Chain extension of recycled poly(ethylene terephthalate) with 2,2′‐(1,4‐phenylene)bis(2‐oxazoline)

The present work provides improved recycled high molecular weight poly(ethylene terephthalate) (PET) by chain extension using 2,2′‐(1,4‐phenylene)bis(2‐oxazoline) (PBO) as the chain extender. PBO is a very reactive compound toward macromolecules containing carboxyl end groups but not hydroxyl end groups. In the case of PET, where both species are present, for even better results, phthalic anhydride (PA) was added in the initial sample, before the addition of PBO. With this technique, we succeeded in increasing the carboxyl groups by reacting PA with the hydroxyl terminals of the starting polymer. From this modification of the initial PET sample, PBO was proved an even more effective chain extender. So, starting from a recycled PET with intrinsic viscosity [η] = 0.78, which would be [η] = 0.69 after the aforementioned treatment without a chain extender or M̄_n = 19,800, we prepared a PET grade having [η] = 0.85 or M̄_n = 25,600 within about 5 min. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 77: 2206–2211, 2000     

Plasma‐induced,solid‐state polymerization of N‐isopropylacrylamide

The radio‐frequency plasma‐initiated polymerization of N‐isopropylacrylamide (NIPAM) in the solid state was performed. The isolated linear polymer was characterized by ¹³C‐NMR, ¹H‐NMR, and Fourier transform infrared spectroscopy, and the effects of selected operational plasma parameters (discharge power and time) on the conversion rates were studied. Reversible transitions at the volume‐phase‐transition temperatures of the swelled poly(N‐isopropylacrylamide) hydrogels were investigated by differential scanning calorimetry. The surface morphologies before and after plasma treatment were followed by scanning electron microscopy. With the obtained X‐ray diffraction results, we propose a solid‐state plasma polymerization mechanism for the NIPAM. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Solid‐state polymerization and bulk crystallization behavior of poly(ethylene terephthalate) (PET)

The main variables involved in solid‐state polymerization of PET homopolymers, originally with molecular weight within the commercial range, were sequentially studied to determine their influence in polymerized products. These variables were precursor crystallinity, catalyst, and time and reaction temperature. An increasing molecular weight sequence was then used to study the bulk crystallization behavior with Avrami analyses. It was determined that thermal conditions at dissolution affect the prereaction morphology. This was important in the polymerization process because it was found that high crystallinity levels in precursors result in higher molecular weights. In agreement with other reports, typical catalysts used in melt polymerizations enhance postpolycondensation processes in the solid state. High reaction times and temperatures were also required to obtain high molecular weights. As the molecular weight increased, there was a decrease in nucleation density and Avrami analyses, applied to the isothermal bulk crystallization, indicating that the nucleation process changed from instantaneous to spontaneous with the increase in molecular weight. The consequences and relative importance of the observed results is discussed. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 75: 78–86, 2000     

The rate acceleration in solid‐state polycondensation of PET by nanomaterials

The effect of nanomaterials on the solid‐state polycondensation (SSP) of PET was investigated using intrinsic viscosity measurement, wide‐angle X‐ray diffraction, differential scanning calorimetry, and polarizing microscope. The results showed that the montmorillonite nanomaterials could greatly increase the rate of solid‐state polycondensation of PET, probably due to the nucleation of montmorillonite nanomaterials for PET crystallization, which resulted in lower crystallinity, more small crystals, and more surfaces of the crystals. The surfaces of microcrystal and richer amorphous regions benefitted the polycondensation reaction of PET and diffusion of volatile by‐products, which led to the higher rate of SSP. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 94: 971–976, 2004     

Post‐extrusion solid‐state polymerization of fully drawn polyester yarns

Post‐extrusion solid‐state polymerization (SSP) of a commercial fully drawn filament yarn (FDY) of poly(ethylene terephthalate) was carried out at 220°C, 230°C, and 240°C for a duration of 30 min to 2 h under inert atmosphere. Molecular weight of the solid‐state polymerized polyester filaments was increased from 1.67 × 10⁴ gm/mol to a maximum of 2.61 × 10⁴ gm/mole for the sample subjected to 240°C for 2 h. The kinetics of the SSP in the highly oriented crystalline FDY polyester filaments was investigated using an empirical relation between initial molecular weight and time of SSP and was found to be greatly enhanced, compared to amorphous unoriented polyester chips. Though the free annealing (i.e., under no tension) of samples at high temperature during solid‐state polymerization had a detrimental effect on the orientation of the FDY yarn, the simultaneous increase in the molecular weight compensated the loss in mechanical properties to a great extent. Application of tension during SSP was found to improve the mechanical properties of the SSP yarn by a small value. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 5113–5122, 2006     

