Modelling nucleation and particle growth in emulsion copolymerization in continuous loop reactors

A mathematical model for emulsion copolymerization in continuous loop reactors is presented. The flow pattern of the loop reactor can be represented by a loop formed by two tubular reactors with axial dispersion. The mathematical model combines this flow model with the physico-chemical characteristics of the emulsion copolymerization. The outputs of the model are monomer conversion, copolymer composition, particle size distribution and latex viscosity. The model was checked during the redox initiated emulsion copolymerization of vinyl acetate and veova 10 carried out in a completely automated continuous loop reactor.     

Mathematical Modeling of Acrylonitrile-Butadiene Emulsion Copolymerization: Model Development and Validation

This paper presents a mechanistic model for the production of nitrile-butadiene rubber (NBR). The mathematical dynamic model was developed in order to simulate the industrial production of NBR via emulsion copolymerization of acrylonitrile (AN) and butadiene (Bd) in batch, continuous and trains of continuous reactors. For this reason, the model was constructed in a parsimonious manner to avoid complex and time-consuming computations that typically result when modeling details of specific aspects of micro/macro scale emulsion polymerization phenomena (i.e., full molecular weight and particle size distributions, detailed species phase-partitioning, etc.). Thus, the model provides average properties for typical emulsion characteristics, such as monomer conversion, copolymer composition, number- and weight-average molecular weights, tri- and tetra-functional branching frequencies, and the number and average size of polymer latex particles. The proposed model is an extension of a previous model developed by our group, and allows for the dynamic modeling of different reactor types and configurations. Model comparisons are made between limited literature data for batch operation, while representative simulation profiles are shown for a reactor train.     

Emulsion polymerization. VI. Concentration of monomers in latex particles

Nonpolymerizing latex particles surrounded by an aqueous phase saturated with monomer absorb only a finite amount of monomer, even if the monomer is a good solvent for the polymer, because the surface energy of each particle increases on swelling. At equilibrium the change in surface energy and the free energy of mixing exactly balance. Equations based on this thermodynamic principle predict with good accuracy the saturation swelling of crosslinked and uncrosslinked latex particles and the partitioning of monomer between the aqueous phase and latex particles at partial saturation. The available experimental data on swelling of latex polymers with monomers are reviewed. Earlier papers assumed that during emulsion polymerization the monomer concentration in the latex particles is independent of conversion as long as monomer droplets are present. This assumption is shown to be a justifiable approximation. The thermodynamics of the swelling of latex particles with a blend of two monomers is presented. The calculations indicate that copolymerization in emulsion should define reactivity ratios differing from those of homogeneous copolymerization by not more than 40% if the solubility of the comonomers in water is low. The reactivity ratio scheme is strictly applicable to emulsion copolymerization if the solvent properties of the two comonomers are identical.     

表面活性单体存在下的MMA/BA乳液共聚合(Ⅱ)聚合动力学及机理

研究了表面活性单体[磺化-十二醇-烯丙基甘油-丁二酸酯钠盐(ZC-L)]的用量对MMA/BA/ZC-L乳液聚合速率和粒径的影响,用CoulterLS230型激光粒径分析仪测定聚合过程中乳液的粒径和粒径分布变化,并与MMA/BA无皂乳液聚合及十二烷基苯磺酸钠存在下的MMA/BA乳液聚合作了比较.[ZC-L]CMC时,成核机理包括均相成核和胶束成核机理,生成的粒子因吸收体系中的表面活性单体而稳定存在.     

表面活性单体存在下的MMA／BA乳液共聚合（Ⅱ）：聚合动力？…

研究了表面活性单体「磺化－十二醇－烯丙基甘油－丁二酸酯钠盐（ＺＣ－Ｌ）」的用量对ＭＭＡ／ＢＡ／ＺＣ－Ｌ乳液聚合速率和粒径的影响,用Ｃｏｒｌｔｉｒ ＬＳ２３０型激光粒径分析仪测定聚合过程中乳液的粒径和粒径分布变化,并与ＭＭＡ／ＢＡ无皂乳液聚合及十二烷基苯磺酸钠存在下的ＭＭＡ／ＢＡ乳液聚合作了比较。「ＺＣ－Ｌ」〈ＣＭＣ时,成核机理为均相成核机理,乳胶粒需依靠粒子间的凝聚来提高表面电荷密度而稳定;「ＺＣ     

