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     

Revisiting emulsion polymerization to produce stable,translucent, nanolatex of partially water‐soluble monomers,ethylacrylate–methylmethacrylate

Stable, translucent nanolatex with monomer weight % as high as 25 was obtained through emulsion copolymerization of partially water‐soluble monomers, ethyl acrylate and methylmethacrylate. The kinetics of reaction, studied at monomer/surfactant (M/S) ratio 10 and 50 showed two intervals and higher rate of particle nucleation for KPS initiated systems. However, AIBN initiated system showed phase separation. The copolymer composition was determined through ¹H‐NMR studies and copolymers showed two glass transition temperatures. Dynamic light scattering studies indicated bimodal distribution of polymer particle size. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 2593–2603, 2003     

Toward a better understanding of the emulsion polymerization of butadiene. I. Continuous conductivity measurements

Continuous conductivity measurements were performed during the batch emulsion polymerization of butadiene along with kinetic and particle size measurements. The critical monomer conversion was obtained around 55% and the rate of polymerization was correlated to the surfactant concentration with an exponent of 0.35 which was not in agreement with the exponent offered by Smith and Ewart. In addition, the evolution of some particle‐related quantities such as particle size and number of particles during the three intervals of the emulsion polymerization and their agreements with Smith‐Ewart mechanism were investigated. The behavior of conductivity in the emulsion polymerization of butadiene normally containing a buffering agent was found to be completely different from the unbuffered one. Comparison of the conductivity profiles with the kinetic and particle‐related quantities represented that the conductivity of the reaction mixture is very sensitive to the changes in the particle size so that any small change in the forms of nucleation, growth, and coagulation is clearly observed in the conductivity profiles. Furthermore, the conductimetric data are capable of determining some important points during the polymerization such as the beginning of the reaction that can be important from the industrial process control point of view. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45262.     

Effects of short chain alcohols on the styrene emulsion polymerization

The effects of a series of short chain alcohols, 1‐butanol (C₄OH), 1‐pentanol (C₅OH), and 1‐hexanol (C₆OH), on the styrene (ST) emulsion polymerization mechanisms and kinetics were investigated. The CMC of the ST emulsions stabilized by sodium dodecyl sulfate (SDS) first decreases rapidly and then levels off when the C_iOH (i = 4, 5, or 6) concentration ([C_iOH]) increases from 0 to 72 mM. Furthermore, at constant [C_iOH], the CMC data in decreasing order is CMC (C₄OH) > CMC (C₅OH) > CMC (C₆OH). The effects of C_iOH (i = 4, 5, and 6) on the ST emulsion polymerization stabilized by 6 mM SDS are significant. This is attributed to the reduction in CMC by C_iOH, the different oil–water interfacial properties, the different concentrations of monomer within latex particles, and the different effectiveness of SDS/C_iOH in stabilizing latex particles. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 4406–4411, 2006     

Development of new concepts for the control of polymerization processes: Multiobjective optimization and decision engineering. II. Application of a Choquet integral to an emulsion copolymerization process

In polymer industry, engineers seek to obtain polymers with prescribed end‐use properties, high productivities, and low cost. Thus, the optimization of a manufacturing process with all those goals and constraints belongs to a problem domain that aims to achieve the best trade‐off possible. This article concerns the optimization of the batch emulsion polymerization of styrene and α‐methylstyrene. An accurate model was developed to describe the complete patterns of the emulsion polymerization. Key parameters of the model were identified on the basis of batch experimental data. The model was then used to simulate, under several operating conditions, the polymerization rate, the overall conversion of monomers, and the number and weight‐average molecular weights. Amulticriteria optimization approach based on an evolutionary algorithm and the concept of dominance from the Pareto frontier theory was used. Last, a decision aid system based on the Choquet integral was proposed to determine the optimal operating conditions with the preferences of the decision maker taken into account. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Semicontinuous emulsion copolymerization of 3‐O‐methacryloyl‐1,2:5,6‐di‐O‐isopropylidene‐α‐D‐glucofuranose (3‐MDG) and butyl acrylate (BA). Monomer feed addition

