Iodine transfer dispersion polymerization (dispersion ITP) with CHI3 and reversible chain transfer catalyzed dispersion polymerization (dispersion RTCP) with GeI4 of styrene in supercritical carbon dioxide

Submicrometer-sized, polystyrene (PS) particles with controlled molecular weight distribution (MWD), were successfully obtained directly as powder state by iodine transfer dispersion polymerization (dispersion ITP) and reversible chain transfer catalyzed dispersion polymerization (dispersion RTCP) in supercritical carbon dioxide (scCO₂) for the first time. These dispersion polymerizations proceeded similarly reaching 80% conversion in 21 h. In the dispersion ITP, the number-average molecular weight (M_n) nonlinearly increased with the conversion, which were always higher than theoretical values, and the MWD at each conversion was comparatively narrow (M_w/M_n = 1.5–1.7) throughout polymerization. In the dispersion RTCP, M_n also nonlinearly increased with increasing conversion and M_w/M_n values were in the range of 1.3–1.5, which were lower than those of the dispersion ITP. In chain extension tests in bulk systems, the degrees of livingness of PS prepared by the dispersion ITP and the dispersion RTCP in scCO₂ systems were, respectively, estimated to be 56% and 48%. From these results, while more investigation is necessary, it was concluded that both polymerizations with scCO₂ proceeded in a partly controlled manner.     

Analysis of solution polybutadiene polymerizations performed with a neodymium catalyst

This article is regarding the polymerization of 1,3‐butadiene with a neodymium catalyst activated by diisobutylaluminum‐hydride and diethylaluminum chloride (DEAC). The effects of the polymerization conditions (ratio between DEAC and neodymium molar concentrations, polymerization temperature, catalyst concentration, and butadiene concentration) on the polymer yield and molecular weight distribution (MWD) of polybutadiene (PB) samples were evaluated. It is shown that the DEAC/Nd ratio and the polymerization temperature are the reaction variables that influence the MWD and the catalyst performance most significantly. PBs with broad and sometimes bimodal MWD were produced at the analyzed reaction conditions. For this reason, the MWD of the obtained polymer materials was deconvoluted with the help of the Flory most probable distribution, indicating that three or more catalyst sites are required to explain the final MWD of the polymer samples. Finally, it was observed that the analyzed neodymium catalyst is able to produce branched PBs at mild reaction conditions and that the branching frequency depends on the polymerization conditions, which may be useful for development of operation policies at plant site and production of materials with improved performances. POLYM. ENG. SCI., 2011. © 2010 Society of Plastics Engineers     

Structure and morphology of solution blended poly(vinylidene fluoride)/montmorillonite nanocomposites

Nanocomposites based on poly(vinylidene fluoride) were prepared with montmorillonite by solution blending. The samples were characterized by small angle X‐ray scattering, wide angle X‐ray diffraction, Fourier transform infrared spectroscopy, and differential scanning calorimetry. Different crystallization conditions, that is, evaporation of the solvent and coprecipitation with two different antisolvents, H₂O or supercritical CO₂ (scCO₂), were tested and their influence on the resulting structure and morphology of the samples were studied. Coprecipitation with scCO₂ induced an ordinate crystalline framework and an intercalated morphology of clay, with a consequent large improvement in modulus. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

High molecular weight graft stabilisers for dispersion polymerisation of vinylidene fluoride in supercritical carbon dioxide: the effect of architecture