功能单体α-烯烃磺酸钠用于无皂乳液共聚合

用工业原料α-烯烃磺酸钠(AOS)作为功能单体与甲基丙烯酸甲酯(MMA)和丙烯酸丁酯(BA)进行了乳液共聚合,通过测定AOS与MAA的竞聚率,确定了适宜的聚合方式为连续加料法.使用5%AOS制备了高固含量(>60%)的胶乳,并与用十二烷基硫酸钠(SDS)作乳化剂时该体系的乳液共聚合进行了比较.AOS是影响乳液稳定性和胶粒大小的主要因素,当AOS含量为单体总质量的1%时可以得到固含量大于40%粒径小于100 nm的乳液;当AOS含量为5%时可以得到固含量大于60%的乳液.两种情况下胶粒粒径分散性均较窄,明显优于同样条件下用SDS制备的胶乳.使用1%AOS制得的胶乳静置1年后粒径及其分布基本保持不变.     

Preaparation of cationic latexes of poly(styrene-CO-butyl acrylate) and their properties evolution in latex dilution

Cationic latexes were prepared through emulsion copolymerization of styrene(St) and butyl acrylate(BA) with a cationic surfactant,cetyl trimethyl ammonium bromide(CTAB).Latex properties,including particle size,size distribution,ζpotential,surface tension and monomer conversion,were determined for latexes prepared with different CTAB amounts. Evolution of these properties during emulsion polymerization was followed in order to understand the mechanism of the particles formation.Results showed that both particle size andζpotential were function of polymerization time and latex solids.Parallel emulsion polymerizations with cationic,anionic charged initiator and charge-free initiators were also carried out,the latex properties were determined at different polymerization time.All these results were attentively interpreted based on the mechanisms of emulsion polymerization,surfactant adsorption and latex particle stabilization.     

Mechanical properties of films from polymer latices

The mechanical behavior of latex films is governed by their macromolecular nature as well as by their origin from particles dispersed in an aqueous medium. When monomers of different polarity are copolymerized in emulsion copolymerization, a heterogeneous distribution of the polar groups in the latex and the film can occur, owing to the different water solubilities of the comonomers. Films from these latices in many cases show a two-phase morphology, first, consisting of the main polymer within the particles and, second, a phase which is concentrated in the interphase between the original particles and which has a strong influence on the mechanical properties of the films. Films from latices with crosslinked particles behave like homogeneous networks in the linear viscoelastic range, i.e. at small strains. Structured networks are found when latex films are interparticularly crosslinked during or after film formation, e.g. by polar bifunctional monomers or metal salts. Tensile tests of films show that the mechanical strength of latex films develops in the last stage of film formation by interdiffusion and entaglement formation across particle boundaries.     

Non-seeded semi-continuous emulsion polymerization

Semi-continuous emulsion polymerization of acrylic monomers was investigated from the point of view of the particle growth. In the process no seed latex was used and the monomers were fed in an emulsion form. Oscillations of surface tension and particle number indicated a periodical generation and flocculation of particles during the polymerization. Investigation of particle size and molecular weight changes in the first tens of seconds of polymerization has shown that the coagulation process proceeds even in the earliest stage of the polymerization. Initial emulsifier concentration in the reactor strongly affects the particle growth and the final particle number.     

不饱和端基超支化聚合物/丙烯酸酯共聚乳液的研究

利用Si—H加成反应制得了以CC为端基的超支化含硅聚合物,并将其与丙烯酸酯类单体进行乳液共聚,对聚合反应机理及所得聚合物的性能进行了测试分析.结果表明,含有大量CC端基的超支化含硅聚合物能与丙烯酸酯类单体稳定聚合,制得了平均粒径小于100nm高度交联的乳胶粒子.共聚物的红外光谱证实,超支化聚合物的不饱和端基已全部反应,形成了以超支化聚合物为多臂交联点的交联型乳胶粒子.随聚合体系中超支化聚合物用量的增加,乳液聚合反应速率增大,乳胶粒粒径减小,共聚物热稳定性显著提高.     

Evidence for and against concentration gradients in polymerizing latex particles

A single-charge emulsion polymerization involving a monomer which is a good solvent for its polymer is considered. It is shown to be unlikely that within the polymerizing latex particles there are concentration gradients large enough measurably to affect the kinetics of the reaction. The average displacement of monomers due to Brownian motion within the latex particles and in the absence of concentration gradients is calculated. This diffusive mean free path, corresponding to an interval involving less than 1% change in conversion, is shown to be much longer than the radius of the latex particle. Consequently, loci where monomer concentration is perturbed by conversion to polymer are immediately swamped by unreacted monomer. Also, direct experimental evidence exists showing that the monomer concentration in latex particles is about the same when nonpolymerizing latex particles are saturated or during polymerization in the presence of monomer excess. The thermodynamics of saturation swelling preclude the possibility of the existence of large concentration gradients. The arguments that have been advocated in the literature for core–skin separation within polymerizing latex particles were based on conversion data which were thought to be linear with time, while a reexamination indicates that they were not. The observed core–skin separation obtained when butadiene or tritiated styrene were copolymerized with styrene in the presence of a polystyrene homopolymer seed latex has questionable relevance to single-charge homopolymerization. There are reasons to doubt that the distribution of co-monomers within latex particles can be frozen by their conversion to polymers in a two-stage emulsion polymerization.     