Effects of crystallinity on solid‐state polymerization of poly(ethylene terephthalate)

There has been a widely held assumption that the solid‐state polymerization (SSP) rate of poly(ethylene terephthalate) (PET) decreases with increasing crystallinity. Several published articles that purported to prove this assumption were based on faulty experiments. Therefore, a proper experimental procedure has been used to study the true effects of crystallinity on the SSP of PET. The results show that, for PET in pellet and powder forms, the SSP rate increases with increasing crystallinity. This is because an increase in the crystallinity results in increased end‐group concentration in the amorphous phase, where SSP reactions take place, and decreased concentrations of inactive end groups trapped inside the crystals, thereby increasing the rates of end‐group collision and reactions. These positive effects outweigh the negative effect of the increased byproduct‐diffusion resistance because of the increase in crystallinity. As the particle size of PET is increased beyond a critical value of about 7 mm, the SSP rate actually decreases with increasing crystallinity because of the excessively increased byproduct‐diffusion resistance within the PET particles. However, this critical particle size is far greater than the pellet sizes of commercial PET resins. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 623–632, 2006     

Chain extension reactions of unsaturated polyesters with bis(2‐oxazoline)s

Two different bisoxazolines, 2,2′‐(1,3‐phenylene) bis(2‐oxazoline) (1,3‐PBO) and 2,2′‐bis(2‐oxazoline) (BO) were investigated as chain extenders for short chain unsaturated polyesters (UPEs). These extenders reacted readily with carboxyl ends of unsaturated polyesters, leading to rapid molecular weight increase through coupling of oligomeric chains. Commercially available unsaturated polyesters commonly have molecular weights around 1500, usually reached after a 20‐h polyesterification reaction. When bisoxazolines were reacted with short UPE chains obtained at the 6th hour of a commercial polyesterification reaction, the molecular weight of UPE reached 1500 within 5–30 min, which provides economies and prevents the glycol loss and yellowing which are associated with extended reaction times. Styrene solubility, gel time, and thermal and mechanical properties of the chain extended polyesters remained comparable to the commercial UPE, with 8–10 min of gel time and a storage modulus about 3000 MPa. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

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     

A comprehensive model for solid‐state polycondensation of poly(ethylene terephthalate): Combining kinetics with crystallization and diffusion of acetaldehyde

A comprehensive mathematical model was established by considering the main and side reactions for solid‐state polycondensation of poly(ethylene terephthalate). The effect of temperature on chain mobility was used to estimate the rate constants of chemical reactions. The polymer crystalline fraction was modeled as containing only repeat units, thus concentrating end groups and condensates in the amorphous fraction. The diffusion coefficient of acetaldehyde was calculated by the model. The simulation results of this comprehensive model were validated by experimental data reported in literature. The model predictions were important clues for further experimental study on poly(ethylene terephthalate) solid‐state polycondensation. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 3133–3144, 2002; DOI 10.1002/app.10113     

PET recycling: Evaluation of the solid state polymerization process

Many studies have been carried out to make bottle‐to‐bottle recycling feasible. One of the difficulties found is the decrease in the polymer's molar mass, which damages the injection blow molding process. A method usually employed to increase the molar mass of virgin PET consists of solid‐state polymerization (SSP). In this work, we studied the SSP process applied to post‐consumer recycled PET by analyzing the inherent viscosity and amount of carboxylic end groups, and the results of dynamic flow rheometry. Although the results show that the recycling process decreases polymer molar mass, and this indicates degradative processes, SSP was successful in increasing molar mass in post‐consumer recycled PET. This made feasible bottle‐to‐bottle recycling. In addition, the parallel plate rheometry technique was powerful in assessing the degradative process and, therefore, that the SSP process was successful. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci, 2006     