New polymer colloids based on the saccharide monomer, using of 3‐O‐methacryloyl‐1,2:5,6‐di‐O‐isopropylidene‐α‐D ‐glucofuranose (3‐MDG), were prepared by semicontinuous emulsion polymerization, a widely used industrial process. The copolymerization of 3‐MDG and butyl acrylate (BA), by the monomer‐addition technique, at 70°C, using sodium persulfate (Na₂S₂O₈) as an initiator, was investigated. The influence of some reaction parameters, such as the type and concentration of the surfactants as well as the monomer addition rate (R_m) on the polymerization rate (R_p), the colloidal properties, and the stability of the latexes, was studied. It was found that under starved‐feed conditions the polymerization rate and the particle size (D) increased with an increasing rate of monomer addition. The weight‐average molecular weight (M _w) also increased by enhancing R_m and a narrower molecular weight distribution was obtained. Furthermore, the type and the concentration of the surfactants strongly influenced the particle size and its distribution. The effect of the seed stage on the particle size and its distribution was also investigated. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 2091–2102, 2003     

Preparation of raspberry‐shaped styrene‐butadiene‐methyl acrylate‐acrylic acid latex particles by emulsion polymerization followed by alkali/heating method

Monodispersed raspberry‐shaped polystyrene‐butadiene‐methyl acrylate‐acrylic acid particles were made by semi‐batch emulsion polymerization followed by alkali and heat treatment. The particle sizes and size distributions were studied by hydrodynamic chromatography and transmission electronic microscopy. The morphology of the particles was observed by SEM, cryo‐SEM, and TEM. Treatment temperature was found to have a significant impact on the particle size and morphology of the treated latexes. Higher temperatures lead to larger particle sizes and more discernible raspberry domains with sizes around 50 nm on the particle surfaces. Higher levels of alkali did not significantly change the particle size but did increase the total titratable acid amount, presumably due to the hydrolysis of methyl acrylate during the treatment. GPC results showed that higher amount of oligomers or polymers are produced in the serum for the heat‐treated latexes. Divinylbenzene crosslinking agent at the levels of 0.05–3% limited the particle expansion and decreased the serum acid. A possible mechanism of raspberry particle formations was proposed, which involves migration of hydrophilic and hydrophobic species during the heat treatment. Lastly, potential applications for raspberry particles in paper coating were explored. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Identification of nucleation loci in emulsion polymerization processes. II. A systematic study of liquid–liquid emulsions

Identification of the main nucleation sites and characterizing them in terms of their size and composition is prime objective of this research effort. Different nucleation sites have been proposed as the most likely nucleation sites by various researchers. Recent advances in the development of the spectroscopic techniques enable comprehensive characterization of the emulsion at the beginning of the reaction. In this paper, we present the experimental evidence of the existence of a previously unidentified nano‐droplet population of size range 30 to 100 nm in diameter using spectroscopy. Presence of about seventy to eighty percent of the dispersed phase in the nano‐droplet population and large interfacial area make them the most probable particle nucleation loci in emulsion polymerization processes. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 2858–2866, 2006     

Ab initio reversible addition–fragmentation chain transfer emulsion polymerization of styrene/butyl acrylate mediated by poly(acrylic acid)‐block‐polystyrene trithiocarbonate

