Anionic ring-opening polymerization of octamethylcyclotetrasiloxane in emulsion above critical micelle concentration

Batch anionic ring-opening polymerization of octamethylcyclotetrasiloxane in emulsion using nonionic and cationic emulsifiers was studied. The concentration of emulsifiers was set above their critical micelle concentration. Effects of emulsifier concentration, nonionic/cationic emulsifier ratio and cationic emulsifier/initiator (KOH) ratio on the kinetics, average particle size and distribution and on the average molecular weight and distribution were investigated and discussed. At the beginning of the polymerization, empty micelles, active micelles (polymer particles) and monomer droplets co-exist in emulsion. The transport of monomer from monomer droplets toward empty micelles was confirmed by monomer droplets and empty micelles disappearance and by formation of smaller particles. The transport of monomer from monomer droplets toward polymer particles was not confirmed, since the average polymer particle size did not increase during polymerization. It was proposed, that at lower conversions, monomer diffuses from polymer particle interior to particle surface, while at higher conversions, the monomer diffuses from larger to smaller polymer particles. Emulsifier concentration, nonionic/cationic emulsifier ratio and cationic emulsifier/KOH ratio have an evident effect on the kinetics and on the average molecular weight, thus demonstrating that cationic emulsifier participates to the initiation reaction.     

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

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

Effect of stirring on the emulsion polymerization of styrene

The purpose of this paper is to clarify the effect of stirring on the course of emulsion polymerization of, for example, styrene. It establishes the existence of an optimum range of stirring speed and three important factors which must be considered in carrying out emulsion polymerization. (1) Stirring significantly affects the course of reaction in the presence of an imperfectly purified nitrogen atmosphere. Consequently, the number of polymer particles produced and the polymerization rate per particle will be affected. (2) At higher stirring speeds, polymer particles coagulate and coalesce. At lower stirring speeds, the reaction rate is controlled by the monomer transport rate from monomer droplets to the aqueous phase. (3) Stirring contributes to the reduction of the number of micelles because emulsifier molecules are adsorbed onto the surfaces of monomer droplets finely dispersed by the stirring. At low emulsifier concentrations near the critical micelle concentration, this effect cannot be neglected.     

Simulation of particle size distribution in continuous emulsion polymerization styrene monomer

A detailed mathematical model for absolute particle-size distribution in continuous emulsion polymerization of styrene monomer is proposed on the basis of the modified population-balance theory. The computer simulation is then performed for styrene polymerization as an example of a nondesorption system. The effects of emulsifier and initiator concentrations as well as mean residence time on the absolute particle-size-distribution function, total concentration of polymer particles, conversion, average number and weight radii, average number of radicals per polymer particle, and polydispersity of radius are simulated by the model proposed.     

Semibatch anionic ring-opening polymerization of octamethylcyclotetrasiloxane in emulsion

The semibatch anionic ring-opening polymerization of octamethylcyclotetrasiloxane in emulsion was studied under the condition of no seed particles used in polymerization system. Concentration of emulsifier was set above critical micelle concentration. Effect of monomer feed rate on the chemical kinetics, average particle size and distribution and on the polymer molar mass and distribution was investigated. During monomer addition, polymerization rate was constant and controlled by the monomer feed rate. According to the proposed mechanism for anionic polymerization in emulsion, it was assumed that also the number of active polymerization sites and monomer concentration at the particle surface, where propagation occurs, remain constant. A continuous increase of average particle size and absence of extensive condensation reactions at high conversion suggested that the freshly added monomer diffuses toward hydrophobic polymer particles, where it is consumed in propagation reaction and/or accumulated in the particle core.     

醋酸乙烯酯乳液聚合数学模型(Ⅰ) 阶段Ⅰ模型

研究了较大亲水性单体醋酸乙烯酯(VAc)乳液聚合的乳胶粒生成和生长过程,提出了VAc乳液聚合阶段Ⅰ数学模型.该模型既考虑到胶束成核机理,又考虑到水相中低聚物沉淀成核机理.研究了自由基解吸与吸附在单体珠滴上的乳化剂对VAc乳液聚合阶段Ⅰ动力学的影响,并对模型预计结果与实验数据进行了比较和讨论.     