N_2对PET连续固相缩聚生产的影响探讨

结合生产试验结果 ,分析、研究N2 流量、温度及其组分对PET固相缩聚反应速率及产品质量的影响 ,用于指导生产 ,优化调整工艺 ,提高瓶用聚酯的产品质量。     

Crystallization and solid‐state polymerization of poly(aryl ester)s

The crystallization and solid‐state polymerization (SSP) of poly(aryl ester)s was investigated. Oligomers with different end‐groups were prepared by degradation of commercially available poly(aryl ester)s. The SSP of these oligomers was carried out after crystallization and under reduced pressure, in the presence of various catalysts. Polymers were characterized by means of their inherent viscosities and thermal properties. It has been found that Ti(OⁱPr)₄ was a better catalyst for SSP. The structures and morphologies of semicrystalline poly(aryl ester)s were investigated by X‐ray diffraction and differential scanning calorimetry (DSC). Copyright © 2004 Society of Chemical Industry     

Solid‐state polymerization of poly(ethylene 2,6‐naphthalate)

The solid‐state polymerization (SSP) of poly (ethylene 2,6‐naphthalate) (PEN) was studied and compared with that of poly(ethylene terephthalate) (PET). The SSP of PEN, like that of PET, could be satisfactorily described with a modified second‐order kinetic model, which was based on the assumptions that part of the end groups were inactive during SSP and that the overall SSP followed second‐order kinetics with respect to the active end‐group concentration. The proposed rate equation fit the data of the SSP of PEN quite well under various conditions. PEN prepolymers in pellet and cube forms with intrinsic viscosities (IVs) ranging from 0.375 to 0.515 dL/g, various particle sizes, and various carboxyl concentrations were solid‐state polymerized at temperatures ranging from 240 to 260°C to study the effects of various factors. The SSP data obtained in this study could be readily applied to the design of commercial PEN SSP processes. Because PEN and PET share the same SSP mechanism, in general, the SSP behaviors of PEN are similar to those of PET. Thus, the SSP rate of PEN increased with increasing temperature, increasing prepolymer IV, and decreasing prepolymer particle size. However, because of the much higher barrier properties of PEN, the prepolymer particle size and carboxyl concentration had much greater effects on the SSP of PEN than on the SSP of PET. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 1075–1084, 2007     

Broadening of molecular‐weight distribution in solid‐state polymerization resulting from condensate diffusion

A kinetic model for the solid‐state polymerization of poly(bisphenol A carbonate) in a single particle has been developed and used to investigate the broadening of molecular‐weight distribution as a result of slow condensate diffusion. The model is based on melt‐phase transesterification kinetics and Fickian diffusion of phenol, the condensate, in the amorphous regions of the semicrystalline particle. Model predictions compare favorably to experimental data. When diffusion is slow compared to reaction, a condensate concentration gradient is established. This gradient induces a molecular‐weight gradient, which results in a broadened overall molecular‐weight distribution with an overall polydispersity above the theoretical limit for homogenous step‐growth polymerization. As the mass transfer resistance inside the particle is decreased, the average molecular weight increases faster with time, and the overall polydispersity decreases. A stoichiometric imbalance of end groups decreases the obtainable molecular weight but mitigates the deleterious effects of slow condensate diffusion. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 79: 928–943, 2001     

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     

Plasma‐induced solid‐state polymerization modified poly(tetrafluoroethylene) membrane for pervaporation separation of aqueous alcohol mixtures

Acrylamide (AAm) solid state polymerization was induced using argon plasma to improve the pervaporation performance of poly(tetrafluoroethylene) (PTFE) membranes (PTFE‐g‐PAAm) in aqueous alcohol mixtures. The surface morphology, chemical composition, and hydrophilicity changes in the PTFE and PTFE‐g‐PAAm membranes were investigated using ATR‐FTIR, SEM, AFM, X‐ray photoelectron spectroscopy, and water contact angle measurements. The surface hydrophilicity rapidly increased with increasing Ar exposure time, but decreased after longer Ar exposure time because of the degradation in the PTFE‐g‐PAAm membrane grafted layer. Compared with the hydrophilicity of the pristine PTFE membrane (water contact angle = 120°), the argon plasma induced acrylamide (AAm) solid‐state polymerization onto the PTFE surface (water contact angle = 43.3°) and effectively improved the hydrophilicity of the PTFE membrane. This value increases slowly with increasing aging time and then reaches a plateau value of about 50° after 10 days of storage under air. The pervaporation separation performances of the PTFE‐g‐PAAm membranes were higher than that of the pristine PTFE membrane. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102:909–919, 2006     

Effect of β‐cyclodextrin on the solid‐state synthesized polyaniline doped with hydrochloric acid