The mechanisms of latex particle formation and growth in the emulsion polymerization of styrene using the surfactant sodium dodecyl sulfate

A new method is presented that provides experimental information which is qualitatively and quantitatively sensitive to assumptions made as to the mechanisms of free radical entry and of latex particle formation in emulsion polymerization systems. The method consists of (1) obtaining (by electron microscopy) the full particle-size distributions (PSDs) at several different times soon after the cessation of latex particle nucleation, (2) using these PSDs to determine the volume dependences of the various rate coefficients governing particle growth by fitting the data to the appropriate evolution equations, and (3) employing these empirical rate coefficients to find that time dependence of the nucleation rate which fits the early-time PSD (again using the evolution equations). This method is quite sensitive to mechanistic assumptions: for example, one is able to determine whether or not the nucleation rate is an increasing or decreasing function of time. The technique is applied to a styrene nucleation system employing sodium dodecyl sulfate as surfactant at well above the critical micelle conventration. The data cannot be fitted even qualitatively by a simple one-step nucleation mechanis, whether it involes micellar entry or homogeneous nucleation. It is found, on the other hand, that the results can be accurately fitted by assuming that coagulation events between primary colloidal particles, perhaps formed by homogeneous nucleation, dominate both the nucleation process and the entry of free radicals into mature latex particles. In addition, the data indicate that the rate of free radical entry into the latex particles decreases with increasing particle size, at least for particles of unswollen radius less than ca. 40 nm.     

EFFECT OF 2-HYDROXYETHYL METHACRYLATE ON SEMIBATCH EMULSIFIER-FREE EMULSION COPOLYMERIZATION OF METHYLMETHACRYLATE AND BUTYL ACRYLATE

IINTRODUCTIONSemibatchemulsionpolymerizationisanimportalmethodfortheproductionofpolymersforthecoatingsandadhesivesindustries.Thetraditionallatexproductsaregenerallystabilizedbyemulsifiers.However,theemulsifiersremaininginthelatexproductcanhaveanegativeeffectontheapplicationpropertiessuchasadhesiontosubstratesandfilmformationandwaterresistanceofthecoatingmaterials,becausethesmallandmobileemulsifiermoleculestendtomigratetothesurfacelayerofthepolymericfilm.Withtheemulsifier-freeemulsionpolym…     

EFFECT OF 2—HYDROXYETHYL METHACRYLATE ON SEMIBATCH EMULSIFIER—FREE EMULSION COPOLYMERIZATION OF METHYL METHACRYLATE AND BUTYL ACRYLATE

The semibatch emulsifier-free emulsion copolymerization of methyl methacrylate (MMA) and butyl acrylate(BA) in the presence of 2-hydroxyethyl methacrylate(HEMA) initiated by K2S2O8(PSP) was studied.The latex particles can maintain an appreciable stability during the emulsifier-free emulsion copolymerization of MMA and BA in the presence of HEMA.The average particle diameter increase with an increase of total solids content,HEMA content,PSP content,ionic strength of the system and monomer feed rate,and decrease with the monomer feed ration from 3/1 (MMA/BA:molar ration).to 1/3.The stability of this reaction system is improved by adding HEMA as nonionic comonomer,High solids content (50%) latex with monodisperse particle can be obtained using this process.     

Effect of cationic monomer on properties of fluorinated acrylate latex

Cationic fluorinated acrylate latex was prepared via semi-continuous emulsion copolymerization of cationic monomer and other monomers.The resultant latex and its film were characterized with dynamic light scattering detector and contact anglc meter. Influences of amount of DMDAAC on the propcrtics of resultant latex and its film were investigated in detail.Results show that the particle size of the latex has the minimum value and the zeta potential of the latex is increased when the amount of DMDAAC is increased.In addition,the particle size of the latex is unimodal distribution when the amount of DMDAAC is not more than 2.5%. However,the particle size of the latex is bimodal distribution when the amount of DMDAAC is more than 2.5%.The contact angle is varied slightly with the increase of amount of DMDAAC when it is not more than 2.5%.Nevertheless,the contact angle is decreased with the increase of the amount of DMDAAC when it is more than 2.5%.     

