Production of porous suspension polymers using a continuous tubular reactor

The conventional method for the synthesis of porous cross-linked copolymer beads is by suspension polymerisation. Suspension polymerisation reactions are generally performed in a stirred tank, which generally results in a large size distribution. By careful control of the polymerisation conditions, polymer beads can be produced using a tubular poly(tetrafluoroethylene) continuous reactor. Such beads are produced with the same average pore size, but with a lower degree of polydispersity than analogous systems produced in a batch reactor (stirred tank). This is achieved by density-matching the droplet and continuous phases (by the use of a brominated monomer or a porogenic diluent) and increasing the viscosity of the monomer phase (with the addition of small amounts of polystyrene). Received: 26 June 1999/Accepted in revised form: 7 October 1999     

Comparison of Vinyl Acetate - Butyl Acrylate Emulsion Copolymerizations Conducted in a Continuous Pulsed Sieve Plate Column Reactor and in a Batch Stirred Tank Reactor

In this work, vinyl acetate/butyl acrylate emulsion copolymerizations carried out in a continuous tubular reactor (pulsed sieve plate column, PSPC) were compared to those conducted in a semibatch stirred tank reactor under similar operational conditions. In order to minimize the compositional drift along the PSPC, reactions were carried out with different numbers (2, 3 and 4) of lateral feed streams of the more reactive monomer (butyl acrylate). For comparison, fed batch reactions were conducted with the same number of intermittent shot additions of butyl acrylate, at the corresponding batch times. Both systems (tubular and semibatch) with distributed feeding of more reactive monomer are able to reduce composition drift thus providing more uniformity in copolymer composition. In addition, the tubular reactor presents much better control of temperature than the tank reactor, which is important to achieve higher productivity.     

The Influence of Reaction Conditions on the Copolymer Composition in Inverse Miniemulsion

Summary: Water-soluble poly(2-acrylamido-2-methylpropane-1-sulfonic acid-co-1-vinylimidazole) (P(AMPS-co-1-VIm)) and poly(2-acrylamido-2-methylpropane-1-sulfonic acid-co-2-(dimethylamino)ethyl methacrylate (P(AMPS-co-DAMA)) are studied as it is known that the copolymer composition is affected by pH of the monomer phase in inverse miniemulsion. The distribution of the basic monomers in the continuous and dispersed phase changes due to their degrees of protonation. The amounts of the monomers in the cyclohexane phase is determined by gas chromatography, the copolymer composition is studied by elemental and thermogravimetric analysis. An insight into the monomer distribution in the polymer is provided by simultaneous potentiometric and conductometric titration of polymer solutions.     

Copolymerization of isobutylene with 1,4-13C-isoprene

Copolymers of isobutylene with 1,4-¹³C-isoprene have been prepared in methyl chloride solvent at ?90 to ?50°C using aluminum chloride and organoaluminum halide initiators. The examination of these copolymers containing 0.5 to 3.0 mol % of the diolefin by ¹³C-NMR has given new information about the mechanism of the copolymerization. It appears that every macromolecule ends in an isoprene derived unit; that chain transfer to monomer by an isoprene-derived propagating carbocation is the dominant chain breaking process. The copolymer triad sequences have been unambiguously assigned and analyzed in both batch and continuous stirred tank reactor copolymers. The relative concentrations of the triads agree with those predicted by published reactivity ratios.     

Molecular Weight Distribution of Living Radical Polymers

Summary: The molecular weight distribution formed in an ideal living radical polymerization is considered theoretically. It was found that the hypergeometric function that combines the most probable and the Poisson distribution represents a fundamental distribution of the living radical polymers. The number‐ and weight‐average molecular weights are derived for this fundamental distribution, together with those for polymerizations in a batch and in a continuous stirred tank reactor. These average molecular weight functions are obtained based on the arithmetic calculations without deriving the distribution functions. The effect of the monomer transfer reactions on the formed MWD is also considered. The present study clarifies the relationship between the reaction mechanism and the formed molecular weight distribution as well as the fundamental characteristics of living radical polymers.

Calculated number fraction distribution N(r) development with (dashed) and without (solid) the monomer transfer reactions.     

