Effects of the carboxyl concentration on the solid‐state polymerization of poly(ethylene terephthalate)

There are two types of polycondensation reactions in the solid‐state polymerization (SSP) of poly(ethylene terephthalate) (PET), namely, transesterification and esterification. Transesterification is the reaction between two hydroxyl ends with ethylene glycol as the byproduct, and esterification is the reaction between a carboxyl end and a hydroxyl end with water as the byproduct. The SSP of powdered PET in a fluid bed is practically a reaction‐controlled process because of negligible or very small diffusion resistance. It can be proved mathematically that an optimal carboxyl concentration for reaction‐controlled SSP exists only if k₂/k₁ > 2, where k₂ and k₁ are the forward reaction rate constants of esterification and transesterification, respectively. Several interesting observations were made in fluid‐bed SSP experiments of powdered PET: (1) the SSP rate increases monotonously with decreasing carboxyl concentration, (2) k₂ < k₁ in the presence of sufficient catalyst, (3) k₁ decreases with increasing carboxyl concentration if the catalyst concentration is insufficient, and (4) the minimum catalyst concentration required to achieve the highest SSP rate decreases with decreasing carboxyl concentration. In the SSP of pelletized PET, both reaction and diffusion are important, and there exists an optimal carboxyl concentration for the fastest SSP rate because esterification, which generates the faster diffusing byproduct, is retarded less than transesterification in the presence of substantial diffusion resistance. The optimal prepolymer carboxyl concentration, which ranges from 25 to 40% of the total end‐group concentration in most commercial SSP processes, increases with increasing pellet size and product molecular weight. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 1288–1304, 2002     

Solid-state polycondensation of poly(ethylene terephthalate) modified with isophthalic acid: kinetics and simulation

The kinetics for the solid-state polycondensation (SSP) of poly(ethylene terephthalate) modified with isophthalic acid at the protection of nitrogen gas was studied in the paper. A kinetic model controlled by the reversible chemical reactions and the three dimension diffusions of small molecule by-products has been established. The kinetic parameters of the SSP of PET at different temperatures, including the forward rate constants of transesterification reaction (k₁) and esterification reaction (k₂), the diffusion coefficients of EG (D₁) and water (D₂), the concentrations of EG (g_s) and water (w_s) on the surface of PET chips in SSP, and the activation energies of these kinetic parameters were obtained by experiments and solution of the model. Using the model and the kinetic parameters, the SSP of poly(ethylene terephthalate) modified with isophthalic acid can be simulated with good accuracy. In addition, the influences of nitrogen gas flow rate, the chip dimension and the carboxyl end-group concentration of the PET prepolymer on the molecular weight of PET after SSP, and the change of the EG concentration of PET chips with reaction time were also studied by simulation.     

Solid‐state polymerization of poly(ethylene terephthalate): Effect of organoclay concentration

Poly(ethylene terephthalate) (PET)/Cloisite 30B (C30B) nanocomposites of different organoclay concentrations were prepared using a water‐assisted extrusion process. The reduction of the molecular weight (M_w) of the PET matrix, caused by hydrolysis during water‐assisted extrusion, was compensated by subsequent solid‐state polymerization (SSP). Viscometry, titration, rheological, and dynamic scanning calorimetry measurements were used to analyze the samples from SSP. The weight‐average molecular weight (M_w) of PET increased significantly through SSP. PET nanocomposites exhibited solid‐like rheological behavior, and the complex viscosity at high frequencies was scaled with the M_w of PET. The Maron–Pierce model was used to evaluate the M_w of PET in the nanocomposites before and after SSP. It was found that the extent and the rate of the SSP reaction in nanocomposites were lower than those for the neat PETs, due to the barrier effect of clay platelets. Consequently, the SSP rate of PET increased with decreasing particle size for the neat PET and PET nanocomposites. The effect of the M_w of PET on the crystallization temperature, crystallinity, and the half‐time, t_½, of nonisothermal crystallization was also investigated. With increasing M_w of PET, t_½ increased, whereas T_c and X_c decreased. POLYM. ENG. SCI., 54:2925–2937, 2014. © 2014 Society of Plastics Engineers     

Solid‐state polymerization of poly(trimethylene terephthalate)