Particle nucleation in emulsion copolymerization containing multifunctional monomers

Characteristic features of particle nucleation and growth in the emulsion copolymerization of styrene and multifunctional monomers such as ethylene glycol dimethacrylate and divinylbenzene were investigated. It was found that in these emulsion copolymerization systems the rate of polymerization per particle decreased drastically with an increase in the content of the multifunctional monomer in the initial monomer feed, and the number of polymer particles produced, on the other hand, increased corresponding to the decrease in the rate of polymerization per particle. The increase in the number of polymer particles produced was explained on the basis of Smith-Ewart theory, which predicts that the number of polymer particles produced would increase inversely proportional to the 0.4 power of the volumetric growth rate per particle, that is the rate of polymerization per particle during the interval of particle formation (Interval I). It was pointed out that the decrease in the rate of polymerization per particle in Interval I would be due mainly to a decrease in the monomer concentration in the polymer particles which was caused by crosslinking networks of the resultant polymer.     

A kinetic investigation of thermally initiated emulsion copolymerization of styrene and methylmethacrylate without conventional initiators

The thermally initiated emulsion copolymerization of styrene (ST) and methyl methacrylate (MMA) was carried out in the absence of conventional initiators. The hydroperoxide (HPO) concentration in the monomers, sodium dodecyl sulfate (SDS), deionized water, and the formulation of those for emulsion copolymerization were measured. The HPO concentration in ST and MMA increased with the storage time, and were considered to be the major sources of HPO. The thermal decomposition of hydroperoxide in monomers, the thermal initiation of ST by Mayo mechanism, and the complex formation between SDS and the monomers were proposed to be three main sources of the radical generation. It was confirmed that new polymer particles were generated throughout the polymerization process, and consequently resulted in a broader distribution of polymer particle size, compared with that for conventional emulsion polymerization. Approximately 80 wt % of monomer conversion was obtained in the presence of SDS at 373 K in 24 h. The initiation rate of the 30 wt % monomer charge was faster than those of 10 wt % and 20 wt % monomer charge. The latex instability at higher solid content was improved by adding electrolyte to promote the electrostatic repulsion force between the polymer particles. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 455–467, 2002; DOI 10.1002/app.2343     

High pressure semibatch emulsion and miniemulsion copolymerization of vinyl acetate and ethylene

This study presents the experimental study of semibatch emulsion and miniemulsion copolymerization of vinyl acetate (VAc) and ethylene to vinyl acetate-ethylene (VAE) copolymer at 60°C and 80–300 psig. In the miniemulsion copolymerization, a water-soluble initiator (K₂S₂O₈) is used and VAc miniemulsion is prepared in presence of surfactant and cosurfactant using a sonicator or a high-shear homogenizer. Then, ethylene gas is supplied to the reactor at constant partial pressure. In a miniemulsion process, the mass transfer limitations of VAc from monomer droplets to the aqueous phase, and to micelles or polymer latex particles that are present in conventional macro-emulsion polymerization can be eliminated and the transfer of ethylene dissolved in the aqueous phase to the miniemulsion droplets is the major ethylene transport process for the polymerization. The experimental data show that the amount of ethylene incorporation into the copolymer is higher in miniemulsion polymerization than in emulsion polymerization. The ethylene pressure has been found to have a strong impact on the ethylene incorporation into the copolymer phase in both emulsion and miniemulsion copolymerizations but the increase is more pronounced in miniemulsion case. The VAE copolymer latex particles prepared by miniemulsion polymerization exhibited higher storage stability than those prepared by macro-emulsion polymerization.     