Ab initio reversible addition–fragmentation chain transfer (RAFT) emulsion polymerization of styrene/butyl acrylate was investigated with the trithiocarbonate macro‐RAFT agent poly(acrylic acid)‐block‐polystyrene (PAA‐b‐PS) as a stabilizer and a RAFT agent. Influences of the amount of ammonium persulfate (APS), the amount of PAA‐b‐PS and the mass ratio of monomers on emulsion polymerization and film properties are discussed. The particle morphology exhibited spherical‐like structure with particles of about 90 nm in diameter and relatively narrow particle size distribution characterized using transmission electron microscopy and dynamic laser scattering. Fourier transform infrared and ¹H NMR spectra showed that the styrene/butyl acrylate emulsion was successfully synthesized. The monomer conversion increased initially with increasing amount of APS, from 0.4 up to 0.8 wt%, and then decreased. The particle size increased and its distribution decreased gradually with increasing amount of APS. The monomer conversion increased from 76.83 to 94.21% as the amount of PAA‐b‐PS increased from 3 to 4 wt%, and then decreased with further increase of PAA‐b‐PS. The particle size decreased and its distribution increased with increasing amount of PAA‐b‐PS. The water resistance and solvent resistance of the polymer films initially increased and then decreased with decreasing mass ratio of butyl acrylate to styrene. © 2014 Society of Chemical Industry     

Kinetics and particle nucleation mechanism of St/BA/qBVPBr emulsifier‐free cationic emulsion polymerization

Stable functional cationic latices were prepared by emulsifier‐free emulsion copolymerization of styrene (St) and butyl‐acrylate (BA) with 1‐butyl‐4‐vinylpyridinium bromide (qBVPBr) as functional comonomer and azobis(isobutyramidine hydrochloride) (AIBA) as initiator at (70 ± 1)°C. The influences of the reaction temperature, the initiator concentration, and comonomer concentration on the polymerization conversion (x %), polymerization rate (R_p) of poly(St/BA/qBVPBr) emulsions were investigated. The results indicated that x % and R_p increase with increasing qBVPBr or AIBA concentration and temperature, and R_p can be expressed as R_p = K_p[AIBA]^0.73[qBVPBr]^0.08 (r_AIBA = 0.9968; r_qBVPBr = 0.9946, both r_AIBA and r_qBVPBr are linear correlation coefficient) and the apparent activation energy (E_a) is 47.89 kJ mol^?1. In the absence of emulsifier condition, curves of R_p versus reaction time obeyed the typical behavior characterized by Intervals I, II, and III as similar conventional emulsion polymerization. The formation and growth of poly(St/BA/qBVPBr) latex particles has been studied at different reaction times. The results indicate that N_p decrease gradually with time at the early polymerization stages and then reach a constant value after about 20% conversion, but D_p by photon correlation spectroscopy grow continuously as all polymerization proceed. Both the particle size distribution and molecular weight distribution curves are of bimodal size distribution and indicate the participation of at least two mechanisms of particle formation, namely, homogeneous nucleation in the aqueous phase and micellar nucleation. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

The effects of electrolyte concentration in the emulsion polymerization of styrene

Using concentrations below that required to coagulate the latex, the effects of the addition of potassium chloride on the emulsion polymerization of styrene have been investigated. When potassium decanoate (an emulsifier with a high critical micelle concentration (c.m.c.)) is used the increase in the concentration of micellar emulsifier and the decrease in the area occupied by an emulsifier molecule at the polymer/water interface are significant. When this is taken into account Gardon's equation for latex particle size reproduces the trend of the experimental results at the lower electrolyte concentrations. The agreement can be made quantitative by choosing alternative values for the propagation rate constant of styrene and the rate of radical formation from persulphate. With potassium octadecanoate (which has a low c.m.c.) and with potassium decanoate at the higher electrolyte concentrations these factors cannot account for the results observed.     

Applicability of hemicyanine phenyltrialkylborate salts as free‐radical photoinitiators in the visible‐light polymerization of acrylate