The solid‐state polymerization (SSP) of poly(trimethylene terephthalate) (PTT) has been studied and compared with that of poly(ethylene terephthalate) (PET). Because PTT and PET share the same SSP mechanism, the modified second‐order kinetic model, which has successfully been used to describe the SSP behaviors of PET, also fits the SSP data of PTT prepolymers with intrinsic viscosities (IVs) ranging from 0.445 to 0.660 dL/g. According to this model, the overall SSP rate is ?dC/dt = 2k_a(C ? C_ai)², where C is the total end group concentration, t is the SSP time, k_a is the apparent reaction rate constant, and C_ai is the apparent inactive end group concentration. With this equation, the effects of all factors that influence the SSP rate are implicitly and conveniently incorporated into two parameters, k_a and C_ai. k_a increases, whereas C_ai decreases, with increasing SSP temperature, increasing prepolymer IV, and decreasing pellet size, just as for the SSP of PET. Therefore, the SSP rate increases with increasing prepolymer IV and increasing SSP temperature. The apparent activation energy is about 26 kcal/mol, and the average SSP rate about doubles with each 10°C increase in temperature within the temperature range of 200–225°C. The SSP rate increases by about 30% when the pellet size is decreased from 0.025 to 0.015 g/pellet. Compared with PET, PTT has a much lower sticking tendency and a much higher SSP rate (more than twice as high). Therefore, the SSP process for PTT can be made much simpler and more efficient than that for PET. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 3188–3200, 2003     

Free radical polymerization in ionic liquids—Influence of the IL-concentration and temperature

The influence of the ionic liquid (IL) 1-ethyl-3-methylimidazoliumethylsulfate ([EMIM]EtSO₄) on the polymerization kinetics of methyl methacrylate was investigated. ILs are liquids with relatively high polarities and viscosities. These two characteristic properties are strongly correlated with the rate coefficients of propagation k_p and termination k_t of polymerizations carried out in ILs. The rate constant of termination k_t decreases when the concentration of ionic liquid, and thus the viscosity is increased, whereas the propagation rate coefficient k_p increases with increasing IL content. The viscosity of ILs can be varied by either working with mixtures of ILs with conventional organic solvents – here the IL [EMIM]EtSO₄ was mixed with dimethyl formamide (DMF) – or by variation of the temperature. The studies were carried out to determine the influence of the viscosity on the propagation and the termination reaction as well as the molecular weight distribution.     

Structure and viscoelastic properties of epoxy resins prepared from o-cresol novolacs

The relation between the structure and viscoelastic properties of the epoxy resins prepared from o-cresol novolacs was studied. Our model epoxy resins were two kinds of epoxy compounds synthesized from three-nuclei and four-nuclei o-cresol novolacs. In addition to these models, a commercially available o-cresol novolac-type epoxy resin was also studied. Each of the three epoxy compounds was cured with one of three kinds of novolacs, which were starting materials of the above-mentioned epoxy resins. Characteristic properties of the cured resins, such as glass transition temperature (T_g), average molecular weight between crosslinking points (M¯_c), and front factor (?) were obtained. It was concluded that the number of functional groups contained in the curing system almost dominated the viscoelastic properties of the cured resins.     

Curing behavior of epoxy resin having hydroxymethyl group and different molecular weight distribution

o-Cresol novolac-type epoxy resins having hydroxymethyl group were synthesized. These epoxy resins were cured with a mixture of 4,4′-diaminodiphenylmethane and m-phenylenediamine (molar ratio, 6:4) as a hardener. Effects of molecular weight distribution of epoxy resins on curing behavior were studied. Curing behavior of epoxy resins with hardener were examined by differential scanning calorimetery (DSC), and cure reaction parameters were obtained. Viscoelastic properties of the cured epoxy resins were studied by dynamic mechanical analyzer. It was found that the lower the average molecular weight of the epoxy resin, that is, the higher the concentration of hydroxymethyl group, the shorter the onset time of exothermal reaction, the higher the rate constant (k), and the lower the activation energy (E_a) were. It was also found that glass transition temperature (T_g) of fully cured epoxy resins was higher than those of fully cured general novolac-type epoxy resins.     