低相对分子质量苯乙烯-马来酸酐交替共聚物的合成

将引发剂偶氮二异丁腈(AIBN)、共聚单体苯乙烯(St)和马来酸酐(MA)溶解于甲苯中,采用沉淀聚合法合成苯乙烯-马来酸酐共聚物(SMA).分别研究了反应温度、引发剂用量、反应时间、单体配比和单体浓度对聚合物得率和酸酐含量的影响.采用正交实验确定最优反应条件为:单体浓度20%,单体物质的量比为1∶1,引发剂用量为0.60%,反应温度为86℃,反应时间2h,产物得率为86.86%,酸酐含量为50.28%.并利用傅里叶变换红外光谱(FTIR)、核磁共振碳谱(~(13)C NMR)、凝胶渗透色谱(GPC)和热分析法分别研究聚合物的分子结构、相对分子质量及相对分子质量分布和热稳定性.结果表明产物是苯乙烯-马来酸酐交替共聚物,相对分子质量分布较窄,具有良好的热稳定性.     

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.     

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.     

Block Index for Characterizing Olefin Block Copolymers

Summary: Olefin block copolymers produced by chain shuttling catalysis exhibit crystallinity characteristics that are distinct from what would be expected for typical random olefin copolymers with comparable monomer compositions produced from either ‘single-site’ or heterogeneous catalysis. Olefin block copolymers produced by chain shuttling catalysis have a statistical multiblock architecture. A unique structural feature of olefin-based block copolymers is that the intra-chain distribution of comonomer is segmented (statistically non-random). Fractionating an olefin block copolymer by preparative temperature rising elution fractionation, TREF, results in fractions that have much higher comonomer content than comparable fractions of a random copolymer collected at an equivalent TREF elution temperature. We have developed a “block index” methodology which quantifies the deviation from the expected monomer composition versus the analytical temperature rising elution fractionation, ATREF, elution temperature. When interpreted properly, this index indicates the degree to which the intra-chain comonomer distribution is segmented or blocked. The unique crystallization behavior of block copolymers determine the magnitude of the block index values because the highly crystalline segments along an otherwise non-crystalline chain tend to dominate the ATREF (and DSC) temperature distributions.     

Molecular weight distribution in emulsion polymerization. II. The copolymer case

A model for evaluating instantaneous degree of polymerization distribution and the chain composition distribution of copolymers produced in emulsion is developed. The approach adopted is based on the mathematics of Markov processes and represents an extension of the one developed for homopolymers in Part I. As in the homopolymer case, the main aspect of the theoretical treatment is the definition of the proper one step transition probability matrix through the so called subprocess-main process procedure. The model accounts for monomolecular and bimolecular termination (both by combination and disproportionation) and, in principle, it can be applied to any number of reacting monomer species as well as to any number of active chains per particle. However, only the 0–1–2 and 0–1–2–3 emulsion copolymerization systems are discussed in detail. In the case of the chain composition distribution, the model allows the calculation of its moments only, through the method of the Generating Function associated with the probability density function. The expression obtained for the instantaneous probability density functions, as well as for the corresponding cumulative distributions, are all in explicit form and involve only algebraic operations among matrices. Efficient numerical procedure for their application are reported in the Appendix. Illustrative calculations are reported for a 0–1–2–3 copolymerization system, simulating the copolymer styrene–methylmethacrylate. The effect of the various termination mechanisms on the distribution of degrees of polymerization and on the first two moments of the chain composition distribution is discussed in detail. Finally, the three dimensional overall distribution function of both chain length and composition is shown under the assumption of Gaussian type chain composition distribution.     

Modeling molecular weight distribution and effect of termination in controlled radical polymerization: A novel and transformative approach

A theory for polymer molecular weight distribution (MWD) in atom transfer radical polymerization (ATRP) has been derived by using analogy to a series of continuous stirred tank reactors (CSTRs). This approach relates one activation cycle in ATRP to one reactor in CSTRs. The derived MWD expression includes effect of radical termination and allows detailed investigation on the factors that determine the polymer distribution, namely the level of “control” and “livingness.” The level of control means the average number of activation cycles experienced by individual chains. The degree of livingness is quantified by the fraction of terminated chains. It was found that the effect of livingness and control on MWD is complex. Large number of activation cycles does not guarantee a narrow distribution. There exists an optimum value of activation cycles to achieve the lowest polydispersity by balancing the control (achieved by increasing activation cycles) with the loss of livingness (also caused by increasing activation cycles). The distribution for ATRP is in‐between Poisson and Flory distributions, determined by the level of control and livingness. In general, having high degree of livingness and maintaining control are both necessary conditions to obtain narrow MWD. © 2013 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2014 , 52, 639–651     

Molecular‐Weight‐Distribution Modelling of Radical Polymerization in Batch and Continuous Reactors with Transfer to Polymer Leading to Gel Formation