The photoinitiation ability of photoredox pairs composed of a hemicyanine dye cation and different borate anions for the radical polymerization of 2‐ethyl‐2‐(hydroxymethyl)‐1,3‐propanediol triacrylate was investigated. In such a system, the excited dye chromophore is reduced by different tetraorganylborate anions. Upon irradiation at 488 nm, reductive carbon–boron bond cleavage occurs, producing reactive radicals, which start the chain reaction. The efficiency of bond‐breaking processes was found to be dependent on the nature of both the acceptors and the donors. The experimental results show that the photoinitiating ability of the tested photoredox pairs were controlled by both the driving force of the electron‐transfer process between the electron donor and the electron acceptor and the reactivity of the free radical that resulted from the secondary reactions occurring after the photoinduced electron‐transfer process. Using the nanosecond flash photolysis method, we studied the spectral and kinetic characteristics of the triplet state of cyanine dye and determined the rate constants of the triplet quenching by phenyltrialkylborate salts. The results obtained show that the tetramethylammonium phenyl‐tri‐n‐butylborate (TB7) has a faster electron‐transfer rate than the tetramethylammonium n‐butyltriphenylborate (TB2) salt, which bore only one butyl group attached to the boron. The relative initiator efficiency of the triphenylbutylborate salts, as compared to the corresponding phenyltrialkylborate salts with a common chromophore, was determined. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Online monitoring of the evolution of the number of particles in emulsion polymerization by conductivity measurements. I. Model formulation

A conductivity meter is an inexpensive instrument that can easily be installed in polymerization reactors. This instrument can be used to monitor ionic species without time‐consuming calibrations. A probe is inserted into the media, providing in situ measurements of conductivity in real time. For emulsion polymerization reactions, the conductivity meter can respond to changes in the ionic surfactant concentration, allowing the determination of surfactant dynamics in the media. The surfactant concentration can then be related to the changes in the surface area of the polymer particle phase, which can be linked to nucleation or coagulation phenomena. In this study, a conductivity meter was coupled to a calorimetric reactor to provide in situ and online measurements of conductivity during the emulsion polymerization of styrene, with sodium dodecyl sulfate as an anionic surfactant and with potassium persulfate as a free‐radical initiator. A semiempirical model was built to describe the conductivity signal as a function of the latex composition and the reactor temperature. The model was inverted and combined with the available conductivity signal, conversion, and temperature measurements and was able to accurately predict the number of polymer particles in the latex and the surfactant concentrations in the many phases, without online measurements of the particle size. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 1213–1226, 2003     

Recalculation of the monomer reactivity and experimental differences in emulsion and microemulsion copolymerizations of partially water‐soluble monomers

On the basis of the copolymerization data for the emulsion and microemulsion polymerizations of ethyl acrylate and methyl methacrylate, the monomer concentrations at the copolymerization loci were calculated, with the assumption that the sum of their concentrations at the polymerization loci was equal to unity. The equivalency of the locus and feed concentrations, as for styrene, was invalid because of the partial water solubility of both the monomers. Consequently, the locus concentration rather than the initial feed concentration was used to recalculate the monomer reactivity at the actual site of polymerization, and this was called the true reactivity ratio. The apparent reactivity ratios for emulsion and bulk polymerizations were different, whereas those for microemulsion and bulk polymerizations were similar. This difference was attributed to the mode of polymerization in the emulsions and microemulsions, leading to different copolymer compositions for similar initial feed concentrations. This was verified experimentally from the thermal properties and particle size distribution measurements. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 2802–2810, 2002     

Kinetics of RAFT emulsion polymerization of styrene mediated by oligo(acrylic acid‐b‐styrene) trithiocarbonate

The kinetics of ab initio reversible addition‐fragmentation chain transfer (RAFT) emulsion polymerization of styrene using oligo(acrylic acid‐b‐styrene) trithiocarbonate as both polymerization mediator and surfactant were systematically investigated. The initiator concentration was set much lower than that in the conventional emulsion polymerization to significantly suppress the irreversible termination reaction. It was found that decreased rapidly but the nucleation efficiency of micelles increased with the decrease of the initiator concentrations due to the significant radical exit. The particle number ( ) did not follow the classic Smith–Eward equation but was proportional to [I]^?0.4[S]^0.7. It was suggested that RAFT emulsion polymerization could be fast enough for commercial use even at extremely low initiator concentrations and low macro‐RAFT agent concentrations due to the higher particle nucleation efficiency at lower initiator concentration. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2126–2134, 2016     

Novel N‐ethyl‐2‐styrylquinolinium iodides as sensitizers in the photoinitiated free‐radical polymerization of trimethylolopropane triacrylate. II