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     

Kinetics of the solid‐state polymerization of nylon‐6

The kinetics of the thermally induced solid‐state polymerization (SSP) of nylon‐6 were examined in both a fixed‐bed reactor and a rotary reactor. Factors such as the regulator content, the reaction temperature and time, the particle size, the type and geometry of the nylon‐6 prepolymer, the nitrogen gas flow rate, the water content of the nitrogen gas flow, and the polymerization process were studied. The results showed that the regulator content, the reaction temperature and time, and the particle size were the primary factors, and that the others were negligible. Moreover, the SSP rate and number‐average molecular weight (M_n) increased with increasing reaction temperature and time and decreasing particle size. The SSP rate and M_n had maximum values with increasing regulator content in an experimental range of 0.03–0.07 wt %. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 616–621, 2002; DOI 10.1002/app.10341     

Melting behavior,isothermal and nonisothermal crystallization kinetics of EPPE/mLLDPE blends

Melting behavior and crystallization kinetics of easy processing polyethylene (EPPE) and the blends of EPPE/mLLDPE were studied using differential scanning calorimetry at various crystallization temperature and cooling rates. The Avrami analysis was employed to describe the isothermal and nonisothermal crystallization process of pure polymers and their blends, and a method developed by Mo was applied for comparison. Kinetic parameters such as the Avrami exponent (n), the kinetic crystallization rate constant (k and k_c), the peak temperatures (T_p), and the half-time of crystallization (t_1/2), etc. were determined. The appearance of double melting peaks and the double crystallization peaks of the polymers showed that the main chain and the branches crystallize seperately, but the main chains of two polymers can crystallize together and mLLDPE act as nuclei while EPPE crystallizes. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Monomolecular chain termination in the kinetics of dimethacrylate postpolymerization

The kinetics of postpolymerization (after ultraviolet illumination was stopped) for a number of dimethacrylates that differed by nature and molecular mass was experimentally studied over a wide range of temperatures. A series of kinetic curves that differed by the starting conversion of the dark period of time was obtained for every temperature. The proposed kinetic model of the process is based on the following main principles: (1) the process at an interface on the liquid monomer–solid polymer (micrograins) boundary takes a main share of the kinetics of postpolymerization; (2) chain termination at an interface is monomolecular, is controlled by the chain propagation rate, and represents by itself the self‐burial act of active radicals in the conformation trap; and (3) monomolecular chain termination is characterized by a wide spectrum of characteristic times and that is why the function of the relaxation is described by Kohlrausch's stretched exponential law. The obtained kinetic equation was in good agreement with all of the sets of experimental data. This permitted us to estimate the rate constant of chain termination (k_t) and to determine the scaling dependence of k_t on the molar‐volumetric concentration of the monomer in bulk [M₀]. We assumed that the stretched exponential law and scaling dependence k_t from [M₀] were characterized by common peculiarities, namely, a wide range of characteristic times of relaxation possessed by a property of the fractal set. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 2376–2382, 2004     

Fractal analysis of polymer molecular weight distribution: Dynamic scaling

The correctness of the molecular weight distribution (MWD) of a poly(dimethyl diallyl ammonium chloride) type was shown in the frame‐work of the dynamic distribution function of the irreversible aggregation cluster–cluster model. The buildup of a generalized distribution curve confirms the possibility to describe the polymerization processes within the framework of the mentioned model and allows one to predict the kinetics of MWD changes as the function of the initial monomer concentration c₀ and reaction time t. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 2382–2384, 2003     

Transparency of recycled polypropylene film

Turbidity of quenched polypropylene films was measured as a function of the film thickness and number of times film was recycled. Turbidity τ is defined by τ = (1/d) ln (I_o/I_t), where I_o and I_t are the intensity of the incident and transmitted lights, respectively, and d is the thickness of the sample. We assume here that most of the attenuation of light is due to scattering from superstructure in the film, such as spherulites, since no characteristic absorption bands are present in the wavelength region studied in this work. Turbidity varied sigmoidally with film thickness. It remained constant when the film thickness was lower than ca. 400 μm and then increased with film thickness and reached a plateau around 800 μm. When the film preparation was repeated, turbidity increased exponentially with the number of recycles. The spherulite size, however, was an invariant against the number of recycles and was dependent upon film thickness. The variation of turbidity with film thickness and the number of recycles is discussed.     