乳液聚合成核阶段的模拟与分析

建立了乳液聚合成核阶段的Monte Carlo模型，并用计算机对一个体积为10^-17m^3的微型反应器中苯乙烯的乳液聚合进行了模拟。以计算机生成随机数作为自由基被胶束和乳胶粒捕获的几率，模拟了在微型反应器中每一个自由基的生成、被胶束或乳胶粒捕获的过程以及每一个乳胶粒的生成及增长过程。通过对每一个乳胶粒在增长过程中各参数的统计计算，研究了乳液聚合成核阶段诸参数(乳胶粒数目、乳胶粒直径与粒径分布、单体转化率、聚合反应速率等)与乳化剂浓度[S]及引发剂浓度[I]的关系。结果表明，苯乙烯的乳液聚合体系中乳胶粒数目与[S]^0.5996[I]^0.4016成正比：在成核阶段乳胶粒直径分布先变宽后变窄，乳液聚合过程中乳胶粒直径分布有自动变窄的趋势；成核阶段持续时间t12与[S]^0.60[I]^0.60成正比，成核阶段结束时的单体转化率X12与[S]^1.20[I]^0.20成正比。     

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

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

Seeded emulsion polymerization of n-butyl acrylate utilizing miniemulsions

Nucleation of polymer particles in the seeded emulsion polymerization of n-butyl acrylate (BuA) was studied through experiments designed to control the amount of new particles formed. The results show that for the batch and semicontinuous seeded polymerization of BuA, a small amount of new particles was formed in the system in which the monomer was added neat, whereas a singificant amount of new particles was formed when the monomer was added as a miniemulsion. This suggests that new particles formed in the miniemulsion process were from nucleation of the monomer droplets. These experiments also showed that monomer-droplet nucleation decreased with increasing seed concentration in the reactor. For the seeded semicontinuous polymerizations, monomer-droplet nucleation decreases with decreasing BuA miniemulsion feed rate. The results also show that monomerdroplet nucleation takes place whenever miniemulsion droplets exist in the reactor. This study suggests that miniemulsions can be used to control the particle size distribution of a polymer latex system.     

Mass transfer in emulsion polymerization: An experimental and modelling study

A model is proposed to describe the impact of interphase monomer transfer on the emulsion polymerization of vinylidene fluoride (VDF). The model is validated with experimental data of the rate of polymerization and particle size distribution (PSD). During a typical emulsion polymerization process, the VDF monomer is in a gas or supercritical state, and thus much lighter than the aqueous phase in which the polymerization takes place. For this reason, the flux of monomer into the aqueous phase can depend on the type, number, and distribution of agitators on the shaft, as well as the rotation rate. The new model incorporates the interphase mass transfer coefficient into a standard emulsion polymerization model to demonstrate the impact of the agitation (in the broadest sense) on the rate of polymerization and the PSD.     

高分子聚合物包覆无机纳米粒子的研究进展

简单介绍了非液滴内成核法、液滴内成核法包覆无机纳米粒子的原理,重点讨论了乳液聚合法、无皂乳液聚合法、分散聚合法、悬浮聚合法、细乳液聚合法包覆无机纳米粒子的优缺点。针对包覆过程中产生的独立聚合物粒子、独立无机粒子,提出采用引发剂吸附在无机颗粒表面、采用反应性乳化剂和偶联剂处理无机粒子并控制单体用量;针对包覆多个无机粒子,提出采用聚合前超声空化技术。     

Semibatch anionic ring‐opening polymerization of octamethylcyclotetrasiloxane in emulsions: effect of the amount of seed polymer particles

Semibatch anionic ring‐opening polymerization of octamethylcyclotetrasiloxane with the use of seed polymer particles in emulsions was studied. The concentration of the emulsifier was set above the critical micelle concentration. We investigated the effect of the amount of seed polymer particles on the chemical kinetics and the average particle size and distribution. During monomer starving conditions the polymerization rate strongly depended on the monomer feed rate and not on the amount of seed particles. Throughout the entire monomer feed period the average particle size increased. This increase depended on the number and the size of seed particles. In emulsions with higher particle sizes higher equilibrium conversions were obtained. In our opinion, a greater extent of backbiting reactions is responsible for lower equilibrium conversions during and at the end of the process. The seeded semibatch process seems a reasonable choice for designing emulsion products with high monomer conversion and desired particle size. © 2012 Society of Chemical Industry     