A group of high molecular weight graft stabilisers, both fluorinated and non-fluorinated, were synthesised by thermal ring-opening esterification of anhydride copolymers. These included poly(methyl vinyl ether-alt-maleic anhydride) and poly(maleic anhydride-octadecene) and were reacted with alcohols, including 1H,1H,2H,2H-perfluorooctanol, 1H,1H,2H,2H-perfluoro-dodecanol and 1-octanol. The stabilisers were fully characterised by ¹H, ¹⁹F and ¹³C nuclear magnetic resonance, diffuse reflectance Fourier transform infrared spectroscopy, and thermal analysis. Their phase behaviour in supercritical carbon dioxide (scCO₂), vinylidene fluoride (VDF), and a mixture of scCO₂/VDF was also studied using a variable volume view cell. Each stabiliser was tested for the dispersion polymerisation of VDF in scCO₂. The effect of the stabiliser architecture on the molecular weight and morphology of the poly(vinylidene fluoride) (PVDF) polymer product was investigated. Steric stabilisation effects were observed. Gel permeation chromatography and scanning electron microscopy were used for the characterisation of the molecular weight and morphology of PVDF polymers.     

Understanding multivinyl monomer photopolymerization kinetics through modeling and GPC investigation of degradable networks

Multivinyl monomers that react to form highly crosslinked, biodegradable networks are being developed as scaffolds for tissue engineering and vehicles for drug delivery; however, this work demonstrates their usefulness in characterizing better the complexities of the kinetics and structural evolution during crosslinking photopolymerization. The molecular weight distributions (MWDs) of the degradation products of networks formed through the free radical photopolymerization of multivinyl monomers validate a novel kinetic model to test hypotheses as to the important kinetic mechanisms during crosslinking. The kinetic model, in conjunction with the experimental results for the degradable network, provides insight into the fundamental termination mechanisms (i.e. chain length dependent termination (CLDT), chain transfer to either a unimolecular species or polymer, and the accumulation of persistent radicals) that control the MWD of the backbone kinetic chains throughout the polymerization. Specifically, the importance of CLDT during autoacceleration and the impact of light intensity on the MWD of the backbone kinetic chains are presented.     

Crosslinked microparticle preparation in supercritical carbon dioxide with photopolymerization

An antisolvent processing technique by simultaneous compressed antisolvent precipitation and photopolymerization for cross-linked polymer microparticles formation was presented in this paper. In this process, photopolymerization of the homogeneous solution composed of methylene chloride, poly(ethylene glycol)600 diacrylate (PEG600DA) as monomer and diphenyl-(2,4,6-trimethylbenzoyl)-phosphine oxide (TPO) or 2,2-dimethoxy-2-phenylacetophenone (DMPA) as photoinitiator resulted to microparticle when it was sprayed into supercritical carbon dioxide (scCO₂) and simultaneously exposed to initiating light. High miscibility of the solvent in scCO₂ made methylene chloride quickly extracted from the dispersion phase, leaving very high concentrations of monomer (PEG600DA) dispersed in scCO₂. The high monomer concentration combined with photo initiating polymerization facilitates rapid reaction rates and ultimately lead to polymer precipitation. Particle size and morphology were adjustable by changing the processing conditions, such as temperature and pressure. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Modeling of precipitation polymerization II: calculation of macroradicals concentrations in the continuous and dispersed phases

According to Hunkeler model, precipitation polymerization of acrylic acid in organic media takes place simultaneously in the both dispersed and continuous phases. In this research, a model is presented based on mass balances of individual species. Hence, concentrations of macroradicals and polymer chains, in different chain lengths, were calculated in the both phases. Number- and weight-average degrees of polymerization and their distributions were concluded in the both dispersed and continuous phases. Calculation of macroradicals concentration was conducted with quasi-steady state approximation (QSSA) as well as without QSSA (based on the governing differential equations). Macroradical precipitate as soon as reaching to critical chain length. Moreover, precipitation is the main termination reaction in the continuous phase. Polymer with critical chain length is the most populated species in the dispersed phase. Comparison of theoretical and experimental results is in good agreement. QSSA theory gives better results than without QSSA theory because occlusion of macroradicals in the dispersed phase does not occur in the precipitation polymerization of water-soluble monomers in the organic media. This article has proved that the polydispersity index (PDI) of polymer product in the precipitation polymerization of acrylic acid in toluene that follows simultaneous polymerization model is less than that of PDI in the other free radical polymerization methods. Centrifugation method was used to sediment fine polymer particles. The yield of reaction was increased by sedimentation process.     