The coupled relaxation model for toner melt rheology

Process changes aimed at improving printer engine performance must take into consideration not only the process variables (such as nip temperature and pressure and process time t_o), but also the melt rheological variables (such as the characteristic time scale of the toner T_c). The melt rheology relevant to the electrophotographic toner fusing process is discussed. One criterion for toner quality can be conveniently measured through the Deborah number De, which is the ratio of T_c to t_o. Modification of the melt rheology by matrix polymer composition and carbon black size and concentration has previously been explored. Here, the melt rheology of toners with a range of gel content was studied using a step shear test. The coupled relaxation model was employed to fit the stress relaxation data. The viscoelastic properties were calculated from the melt data with this model. These properties were then used to estimate the strain deformation of the toner as it passes through the nip with arbitrary residence time and nip pressure as a function of gel content. This method can be used to match the toner melt properties with the processing conditions.     

Chemistry and kinetics of LAS acid thermal decomposition

The emission of sulfur dioxide (SO₂) from linear alkylbenzene sulfonate (LAS) acid (LASH) at high temperatures has been studied. Rate constants and Arrhenius parameters have been determined, enabling estimation of the amount of SO₂ evolved under any time/temperature combination for risk assessment purposes. Further analysis of the kinetic data and comparison with earlier molecular modeling work on the mechanism of sulfonation of linear alkyl benzene (LAB) to make LASH provide insight into the reaction pathway of SO₂ formation by thermal decomposition of LASH. For risk assessment purposes, the calculation is as follows: Estimate k from k=3.9×10⁷·e^{−13,000/(273+T)}, where T is in degrees C and k is in s⁻¹. Estimate N(SO₂,t), the number of moles of SO₂ evolved when N(LASH₀) moles of LASH are heated for t s at T ^oC, from: N(SO₂,t)=N(LASH₀)×(1−e^−kt ).     

Dissolution kinetics of alumina in molten CaO–Al2O3–FetO–MgO–SiO2 oxide representing the RH slag in steelmaking process

In order to effectively remove alumina inclusions suspending in ultra-low C steel during RH process, the dissolution kinetics of alumina in molten CaO–Al₂O₃–Fe_tO–MgO–SiO₂ oxide was investigated. A crucible dissolution technique was used where the alumina crucible was allowed to dissolve in the slag of various conditions ((% CaO)/(% Al₂O₃), (% Fe_tO), temperature). The obtained data were interpreted using a kinetic mass transport equation to obtain the mass transport coefficient (k_m) in each condition. Increasing (% CaO)/(% Al₂O₃), (% Fe_tO), and temperature increased the dissolution rate as well as the k_m provided that the slag composition is not close to its saturation composition by alumina. In order to simulate the dissolution of alumina inclusion in the RH slag, which cannot be measured by a confocal scanning laser microscopy (CSLM) at present due to the opaqueness of the slag, the modified invariant interface approximation was employed. Along with the obtained k_m, the viscosity of slag, and a reference experiment using the CSLM, the dissolution kinetics of alumina inclusion in the Fe_tO-containing RH slag was predicted. The time required for the dissolution of alumina inclusions from liquid steel to RH slag was discussed.     

Isothermal crystallization kinetics in binary miscible blend of poly(ε‐caprolactone)/tetramethyl polycarbonate

The crystallization kinetics of pure poly(ε‐caprolactone) (PCL) and its blends with bisphenol‐A tetramethyl polycarbonate (TMPC) was investigated isothermally as a function of composition and crystallization temperature (T_c) using differential scanning calorimetric (DSC) and polarized optical microscope techniques. Only a single glass‐transition temperature, T_g, was determined for each mixture indicating that this binary blend is miscible over the entire range of composition. The composition dependence of the T_g for this blend was well described by Gordon–Taylor equation with k = 1.8 (higher than unity) indicating strong intermolecular interaction between the two polymer components. The presence of a high T_g amorphous component (TMPC) had a strong influence on the crystallization kinetics of PCL in the blends. A substantial decrease in the crystallization kinetics was observed as the concentration of TMPC rose in the blends. The crystallization half‐time t_0.5 increased monotonically with the crystallization temperature for all composition. At any crystallization temperature (T_c) the t_0.5 of the blends are longer than the corresponding value for pure PCL. This behavior was attributed to the favorable thermodynamics interaction between PCL and TMPC which in turn led to a depression in the equilibrium melting point along with a simultaneous retardation in the crystallization of PC. The isothermal crystallization kinetics was analyzed on the basis of the Avrami equation. Linear behavior was held true for the augmentation of the radii of spherulites with time for all mixtures, regardless of the blend composition. However, the spherulites growth rate decreased exponentially with increasing the concentration of TMPC in the blends. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 3307–3315, 2007     

