.45), using PS S C(S) S PS as macro‐photoinitiator under UV irradiation at room temperature. This indicated that this reversible and valid strategy led to a better controlled block copolymer with defined structures. Copyright © 2007 Society of Chemical Industry     

Polystyrene/calcium carbonate nanocomposites prepared by in situ polymerization in the presence of maleic anhydride

Polystyrene (PS)/calcium carbonate (CaCO₃) nanocomposites were prepared by in situ polymerization in the presence of maleic anhydride (MA). The composites were characterized by Fourier transform infrared spectra, gel permeation chromatography, differential scanning calorimetry, controlled stress rheometer, scanning electron microscope (SEM), small‐angle X‐ray scattering (SAXS), and mechanical test. Results show that the copolymer of styrene (St) and MA formed during the polymerization acts as a compatibilizer between PS and nanometer calcium carbonate (nano‐CaCO₃) particles, resulting in an increase in the glass transition temperature of the composite. The complex modulus and the impact strength of the PS/nano‐CaCO₃ composite show an increase with the addition of MA on account of the enhanced interfacial adhesion and the increased molecular weight. SEM and SAXS analyses indicate that a finer dispersion of nanoparticles and an increased homogeneity of the PS/nano‐CaCO₃ composites are obtained with application of a small amount of MA. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci., 2013     

Effect of in situ synthesized macroactivator on morphology of PA6/PS blends via successive polymerization

In situ polymerization and in situ compatibilization was adopted for preparation of ternary PA6/PS‐g‐PA6/PS blends by means of successive polymerization of styrene, with TMI and ε‐caprolactam, via free radical copolymerization and anionic ring‐opening polymerization, respectively. Copolymer poly(St‐g‐TMI), the chain of which bears isocyanate (? NCO), acts as a macroactivator to initiate PA6 chain growth from the PS chain and graft copolymer of PS‐g‐PA6 and pure PA6 form, simultaneously. The effect of the macroactivator poly(St‐g‐TMI) on the phase morphology was investigated in detail, using scanning electron microscopy. In case of blends with higher content of PS‐g‐PA6 copolymer, copolymer nanoparticles coexisting with the PS formed the matrix, in which PA6 microspheres were dispersed evenly as minor phase. The content of the compositions (homopolystyrene, homopolyamide 6, and PS‐g‐PA6) of the blends were determined by selective solvent extraction technique. The mechanical properties of PA6/PS‐g‐PA6/PS blends were better than that of PA6/PS blends. Especially for the blends T10 with lower PS‐g‐PA6 copolymer content, both the flexural strength and flexural modulus showed significantly improving because of the improved interfacial adhesion between PS and PA6. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Kinetics of polymerization and particle stabilization mechanism on dispersion copolymerization of styrene and divinylbenzene

Monodisperse highly crosslinked microspheres were prepared by dispersion copolymerization of styrene and divinylbenzene in an ethanol/water medium using poly(N‐vinylpyrrolidone) (PVP) as the stabilizer. The locus of polymerization and growth of particles were investigated. The polymerization kinetics, average particle diameter (D_n), polydispersity index (PDI), and numbers of particles (N_p) were presented. When the initial styrene concentration is below 20%, the results indicate that the polymerization occurs in the particles, and the particles grow to their final size by the diffusion of monomer and oligomer into the existing particles. The polymerization rate can be described by the equation R_p = k[l]^0.87 ([St]^1.91 + [DVB]^0.09) (1 + [PVP]^0.01) exp(? 45.35/RT). The data from infrared spectroscopy demonstrated that the graft stabilizer was present. The dissolution experiments show that the crosslinking reaction occurred irregularly in batch dispersion polymerization. Using the postaddition approach, up to 3% divenylbenzene (DVB) was successfully incorporated in the synthesis of coagulum‐free substance, and monodisperse crosslinked 5 μ m microspheres with a superior resistance to solvents have been prepared. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 85: 2230–2238, 2002