Molecular weight distribution in emulsion polymerization. I. The homopolymer case

A model for evaluating the instantaneous degree of polymerization distribution of homopolymers produced in emulsion, based on the mathematics of the Markov chains, is developed. The model accounts for any number of active chains per particle, as well as for the two fundamental mechanisms of chain termination: mono- and bi-molecular, both by combination and by disproportionation. The core of the model is the so called subprocessmain process treatment, which allows us to correctly evaluate the degree of polymerization of the chains growing in the polymer particles, by distinguishing between the events experienced by the polymer chain which imply a change of its degree of polymerization (subject transitions) and those which imply only a change in the particle state (environment transitions). This is obtained by properly defining the one-step transition probability matrix of the relevant Markov process. Once this is done, the evaluation of the distribution of the degrees of polymerization reduces to a few simple operations among matrices. Explicit expressions for the instantaneous probability density functions and the relative cumulative distributions are obtained. The application of such relationships is facilitated by the numerical procedures reported in the Appendices. The results of the model developed in this work are in agreement with those of earlier models in the range of parameter values of practical interest. In the limit of very low molecular weights, only the model developed in this work provides the correct answer. Moreover, a much more significant result is its applicability to the case of emulsion copolymerization, as it is shown in Part II.     

Modeling the reversible addition–fragmentation transfer polymerization process

A kinetic model has been developed for reversible addition–fragmentation transfer (RAFT) polymerization with the method of moments. The model predicts the monomer conversion, number‐average molecular weight, and polydispersity of the molecular weight distribution. It also provides detailed information about the development of various types of chain species during polymerization, including propagating radical chains, adduct radical chains, dormant chains, and three types of dead chains. The effects of the RAFT agent concentration and the rate constants of the initiator decomposition, radical addition, fragmentation, disproportionation, and recombination termination of propagating radicals and cross‐termination between propagating and adduct radicals on the kinetics and polymer chain properties are examined with the model. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 1553–1566, 2003     

Simulation model for the molecular weight distribution in emulsion polymerization

A Monte Carlo simulation model for the kinetics of emulsion polymerization is proposed. In the present model, the formation of each polymer molecule is simulated by the use of only a couple of probability functions; therefore, the calculation can be handled well even on personal computers. It is straightforward to account for virtually any kinetic event, such as the desorption of oligomeric radicals and chain length dependence of kinetic parameters, and as a consequence very detailed information such as the full distributions of the dead polymer molecular weights and the macroradicals among various polymer particles can be obtained. When bimolecular terminations are the dominant chain stoppage mechanism, the instantaneous molecular weight distribution (produced in a very small time interval) becomes broader than that for homogeneous polymerizations due to a higher possibility that short and long polymer radicals react with each other if bimolecular reactions are fast enough. The increase in the polydispersity of the MWD is fairly large, especially when bimolecular termination by disproportionation is significant; however, the gel permeation chromatography (GPC) may not be a suitable analytical technique to detect such broadening since oligomeric peaks may not be observed in the elution curve. The present simulation method provides greater insight into the complicated phenomena of emulsion polymerizations. © 1995 John Wiley & Sons, Inc.     

Modeling stable free-radical polymerization

A kinetic model has been developed for stable free-radical polymerization (SFRP) processes by using the method of moments. This model predicts monomer conversion, number-average molecular weight, and polydispersity of molecular weight distribution. The effects of the concentrations of initiator, stable radical, and monomer, as well as the rate constants of initiation, propagation, termination, transfer, and the equilibrium constant between active and dormant species, are systematically investigated by using this model. It is shown that the ideal living-radical polymerization having a linear relationship between number-average molecular weight and conversion and a polydispersity close to unity is the result of fast initiation, slow propagation, absence of radical termination, and a high level of dormant species. Increasing stable radical concentration helps to reduce polydispersity but also decreases polymerization rate. Thermal initiation significantly broadens molecular weight distribution. Without the formation of dormant species, the model predicts a conventional free-radical polymerization. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 2692–2704, 1999     

Evaluation of the Chain Length Distribution in Free‐Radical Polymerization, 1. Bulk Polymerization

A method for the direct computation of the chain length distribution in a bulk polymerization is developed, based on the discretization procedure introduced by Kumar and Ramkrishna (Chem. Eng. Sci. 1996 , 51, 1311) in the context of particle size distribution. The overall distribution of chain lengths is partitioned into a finite number of classes which are supposed to be concentrated at some appropriate pivotal chain lengths. Several of the involved reactions lead to the formation of chain whose length differs from the pivotal values. Rules have been introduced in order to share chains between two contiguous classes, which have been designed so as to preserve two well‐defined properties of the distribution, such as, for example, two of its moments. The method has been applied to a polymerization system including propagation, bimolecular terminations and two different chain branching mechanisms: chain transfer to polymer and crosslinking. In addition, complex systems such as one with chain length‐dependent kinetic constants or a two‐dimensional distribution of chain length and number of branches have been considered.     