Spouted bed drying of agricultural grains

It is shown that the presence of a “slotted draft tube” results in reduced air requirements for spouting and improved drying performance. Experimental data are presented on batch as well as continuous spouted bed drying of wheat, paddy, maize and peas. The variables studied are feed moisture content (Q_o), inlet air temperature (T_o), bed mass hold-up (M_p), inlet superficial air velocity (u_o) and bed diameter (D_c) in batch drying, and the above variables and solids feed rate (F_s) in continuous drying. The data on average overall drying rate, ?_m, in kg moisture evaporated per unit time per kg bed solids, is found to be correlatable as ?_m, = k (50Q_o + 0.118T_o ? 12.5) 10^?5, and the single parameter k is presented for wheat, paddy, maize and peas for both batch and continuous modes of spouted bed drying. The correlation obtained should be useful in dryer design for the grains studied as well as for other similar materials.     

Copolyester studies. VII. The dyeing behavior of undrawn fibers derived from tetramethylene terephthalate: Poly(tetramethylene oxide) random block copolymers

A series of copolymers based on poly(tetramethylene terephthalate) containing poly(tetramethylene oxide) blocks whose molecular weights ranged from 1000 to 5000 in concentrations from 10 to 30% by weight was prepared. The polymers were melt spun into fibers and the undrawn fibers dyed with a disperse dye at three temperatures. The equibrium adsorption and diffusion coefficient of the dye increased with both the molecular weight and concentration of the polyether. The equilibrium adsorption varied linearly with both the molecular weight and concentration. It has been assumed that the equilibrium dye partition coefficient K_M gives a parameter of the accessibility, V, of the fiber for dye. If the diffusion coefficient D_M is given by D_M = VD_o/τ, where D_o is the diffusion coefficient of the dye in the amorphous regions and τ is a tortuosity factor, a good correlation can be obtained between K_M and D_M, suggesting that changes in D_o/τ vary in a systematic fashion.     

Synthesis and characterization of poly(L‐lactide‐co‐ϵ‐caprolactone)‐b‐poly(L‐lactide) biodegradable diblock copolyesters: Effect of the block lengths on their thermal properties

Poly(L ‐lactide‐co‐ε‐caprolactone)‐b‐poly(L ‐lactide) [P(LL‐co‐CL)‐b‐PLL] diblock copolyesters were synthesized in a two‐step process with 1‐dodecanol (DDC) and stannous octoate as the initiating system. In the first‐step reaction, a 50:50 mol % amorphous poly(L ‐lactide‐co‐ε‐caprolactone) [P(LL‐co‐CL)] copolyester was synthesized via the bulk copolymerization of L ‐lactide and ε‐caprolactone, which was followed by the polymerization of the PLL crystalline block at the end chain in the second‐step reaction. The yielded copolyesters were characterized with dilute‐solution viscometry, gel permeation chromatography, ¹H‐ and ¹³C‐NMR, and differential scanning calorimetry methods. The molecular weights of the P(LL‐co‐CL) copolyesters from the first‐step reaction were controlled by the DDC concentrations, whereas in the second‐step reaction, the molecular weights of the P(LL‐co‐CL)‐b‐PLL diblock copolyesters depended on the starting P(LL‐co‐CL) copolyester molecular weights and L ‐lactide/prepolymer molar ratios. The starting P(LL‐co‐CL) copolyester molecular weights and PLL block lengths seemed to be the main factors affecting specific thermal properties, including the melting temperature (T_m), heat of melting (ΔH_m), crystallizing temperature (T_c), and heat of crystallizing (ΔH_c), of the final P(LL‐co‐CL)‐b‐PLL diblock copolyester products. T_m, ΔH_m, T_c, and ΔH_c increased when the PLL block lengths increased. However, these thermal properties of the diblock copolyesters also decreased when the P(LL‐co‐CL) block lengths increased. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2007