Analysis of multiphase polycarbonate polymerization in a semibatch reactor

A physical and chemical model that describes the interfacial condensation of bisphenol-A to polycarbonate in a multiphase gas-liquid-liquid semi-batch reactor is presented. The particular polymerization kinetics model consists of initiation, propagation and termination reactions between dissolved bisphenol-A monomer, phosgene gas, a phenolic polymer chain growth stopper and various resulting polymer species. Using these kinetics, a physical model for a semi-batch stirred tank reactor is developed. The model accounts for finite liquid-liquid and gas-liquid mass transfer resistances and includes either plug-flow or complete backmixing of the gas bubbles as options for the gas flow pattern. The model equations are solved using the z-transform method from which the polymer MWD and the moments of the polymer MWD are obtained. The utility of the model as a quantitative means of assessing the effect of various kinetic and transport parameters on the polymer MWD is examined for a particular case.     

Synthesis of cross-linked poly(4-vinylpyridine) and its copolymer microgels using supercritical carbon dioxide: Application in the adsorption of copper(II)

Compared with conventional precipitation polymerization method, cross-linked poly(4-vinylpyridine) (P4VP) and its microgels copolymerized with α-methacrylic acid (MAA) were synthesized through a new route of stabilizer-free polymerization in supercritical fluids. The yellow, dry, fine powders were directly obtained from precipitation polymerization of 4-vinylpyridine in supercritical carbon dioxide (scCO₂) at pressures ranging from 70.0 to 230 bar, using N,N′-methylenebisacrylamide as cross-linker. The effects of the reaction pressure, cross-linker ratio, initiator concentration, and reaction time were investigated. The capacity of this microgel for adsorption of copper(II) was also studied. At higher cross-linker concentrations, a high yield of the cross-linked P4VP microgel was generated in scCO₂, and its particle size was less than 300 nm. Polymerization of cross-linked P4VP in scCO₂ was extremely sensitive to the density of the continuous phase. The adsorption followed the Langmuir isotherm. The adsorption capacities of cross-linked P(4VP-co-MAA) and cross-linked P4VP were 47.2 and 26.9 mg g⁻¹, respectively.     

Effect of chain length distribution on thermal characteristics of model polytetrahydrofuran (PTHF) networks

A series of model polytetrahydrofuran (PTHF) networks were synthesized via end-linking reactions of α, ω-allyl PTHF oligomers with a stoichiometric tetrafunctional crosslinker. The telechelic PTHF oligomers were synthesized by living cationic ring-opening polymerization of tetrahydrofuran followed by a termination reaction with allyl alcohol. Networks thus prepared have well-controlled architecture in terms of the inter-crosslink chain length (M_c) and chain length distribution: resulting in unimodal, bimodal and clustered structures. Unimodal network was prepared by using polymer chains of same molecular weight, bimodal networks were synthesized by using two groups of polymer chains with different average molecular weights, and the clusters are prepared by incorporating clusters of networks with small molecular weight chains in a network matrix made of longer chains. Thermal characteristics of these model networks were investigated as a function of crosslink density, as well as inhomogeneities of crosslink distribution using DSC. We demonstrate that glass transition temperature (T_g) and crystallization behavior (melting temperature and crystallinity) of the networks are both strongly influenced by crosslink density (M_c). By comparing the unimodal, bimodal and clustered networks with similar average M_c, the effects of inhomogeneities in the crosslink distribution on the thermal properties were also investigated. Results show that inhomogeneities have trivial influence on T_g, but strongly affects the crystallization behavior. Moreover, the effects of the content ratio and length ratio between long and short chains, and the effects of cluster size and size distribution on the thermal characteristics were also studied.     