Molecular weight distribution in nonlinear emulsion polymerization

A modelistic study of the molecular weight distribution (MWD) formed in emulsion polymerization that involves chain transfer to polymer is conducted, by focusing our attention to the effect of very small reaction volume on the formed MWD. In emulsion polymerization, a polymer radical that causes polymer transfer reaction must choose the partner only within the same particle, which makes the expected size of the polymer molecule to be chosen smaller compared with the corresponding polymerization system that involves an infinitely large number of polymeric species. The usual assumption for homogeneous polymerization that the rate of chain transfer to a particular polymer molecule is proportional to its chain length cannot be used, except when branching frequency is low and particle size is large enough. This fact invalidates the direct use of models developed for homogeneous nonlinear polymerizations to emulsion polymerizations. Model equations that could be used to assess the significance of the limited space effects on the MWD under a given polymerization condition are also proposed. © 1997 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 35 : 1515–1532, 1997     

The effect of Co(II)‐mediated catalytic chain transfer on the emulsion polymerization kinetics of methyl methacrylate

The effect the catalytic chain transfer agent, bis[(difluoroboryl) dimethylglyoximato] cobalt(II) (COBF), on the course of the ab initio emulsion polymerization of methyl methacrylate, and the product properties in terms of the molecular weight distribution were investigated. The emulsion polymerization kinetics have been studied with varying surfactant, initiator, and COBF concentrations. The experimentally determined average number of radicals per particle strongly depends on the concentration of COBF and proves to be in good agreement with the results of model calculations. The apparent chain transfer constant, determined up to high conversion, is in excellent agreement with the predicted value based on a mathematical model based on COBF partitioning and the Mayo equation. The results of this work enhance the fundamental understanding of the influence a catalytic chain transfer agent has on the course of the emulsion polymerization and the control of the molecular weight distribution. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 5078–5089, 2009     

Postgel properties in the statistical crosslinking of heterochains. II. Free‐radical crosslinking copolymerization

The heterochain crosslinking theory is applied to postgel behavior in the free‐radical crosslinking copolymerization of vinyl and divinyl monomers. In this context, the crosslinked polymer formation can be viewed as a system in which the primary chains formed at different times are combined in accordance with the statistical chain‐connection rule governed by the chemical reaction kinetics. Because the primary chains are formed consecutively, the number of chain types N must be extrapolated to infinity, N → ∞. Practically, such extrapolation can be conducted with the calculated values for only three different N values. The analytical expressions for the weight fraction and average molecular weights of the sol fraction are derived for the general primary chain length distribution function in free‐radical polymerization. Illustrative calculations show that the obtained results agree with those from the Monte Carlo method, and that the postgel properties in free‐radical crosslinking copolymerization systems could be significantly different from those in randomly crosslinked systems. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 2342–2350, 2000     

The effect of different catalytic chain transfer agents on particle nucleation and the course of the polymerization in ab initio batch emulsion polymerization of methyl methacrylate

The effect a Co(II) based catalytic chain transfer agent (CCTA) has on the course of the polymerization and the product properties of an emulsion polymerization is governed by the intrinsic activity and the partitioning behavior of the catalyst. The effect on the conversion time history, the molecular weight distribution and the particle size distribution is evaluated in batch emulsion polymerization of methyl methacrylate for three different CCTAs, which cover a range of intrinsic activities and partitioning behaviors. It was demonstrated that radical desorption from the particle phase to the aqueous phase preceded by chain transfer is the main kinetic event controlling the course of the polymerization and the product properties in terms of the particle size distribution. The experimental results show that the aqueous phase solubility of the CCTA is the key parameter controlling the course of the polymerization and the particle size distribution. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 1038–1048, 2010     

Calculation of Molecular Weight Distributions in Non‐Linear Free‐Radical Polymerization Using the Numerical Fractionation Technique

Mathematical Modeling of non‐linear polymerization systems subject to gel formation is a challenging endeavor. At the gel point, the second and higher molecular weight moments diverge to infinity making it impossible to obtain the molecular weight distribution (MWD). The numerical fractionation (NF) technique utilizes a refinement of the method of moments to model non‐linear polymerization systems that form gel. Since the method of moments yields results in terms of average quantities, some information is lost when reconstructing the MWD using NF. As a consequence, a broad shoulder appears at the high chain length end of the MWD tail. This study demonstrates that the validity of the gamma distribution deteriorates for the broader branched polymer generations and evaluates the performance of various alternative model distributions. Proper selection of the model distribution enhances the NF‐reconstructed MWD.     

简单共聚模型的分布函数与组成方程推导

针对自由基共聚合反应歧化终止和偶合终止两类机理生成的线型共聚物,应用统计物理的基本原理,对处于最可几分布状态下的线型共聚物分子量分布函数进行了理论推导,并以此分布函数,结合自由基共聚合机理动力学处理和概率计算,从另一种途径得到Mayo-Lowis和Alfrey-Goldfinger简单共聚物组成方程,研究结果有助于进一步理解简单共聚模型组成方程的物理学基础,同时也将为线型自由基共聚合反应机理的研究提供一个新方法.     