A novel approach to prepare core/shell polymer latex particles with high sulphonate contents

Crosslinked x-P(St-MAA) seed latex was first prepared via soap-free emulsion copolymerization of styrene (St) and methyl methacrylic acid (MAA) with divinyl benzene as crosslinker and ammonium persulfate as initiator, and x-P(St-MAA)/x-P(St-NaSS) core/shell latex particles were then synthesized through a novel seeded emulsion copolymerization of St and sodium styrene sulphonate (NaSS) in the presence of water-soluble crosslinker N,N′-methylene bisacrylamide (BAA) using oil-soluble 2,2-azobis isobutyronitrile as initiator. TEM observation indicated that narrow dispersed core/shell latex particles were obtained, and element analysis showed that NaSS unit content in the whole particle and in the shell reached 22.8 wt% and 51.2 wt%, respectively.     

Drug-carrying latices for prolonged release of drugs

Dichlorophene was used as a model drug. Drug-carrying latex particles were prepared by soap-free emulsion copolymerization of dichlorophene acrylate with some hydrophilic methacrylate comonomers. The comonomers used affected not only the structure and colloidal stability of particles, but also the drug-activity of particles. Preliminary study of the drug activity revealed that highly hydrophilic latex particles were very stable and too inactive to be engulfed by amoebae and kill them. On the contrary, less hydrophilic particles carrying a large amount of drug can be an effective device to release drugs at a moderate rate to fight against extracelluar targets such as parasites.     

Preparation of HPMC–EA–DMAEMA nanosized latex

Nanosized copolymer latex of hydroxypropylmethylcellulose (HPMC) grafted with ethyl acrylate (EA) and dimethylaminoethyl methacrylate (DMAEMA) has been prepared by acidifying submicron-sized latex particles synthesized by soap-free emulsion graft copolymerization using potassium persulfate (KPS) as initiator. The effects on the diameter of the latex particles of different conditions, for example concentration of DMAEMA, amount of HPMC, and ratio of HCl to DMAEMA for acidification, were investigated. It was found that increasing the mole ratio of HCl to DMAEMA to 1.0 and increasing the DMAEMA content both resulted in a decrease in particle diameter, whereas increasing the amount of HPMC resulted in larger particle sizes. Measurement by dynamic light scattering (DLS) revealed the diameter of the latex particles was >200 nm before acidification and <100 nm after acidification. Evidence of grafting was obtained by use of Fourier transform infrared (FTIR) spectroscopy. Transmission electron microscopy (TEM) was used to characterize the morphology of the copolymer particles before and after acidification.     

Preparation of sulphonate-containing core/shell latex particles via seeded emulsion copolymerization

<正>In this study,P(St-MAA) seed latex particles were first prepared via soap-free emulsion polymerization of styrene(St) and methacrylic acid(MAA),then the seed particles were allowed to swell with St at room temperature,and the P(St-MAA)/P(StNaSS) core/shell latex particles were then synthesized via seeded emulsion copolymerization of St and sodium styrene sulphonate (NaSS) using AIBN as initiator in the presence of N,N'-methylenebisacrylamide(BAA,water-soluble crosslinker).Results showed that the polymerization could be carried out smoothly when the ratio of BAA to total monomers was less than 3 mol%,the narrow dispersed P(St-MAA) seed particles with the diameter of 150 nm and the P(St-MAA)/P(St-NaSS) core/shell latexes with the particle size of about 200 nm were synthesized.When the 25/75 mole ratio of NaSS/(St + MAA) and 2 mol%of BAA were used in the seeded emulsion polymerization,the resulted P(St-MAA)/P(St-NaSS) latex product showed a low weight loss after water extraction,and the NaSS unit content in the whole particle and in the shell reached 11.7 mol%and 34.6 mol%,respectively.     

反应性乳化剂存在下的五元苯丙乳液共聚合

采用反应性乳化剂SE-10N,通过正交实验及单因素实验确定了以苯乙烯、甲基丙烯酸甲酯、丙烯酸丁酯、丙烯酸和丙烯腈为单体的五元无皂苯丙共聚乳液的组成及聚合工艺。所制得的无皂乳液稳定,其乳胶粒大小均匀,粒径为50~60nm,比同组成的有皂乳液乳胶粒的粒径稍小。乳液涂膜透明、硬度达H级;其硬度、耐水性及钙离子稳定性均较同组成有皂乳液的好。