Generation of microcellular foams of PVDF and its blends using supercritical carbon dioxide in a continuous process

Use of supercritical carbon dioxide (scCO₂) as a blowing agent to generate microcellular polymer foams (MPFs) has recently received considerable attention due to environmental concerns associated with conventional organic blowing agents. While such foams derived from amorphous thermoplastics have been previously realized, semicrystalline MPFs have not yet been produced in a continuous scCO₂ process. This work describes the foaming of highly crystalline poly(vinylidene fluoride) (PVDF) and its blends with amorphous polymers during extrusion. Foams composed of neat PVDF and immiscible blends of PVDF with polystyrene exhibit poor cell characteristics, whereas miscible blends of PVDF with poly(methyl methacrylate) (PMMA) yield foams possessing vastly improved morphologies. The results reported herein illustrate the effects of blend composition and scCO₂ solubility on PVDF/PMMA melt viscosity, which decreases markedly with increasing PMMA content and scCO₂ concentration. Morphological characterization of microcellular PVDF/PMMA foams reveals that the cell density increases as the PMMA fraction is increased and the foaming temperature is decreased. This study confirms that novel MPFs derived continuously from semicrystalline polymers in the presence of scCO₂ can be achieved through judicious polymer blending.     

Slow initiation by tert-butoxybenzenes in living cationic polymerization of isobutylene

Summary tert-Butoxybenzenes including the 4-substituted derivatives of anisole, toluene and p-chlorobenzene have been synthesized and studied as initiators in combination with TiCl₄ for polymerization of isobutylene (IB) in CH₂Cl₂/methylcyclohexane (MeCHx) solvent mixtures at -78°C. Living polymerizations with slow initiation were observed by the allmonomer-in (AMI) and incremental monomer addition (IMA) techniques, and polymers with narrow molecular weight distribution (MWD) (M_w/M_n>1.1) were obtained under certain conditions. Aging of the initiating system prior to charging the monomer does not improve the initiating efficiency. It has been found that the initiating efficiency can be increased by increasing the solvent polarity, however, the relative volume of CH₂Cl₂ is limited in order to avoid polymer precipitation and bimodal MWD.     

Modelling of polymerization kinetics and molar mass development in the nitroxide-mediated polymerization (NMP) of styrene in supercritical carbon dioxide using the PC-SAFT equation of state

A mathematical model for polymerization kinetics and molar mass development in the nitroxide-mediated polymerization (NMP) of vinyl monomers in supercritical carbon dioxide (scCO₂) has been developed. The method of moments is used for molar mass development. The perturbed-chain statistical associating fluid theory (PC-SAFT) equation of state is used to estimate the number of stable phases present at equilibrium in the reaction mixture, critical number average chain length at which polymer particles are formed, and monomer concentration in each phase. Pure and binary PC-SAFT interaction parameters are estimated from liquid–liquid equilibrium (LLE) and liquid–vapour equilibrium (LVE) experimental data at 60 to 129°C. The effect of pressure on monomer conversion and molar mass development in the polymerization of styrene (Sty) using benzoyl peroxide (BPO) and 2,2,6,6-Tetramethylpiperidinyl-1-oxyl (TEMPO) at 120°C and 300–500 bar is studied. It was observed that increasing pressure increases polymerization rate without significantly affecting molar mass development.     

Molecular Weight Distribution of Polystyrene Produced in a Starved Feed Reactor

A starved feed reactor (SFR) is a semi-batch polymerization reactor where initiator and monomer are fed slowly into a fixed amount of solvent. The polymerization is carried out isothermally at elevated temperatures, The added initiator decomposes instantaneously and the added monomer polymerizes immediately. The molecular weight (MW) and molecular weight distribution (MWD) of the product polymer can be effectively controlled by the feed ratio of monomer to initiator. This paper preaeats a study on the MWD of styrene polymerization in a SFR. The MWD model parameters are regressed with experimeatvJ data. Although the solids fraction in the SFR is high (higher than 50%), vlscceity is not too high and the “gel effect“ is weak due to the low molecular weight of the products. It is found that the termination rate constant is a power function of molecular weight, radicals terminate via 100% combination,the thermal iuitiation can be neglrcted even at high reaction temperature studied. And calculated results indicate that in the SFR, the validity of the long chain assumptinn becomes doubted. It appears that other alterative assumption should be found for an improved model.     