Heinz Gerrens Revisited: A New Look at the Impact of Reactor Type on Polymer Chain Morphology

The equations for predicting molecular weight distribution, copolymer composition distribution, and copolymer sequence distribution for three polymerization mechanisms (monomer linkage with termination, monomer linkage without termination, and polymer linkage), and three reactor types (batch/plug flow, homogenous continuous stirred tank, and segregated continuous stirred tank) are assembled from various sources and compared and contrasted.     

Molecular weight distribution in free radical polymerization with long-chain branching

A new theory to predict the molecular weight distribution in free radical polymerization that includes chain transfer to polymer is proposed. This theory is based on the branching density distribution of the primary polymer molecules. The branching density distribution provides the information on how each chain is connected to other chains, and therefore, a full molecular weight distribution can be calculated by application of the Monte Carlo simulation. The present theory accounts for the history of the generated branched structure and can be applied to various reaction systems that involve branching and crosslinking regardless of the reactor types used. The present simulation confirmed the validity of the method of moments in a batch polymerization proposed earlier. It was shown clearly why gelation never occurs by chain transfer to polymer without the assistance of other interlinking reaction such as bimolecular termination by combination. © 1993 John Wiley & Sons, Inc.     

RAFT聚合合成高分子量嵌段聚合物

以合成高分子量聚合物为目标,以苯基二硫代乙酸-1-苯基乙酯(PEPDTA)作为RAFT试剂,研究引发剂的种类(偶氮二异丁腈(AIBN)、1-1′-偶氮环己腈(ACC))、用量及聚合温度对苯乙烯/丙烯酸丁酯RAFT共聚合过程和聚合物结构的影响.结果发现,由于体系中RAFT浓度很低,相应的引发剂浓度要比传统自由基聚合低得多,只有采用较高的聚合温度和低分解速率常数的引发剂(ACC),才能制得无活性聚合物分率低(<0.1)、分子量高的聚合物,并进一步得到杂质含量少、分子量分布窄的嵌段聚合物.     

Modeling molecular weight distribution in emulsion polymerization reactions with transfer to polymer

A mathematical model was developed for the computation of the dynamic evolution of molecular weight distributions (MWDs) during nonlinear emulsion polymerization reactions. To allow the direct computation of the whole MWD, an adaptive orthogonal collocation technique was applied. The model was validated with experimental methyl methacrylate/butylacrylate (BuA) semicontinuous and vinyl acrylate (VA)/Veova10 continuous emulsion polymerization results. Both systems considered introduce significant chain‐transfer reactions to polymer chains as a result of the presence of BuA and VA, respectively. The model developed was able to represent quite properly the kinetics and MWD of polymer samples during emulsion polymerizations. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3513–3528, 2001     

Reconstruction of the Chain Length Distribution for Vinyl‐Divinyl Copolymerization Using the Numerical Fractionation Technique

A proposed theory for evaluating the chain length distribution (CLD) using the numerical fractionation (NF) technique was extended to the vinyl‐divinyl (VDV) copolymerization. The CLD is reconstructed for this system, in which pendant double bond propagation leads to crosslinking and gel formation. The method was earlier developed for a non‐linear free‐radical polymerization scheme where chain transfer to polymer and termination by combination resulted in gel formation. The VDV study presented indicates that the proposed method of weighted summation (WS) accurately predicts the resulting CLDs evaluated using NF.

Comparison of the overall polymer NF and the direct solution CLDs near the gel point.     

Modeling and Experimentation of RAFT Solution Copolymerization of Styrene and Butyl Acrylate,Effect of Chain Transfer Reactions on Polymer Molecular Weight Distribution

Chain transfer reactions widely exist in the free radical polymerization and controlled radical polymerization, which can significantly influence polymer molecular weight and molecular weight distribution. In this work, the chain transfer reactions in modeling the reversible addition–fragmentation transfer (RAFT) solution copolymerization are included and the effects of chain transfer rate constant, monomer concentration, and comonomer ratio on the polymerization kinetics and polymer molecular weight development are investigated. The model is verified with the experimental RAFT solution copolymerization of styrene and butyl acrylate, with good agreements achieved. This work has demonstrated that the chain transfer reactions to monomer and solvent can have significant impacts on the number‐average molecular weight (M_n) and dispersity (Ð).     

Effect of catalyst partitioning in Co(II) mediated catalytic chain transfer miniemulsion polymerization of methyl methacrylate

The effect of catalyst partitioning over the organic and water phases in the catalytic chain transfer mediated miniemulsion polymerization was investigated and a mathematical model developed to describe the instantaneous degree of polymerization of the formed polymer. Experimental and predicted instantaneous degrees of polymerization prove to be in excellent agreement. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 5839–5849, 2008