Full chain‐length distribution (CLD) modelling applying the Galerkin finite‐element method^[1] (FEM) to polymerization reactors featuring a certain degree of gel formation is confronted with extremely long computation times. The paper describes a new method to predict CLDs for systems where gel formation may occur. The new concept is to model a part of the CLD up to a cut‐off length L, while satisfying the full set of population balances. With transfer to polymer as the mechanism responsible for gelation, this gives rise to a closure problem, which has been solved by assuming the dead CLD beyond L to be represented by a part of a Flory distribution. The method could be proved to work by performing simulations and comparing cut‐off CLDs to full CLDs for non‐gelling systems and comparing results for different L for systems with gelation. The model is demonstrated for polymerization reactors, the batch reactor and the continuous stirred‐tank reactor (CSTR), with either disproportionation or recombination termination. Reliable results are obtained for systems with moderate gel formation. Comparing these results to those from moment models including balance equations up to the fourth moment, a number of interesting differences have been found.     

Synthesis of sequence‐controlled copolymers from extremely polar and apolar monomers by living radical polymerization and their phase‐separated structures

A series of copolymers composed of two monomer units having a polar phosphorylcholine group and an apolar fluorocarbon group with a controlled monomer unit sequence were synthesized by a reversible addition‐fragmentation chain transfer (RAFT) living radical polymerization method. 2‐Methacryloyloxyethyl phosphorylcholine (MPC) and 2,2,2‐trifluoroethyl methacrylate (TFEMA) were selected as the monomers, because they have disparate polarity. Furthermore, to investigate the influence of the monomer unit sequence in a polymer chain on the phase‐separated structure in the bulk and surface structure, copolymers having a continuous change in the monomer unit composition along the polymer chain (gradient copolymer) were synthesized, as well as random and block copolymers. The analysis of instantaneous composition revealed a continuous change in the monomer unit composition in the gradient copolymer and the statistical monomer unit sequence in the random copolymer. Thermal analysis assumed that the gradient sequence of the monomer unit would make the phase‐separated structure in the bulk ambiguous, while the well‐defined and monodispersive block sequence would undergo the distinct phase‐separation due to the extreme difference in the polarity of the component monomer units. The preliminary surface characterization of the synthesized polymers indicated the monomer unit sequence in the polymer chain would much influence on the surface structure. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 6073–6083, 2005     

苯乙烯-马来酸酐共聚物的核磁共振分析

利用^1H NMR、^13C NMR及DEPT(无畸变极化转移增强)核磁共振技术研究了苯乙烯-马来酸酐共聚物(SMA)的序列结构和组成，并比较了几种核磁共振实验技术对分析SMA结果的准确性；实验表明^1H NMR是分析组成的简单、快速而有效的方法，DEPT谱进行序列结构计算准确度较高。     

Dynamic states of the Bray-Liebhafsky reaction when sulfuric acid is the control parameter

Dynamic behavior of hydrogen peroxide decomposition catalyzed by iodate and hydrogen ions (the Bray-Liebhafsky reaction), in a continuous stirred tank reactor is investigated. The experimental results are obtained at one operational point in concentration phase space by varying mixed inflow concentrations of the sulfuric acid. The experimental evidences for the onset and termination of oscillatory behavior via the saddle node infinite period bifurcation as well as some kind of the Andronov-Hopf bifurcation are presented. In addition, the possibility of excitability of a stable steady state by thiamine was observed. The article is published in the original.     

The Effect of Residence Time Distribution on the Slurry‐Phase Catalytic Ethylene Polymerization: An Experimental and Computational Study

This work is focused on the development and validation of a model accounting for the impact of the reactor residence time distribution in well‐stirred slurry‐phase catalytic polymerization of ethylene. Particle growth and morphology are described through the Multigrain model, adopting a two‐site model for the catalyst and a conventional kinetic scheme. Particle size distribution and polymer properties (average molecular weights and polydispersity) are computed as a function of particle size through a segregated model, assuming that neither breakage nor aggregation occur. Reactors are modeled by means of fundamental mass conservation equations. The model is applied to a system constituted by a series of two ideal continuous stirred tank reactors, where the synthesis of polyethylene with bimodal molecular weight distribution is performed, employing the initial catalyst size distribution as the only adjustable parameter. The model provides insights at the single particle scale for each specific size, thus highlighting the inhomogeneity which arises from the synergic effects of chemical kinetics and residence time distributions in both reactors. The satisfactory agreement between model results and experimental data, in terms of particle size distribution and average molecular weights, confirmed the suitability of the model and underlying assumptions.     