Results of kinetic studies of two‐component photoinitiator systems used in the visible‐light photoinduced polymerization of 2‐ethyl‐2‐(hydroxymethyl)‐1,3‐propanediol triacrylate are presented. Nine different styrylquinolinum dyes coupled with n‐butyltriphenylborate as a coinitiator have been used as photoinitiating systems. Reactive radicals that initiate the polymerization are formed by the well‐known mechanism of photoinduced electron transfer between dye cations acting as electron acceptors and borate anions acting as electron donors. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Kinetic study of the free‐radical polymerization of vinyl acetate in the presence of deuterated chloroform by 1H‐NMR spectroscopy

The free‐radical polymerization of vinyl acetate was performed in the presence of deuterated chloroform (CDCl₃) as a chain‐transfer agent (telogen) and 2,2′‐azobisisobutyronitrile as an initiator. The effects of the initiator and solvent concentrations (or equivalent monomer concentration) and the reaction temperature on the reaction kinetics were studied by real‐time ¹H‐NMR spectroscopy. Data obtained from analysis of the ¹H‐NMR spectra were used to calculate some kinetic parameters, such as the initiator decomposition rate constant (k_d), k_p(f/k_t)^1/2 ratio (where k_p is the average rate constant for propagation, f is the initiator efficiency, and k_t is the average rate constant for termination), and transfer constant to CDCl₃ (C). The results show that k_d and k_p(f/k_t)^1/2 changed significantly with the solvent concentration and reaction temperature, whereas they remained almost constant with the initiator concentration. C changed only with the reaction temperature. Attempts were made to explain the dependence of k_p(f/k_t)^1/2 on the solvent concentration. We concluded from the solvent‐independent C values that the solvent did not have any significant effect on the k_p values. As a result, changes in the k_p(f/k_t)^1/2 values with solvent concentration were attributed to the solvent effect on the f and/or k_t values. Individual values of f and k_t were estimated, and we observed that both the f and k_t values were dependent on the solvent (or equivalent monomer) concentration. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Population balance modeling of particle size distribution in monomer‐starved semibatch emulsion polymerization

The evolution of particle size distribution (PSD) in the monomer‐starved semibatch emulsion polymerization of styrene with a neat monomer feed is investigated using a population balance model. The system under study ranges from conventional batch emulsion to semicontinuous (micro)emulsion polymerization depending on the rate of monomer addition. It is shown that, contrary to what is often believed, the broadness of PSD is not necessarily associated with the length of nucleation period. The PSDs at the end of nucleation are found to be independent of surfactant concentration. Simulation results indicate that at the completion of nucleation the particle size is reduced and the PSD narrows with decreasing rate of monomer addition despite nucleation time increasing. The broad distribution of particles frequently encountered in semibatch emulsion polymerizations is therefore attributed to stochastic broadening during the growth stage. The zero‐one‐two‐three model developed in this article allows perceiving that the dominant kinetic mechanism may be different for particles with different sizes. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

Morphology of poly(butyl acrylate)/poly(styrene‐co‐methyl methacrylate) latex prepared by starved emulsion polymerization: II. Development of particle morphology

Heterogeneous latexes were prepared by a two‐stage seeded emulsion polymerization process under monomer starved conditions at 80 °C using potassium persulfate as the initiator and sodium dodecyl sulfate as the emulsifier. Poly(butyl acrylate) latexes were used as seeds. The second‐stage polymer was poly(styrene‐co‐methyl methacrylate). By varying the amount of methyl methacrylate (MMA) in the second‐stage copolymer, the polarity of the copolymer phase could be controlled. It was found that the latex particles displayed different morphologies depending on the monomer ratio. The amount of MMA had a significant effect on the evolution of morphology. The morphologies were observed by transmission electron microscopy. In addition, the evolution of the particle morphology was predicted by the mathmatical model for cluster migration. The model gave the same trends as the experimental results. © 2002 Society of Chemical Industry