Modeling the emulsion polymerization of amino-functionalized latex particles

A mathematical model for a semicontinuous seeded cationic emulsion polymerization was developed. The model includes the most distinctive features of the copolymerization of a cationic hydrophilic monomer with a hydrophobic one, including polymerization of the hydrophilic monomer in the outer shell of polymer particles and in the aqueous phase, and the possibility of having radical concentration profiles in the polymer particles.The reactions were carried out by means of a semicontinuous seeded cationic emulsion polymerization under starved conditions for styrene, which was the main monomer employed.The model predicts the evolution of the fractional overall conversions, the thickness of the outer shell, the total surface charge density and the partial conversions for the semicontinuous seeded cationic emulsion polymerization of styrene and aminoethyl methacrylate hydrochloride. Furthermore, the model can distinguish between the surface charge density provided by the cationic monomer than that given by the cationic initiator. Therefore, this model can predict the best conditions to obtain well-defined latexes with specific amounts of surface amino and amidine groups useful for immunoassays.     

Kinetics of vinyl chloride and vinyl acetate emulsion polymerization

The kinetics of vinyl chloride and vinyl acetate emulsion polymerization are reexamined. The validity of Ugelstad's model for systems with high desorption rate is confirmed by simulating conversion histories for both systems at different initiator concentrations and particle numbers. On the basis of the model, it is shown that at ordinary initiation rates, termination reactions are unimportant with respect to molecular weight development in both systems, and as a consequence, molecular weight development is independent of number and size distribution of polymer particles and of initiator and emulsifier level. Based on this conclusion, it is shown that in accordance with experimental facts, the molecular weight distribution obtained in vinyl chloride emulsion polymerization is the most probable distribution, and it is concluded that the number of long-chain branch points per repetition unit is less than 2 × 10^?4 at high conversions. In vinyl acetate emulsion polymerization, an almost logarithmic normal distribution is obtained. The distribution is strongly broadened by branching reactions with the number of long-chain branch points increasing rapidly with monomer conversion. The increase of M_n with increasing conversion is due to terminal double-bond polymerization, while the increase in M_w is due mainly to transfer to polymer.     

Influence of monomer preemulsification on formation of particles from monomer drops in emulsion polymerization

Evidence was obtained supporting the theory that monomer droplets can become a locus of initiation and propagation in emulsion polymerization. This was done by reducing the size of the monomer droplets prior to initiation of polymerization using different preemulsification techniques for a typical latex recipe containing a common anionic surfactant. Monomer droplet size reduction caused an increase in the total surface area of the monomer droplets and thereby increased the competitiveness of these droplets for capturing active free radicals which are generated in the aqueous phase. As the total surface area of the monomer droplets was increased by preemulsification, a corresponding increase in the number of large particles formed by polymerization of these monomer droplets was experimentally measured. This work shows that monomer droplets are a locus of emulsion polymerization. However, the importance of monomer droplet polymerization is limited by their total surface area because of the competition for free radicals with other surfaces and/or particle nucleation processes. The results offer a basis for explaining why broad, and sometimes bimodal, particle size distributions are obtained in some commercial processes where the reactants are preemulsified prior to being charged into a reaction vessel.     

醋酸乙烯酯乳液聚合数学模型(Ⅱ) 阶段Ⅱ与阶段Ⅲ模型

研究了较大亲水性单体醋酸乙烯酯(VAc)乳液聚合动力学,着重剖析了自由基解吸的影响及水相中的聚合反应对总聚合反应速率的贡献,提出了阶段Ⅱ和阶段ⅢVAc乳液聚合数学模型,成功地预计了聚合反应速率、自由基在乳胶粒中的分布及乳胶粒中平均自由基数随转化率的变化规律.并将模型预计结果和实验数据进行了比较和讨论.     

A kinetic study of vinyl acetate polymerization in aqueous media in the absence of emulsifier

In the absence of emulsifying agents, vinyl acetate polymerization in aqueous media was carried out at 50°C over a wide range of initial initiator and monomer concentrations to clarify the effect of reaction conditions on the kinetic behavior of the polymerization system. It was shown that the rate of polymerization was proportional to reaction time and initiator concentration and independent of the number of polymer particles present. The rate could also be successfully explained by the Smith and Ewart theory for emulsion polymerization when the dissolved monomer in water and the Trommsdorff effect were taken into consideration. A set of equations which could account for the effect of dissolved monomer in water on the rate of polymerization is proposed.