Design and Control of Copolymer Composition Distribution in Living Radical Polymerization Using Semi‐Batch Feeding Policies: A Model Simulation

Summary: Although controlled/living radical copolymerization has been extensively studied, the control of copolymer composition distribution receives little attention. In this paper, taking RAFT copolymerization as an example, we develop a mathematical model and simulate copolymerization systems with various reactivity ratios. It is demonstrated that through semi‐batch operations with programmed profiles of slow monomer feeding rate, precise control over copolymer composition distribution (uniform and designed gradient distributions) along polymer chain can be achieved. It is also found that the semi‐batch operations have lower rates of polymerization than their batch counterparts. The reason for this difference is analyzed, and the magnitude depends on the reactivity ratios and targeted copolymer composition. The improvement of the semi‐batch rate by distributing a part of the initiator amount to the monomer feeding tank is found to be minor.

Model‐based design and control over composition distribution of gradient copolymers implemented by semi‐batch operations.     

Properties of polystyrene-poly(methylmethacrylate) random and diblock copolymers in dilute and semidilute solutions

Solution properties for random and diblock copolymers of polystyrene (PS) and poly(methyl methacrylate) (PMMA) have been measured by dynamic and total intensity light scattering in solvents of differing quality. The results are compared with the corresponding properties for PS and PMMA homopolymers of similar molecular weight, in order to determine if interactions between unlike monomers are significant. The hydrodynamic radius (R_h) and diffusion second virial coefficient (k_d) for the random copolymer are found to be larger than the corresponding values for the homopolymers in a solvent which is near-theta for the two homopolymers, whereas no such effect is observed for the block copolymer. This suggests that most intrachain interactions occur a relatively short distance along the chain backbone. In a mutual good solvent R_h and k_d of the random copolymer are comparable to the average of the values for the homopolymers, indicating that in a good solvent monomer/solvent interactions dominate over monomer/monomer interactions. For an isolated diblock copolymer in a mutual good solvent, there is no evidence that interactions between unlike monomers lead to additional expansion of the entire molecule, as measured by R_h, nor expansion of the individual blocks as probed by light scattering with one block optically masked. However, at low but finite concentration there is evidence (the coefficients of the binary interaction terms in the viscosity and the mutual diffusion coefficient, and the second and third virial coefficients) that a weak ordering effect may exist in block copolymer solutions, far from the conditions where microphase separation occurs. Finally, measurements of ternary polymer-polymer-solvent solutions show no dependence on monomer composition or monomer distribution for the tracer diffusion of probe PS-PMMA copolymers in a PMMA/toluene matrix. This indicate that the frictional interaction is largely unaffected by interactions between unlike monomers. However, there is evidence that the thermodynamic interaction is more unfavorable between a random copolymer and the homopolymer matrix than between a diblock and the matrix. © 1994 John Wiley & Sons, Inc.     

X-ray photoelectron spectroscopy: A new method for determination of copolymer composition,and monomer reactivity ratios and monomer sequence distribution therefrom

Copolymer compositions and reactivity ratios for the radical copolymerization of styrene with acrylonitrile have been determined by x-ray photoelectron spectroscopy (XPS). The results obtained by this technique were confirmed by elemental as well as ¹H-NMR (nuclear magnetic resonance) analysis. The monomer sequence distributions have also been calculated utilizing the monomer reactivity ratio values obtained by three different techniques viz., XPS, ¹H-NMR, and elemental analysis. The agreement between the monomer sequence distributions in the copolymer chain by these methods is very satisfactory. © 1997 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 35: 2049–2056, 1997     

Structural analysis of polyethene prepared with rac‐dimethylsilylbis(indenyl)zirconium dichloride/methylaluminoxane in a high‐temperature,continuously stirred tank reactor

A study of ethene solution polymerization with the rac‐dimethylsilylbis(indenyl)‐zirconium dichloride/methylaluminoxane catalyst system in a high‐temperature (140 °C), continuously stirred tank reactor system was carried out. ¹³C NMR, gel permeation chromatography, Fourier transform infrared, and rheological measurements were used for polymer analyses. Polyethylenes with low molecular weights (weight‐average molecular weight ≈ 35–55 kg/mol) and small amounts of methyl, ethyl, and long‐chain branching were produced. ¹³C NMR measurements showed that the long‐chain and methyl branches increased and that the ethyl branch contents decreased with decreasing monomer concentrations. At high monomer concentrations, the chain transfer to the coordinated monomer was concluded to be the predominant chain termination mechanism, whereas the chain transfer to aluminum was dominant at low monomer concentrations, which was evidenced by the fact that the selectivity of end groups was reduced to about 50%. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3292–3301, 2002