Effect of temperature variations on molecular weight distributions: batch,chain addition polymerizations

The Maximum Principle was applied to determine the types of temperature variations that minimize and maximize the breadth of the molecular weight distribution (MWD) for chain addition polymerizations in batch reactors. It was found that the variations which minimize the breadth of the MWD keep the instantaneous number average chain length constant. The variations which maximize the breadth of the MWD are step changes in temperature resulting in bimodal distributions. Numerical and experimental examples of such variations are presented. MWD's with minimum and maximum breadths are compared to those that might be formed by temperature variations in real reactors. Under most conditions, temperature variations appear to have a much greater effect on MWD than residence time distributions and micromixing.     

The radiation-initiated solution polymerization of vinylidene fluoride

The radiation-initiated solution polymerization of vinylidene fluoride was examined in an effort to determine the effect of polymerization conditions on the head-to-head content of the resulting poly(vinylidene fluoride). No appreciable change was observed in the head-to-head content when this new type of polymerization was utilized. However, the polymers which resulted had melting points 10–15°C higher than those of the suspension-polymerized poly(vinylidene fluoride), higher crystallinity, and, when trifluoroacetic acid was used as a solvent, a higher molecular weight.     

POLYMERIZATION KINETICS AND MODELING OF SLURRY ETHYLENE POLYMERIZATION PROCESS WITH METALLOCENE/MAO CATALYSTS

Polymerization methods of ethylene include the slurry, solution, and gas-phase processes. This study investigates polymerization conditions and kinetics under slurry process. Typical metallocene catalyst/cocatalyst Cp₂ZrCl₂/MAO system was used for ethylene polymerization. Two kinds of polymerization kinetics were compared in this study, multiple active-site model and transfer-effect model. The kinetic studies used metallocene-type polymerization kinetics, including catalyst activation, initiation, chain propagation, chain transfer, and termination steps. In addition, kinetic constants of polymerization reaction model were calculated. Calculation results of catalyst activity and molecular weight were compared with experimental results, indicating their good correlation. Moreover, the conventional polymerization was modified to accurately predict the molecular weight behaviors under various reaction conditions with the proposed transfer-effect model. Exactly, how reaction time, pressure, catalyst concentration, and cocatalyst ratio affect catalyst activity and molecular weight of the polymer were also discussed.     

Modeling of molecular weight distribution of gas‐phase polymerization of butadiene

A mathematical model of the molecular weight distribution (MWD) based on a multilayer model and an improved intrinsic kinetics model was proposed to simulate the MWD of the gas‐phase polymerization of butadiene with a heterogeneous catalyst. Intrinsic kinetics and heat and mass‐transfer resistances based on the multilayer model of a polymeric particle were considered in the modeling of the MWD. The effects of the reaction conditions, catalyst particle size, mass‐transfer resistance, deactivation of active sites, and transfer of the polymer chain on the molecular weight and MWD were simulated. The results show that the effects of the deactivation of active sites and transfer of the polymer chain on the average molecular weight are significant and that the effect of the catalyst particle size on the MWD is not significant. The simulation results of the molecular weight and MWD are compared with the experimental results. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 88–103, 2003     

Determination of polymer chain length distributions by numerical inversion of z-transforms

A numerical technique is presented for evaluation of the polymer chain length distribution in polymerization reaction engineering models whose governing equations can be represented in the z-transform domain. The method is based upon an appropriate z-transform inversion relationship that has the form of an inverse discrete Fourier transform which can be efficiently evaluated by the fast Fourier transform algorithm using various existing computer software. The approach is illustrated through several example problems involving polymerization systems and comparisons are made to other alternate solution methods. One of the example problems includes a complex reaction network for polycarbonate polymerization as a novel application. It is shown that the proposed technique requires an order-of-magnitude less computer time to evaluate the polymer MWD when compared to direct numerical integration.