Polyaniline (PANI) salts doped with hydrochloric acid were prepared by using solid‐state polymerization in the presence of β‐cyclodextrin (β‐CD) at room temperature. The fourier transform infrared (FTIR) spectra, ultraviolet‐visible absorption spectra, X‐ray diffraction patterns were used to characterize the molecular structures of these polymers. Cyclic voltammetry study and conductivity measurements were done to investigate their electrochemical behaviors. The morphology of polymers was studied by the scanning electron microscopy and transmission electron microscopy. The results showed that PANI salts prepared in the presence of β‐CD had different physicochemical characteristics compared with PANI salt prepared in the absence of β‐CD. When the molar ratio of aniline to β‐CD was 80/20, the obtained PANI salt displayed higher crystallinity, conductivity and electrochemical properties. However, these properties were opposite on condition that the molar ratio of aniline to β‐CD was 50/50. The results also revealed that the morphology of PANI salt was affected by β‐CD, especially at aniline/β‐CD molar ratio in the feed of 50/50, in which PANI salt displayed rodlike structure morphology with a diameter of near 80–100 nm. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

A comprehensive single‐particle model for solid‐state polymerization of poly(L‐lactic acid)

We propose here, a comprehensive model for the solid‐state polymerization (SSP) of a low to moderate molecular weight (MW) prepolymer of lactic acid, to produce high MW poly(L ‐lactic acid) (PLLA). The reactions are rationally assumed to occur only in the amorphous region, and effective concentrations of end groups, vary with crystalinity, X_c, during SSP. We estimate byproduct diffusivities, D, using free volume theory. The effects of various parameters on the SSP of PLLA prepolymer have been examined with respect to the optimum MW, X_c and D. We introduce self‐consistently, scaling factors of ～ 0.27, in the experimental procedure, to determine via ¹⁹F‐NMR, concentrations of the end groups, after converting them to fluorinated ester groups. The relevant reaction rate constants are obtained by fitting to early time data from representative SSP experiments at 150°C, under high vacuum, on PLLA prepolymer powder (i.e., spherical geometry) of number average MW, M_n0 ～ 10,200 Da, which attains M_n ～ 150,000 Da, via SSP. The subsequent successful comparison of the model predictions with experimental data throughout the entire SSP duration indicates that the model is comprehensive and accounts for all the relevant phenomena occurring during the SSP to synthesize high MW PLLA. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Solid‐state polymerization of poly(ethylene terephthalate). II. Modeling study of the reaction kinetics and properties

Comprehensive modeling studies were used to describe the kinetics of the solid‐state polymerization (SSP) of poly(ethylene terephthalate). The validity of the model was confirmed by the successful fitting of the experimental results for molecular weight increases, at temperatures ranging from 180 to 230°C and for times up to 12 h, with one fitting parameter. The changes in the concentrations for hydroxyl end groups ([? OH]), carboxyl end groups ([? COOH]), vinyl end groups, and terephthalic acid (TPA) were simulated with the model. During SSP, the contents of not only hydroxyl and carboxyl end groups but also vinyl ester end groups and TPA monomer were predicted to decrease as a function of the SSP time and temperature. The effects of the pellet size and the molar ratio of carboxyl end groups to hydroxyl end groups were also calculated. At an end‐group molar ratio ([? COOH]/[? OH]) of around 0.7, a maximum SSP rate was obtained. As the [? COOH]/[? OH] ratio increased, the contents of the vinyl end groups and TPA monomer were predicted to increase. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 213–227, 2003     

Preparation and solid‐state polyamidation of hexamethylenediammonium adipate: The effect of sodium 5‐sulfoisophthalic acid

The effect of sodium 5‐sulfoisophthalic acid (NaSIPA) on the solid‐state polymerization of hexamethylenediammonium adipate was studied. In particular, different polyamide salt grades, such as a model salt of hexamethylenediamine and NaSIPA and a polyamide 6,6 salt containing NaSIPA, were prepared through alternative procedures based on the solution–precipitation technique. Furthermore, selected salt grades were solid‐state‐polymerized in a thermogravimetric analysis chamber under static and flowing nitrogen. Critical reaction parameters, such as the reaction temperature, surrounding gas, and presence of NaSIPA, were investigated to determine the rate‐controlling mechanism of the process. More specifically, NaSIPA significantly influenced solid‐state polyamidation by reducing the reaction rate and changing the prevailing mechanism. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 1609–1619, 2007