Kinetic modeling of controlled living microemulsion polymerizations that use reversible addition–fragmentation chain transfer

Reversible addition–fragmentation chain transfer (RAFT) polymerization is a useful technique for the formation of polymers with controlled architectures and molecular weights. However, when used in the polymerization of microemulsions, RAFT agents are only able to control the polymer molecular weight only at high RAFT concentrations. Here, a kinetic model describing RAFT microemulsion polymerizations is derived that predicts the reaction rates, molecular weight polydispersities, and particle size. The model predicts that at low RAFT concentrations, the RAFT agent will be consumed early in the reaction and that this will result in uncontrolled polymerization in particles nucleated late in the reaction. The higher molecular weight polydispersity that is observed in RAFT microemulsion polymerizations is the result of this uncontrolled polymerization. The model also predicts a shift in the conversion at which the maximum reaction rate occurs and a decrease in the particle size with increasing RAFT concentration. Both of these trends are also consistent with those observed experimentally. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 6055–6070, 2006     

Particle formation under monomer‐starved conditions in the semibatch emulsion polymerization of styrene. I. Experimental

Particle formation and particle growth compete in the course of an emulsion polymerization reaction. Any variation in the rate of particle growth, therefore, will result in an opposite effect on the rate of particle formation. The particle formation in a semibatch emulsion polymerization of styrene under monomer‐starved conditions was studied. The semibatch emulsion polymerization reactions were started by the monomer being fed at a low rate to a reaction vessel containing deionized water, an emulsifier, and an initiator. The number of polymer particles increased with a decreasing monomer feed rate. A much larger number of particles (within 1–2 orders of magnitude) than that generally expected from a conventional batch emulsion polymerization was obtained. The results showed a higher dependence of the number of polymer particles on the emulsifier and initiator concentrations compared with that for a batch emulsion polymerization. The size distribution of the particles was characterized by a positive skewness due to the declining rate of the growth of particles during the nucleation stage. A routine for monomer partitioning among the polymer phase, the aqueous phase, and micelles was developed. The results showed that particle formation most likely occurred under monomer‐starved conditions. A small average radical number was obtained because of the formation of a large number of polymer particles, so the kinetics of the system could be explained by a zero–one system. The particle size distribution of the latexes broadened with time as a result of stochastic broadening associated with zero–one systems. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3940–3952, 2001     

Sterically stabilized emulsion polymerization of styrene: Pseudo‐semicontinuous approach

The sterically stabilized emulsion polymerization of styrene initiated by a water‐soluble initiator at different temperatures has been investigated. The rate of polymerization (R_p) versus conversion curve shows the two non‐stationary‐rate intervals typical for the polymerization proceeding under non‐stationary‐state conditions. The shape of the R_p versus conversion curve results from two opposite effects—the increased number of particles and the decreased monomer concentration at reaction loci as the polymerization advances. At elevated temperatures the monomer emulsion equilibrates to a two‐phase or three‐phase system. The upper phase is transparent (monomer), and the lower one is blue colored, typical for microemulsion. After stirring such a multiphase system and initiation of polymerization, the initial coarse polymer emulsion was formed. The average size of monomer/polymer particles strongly decreased up to about 40% conversion and then leveled off. The initial large particles are assumed to be highly monomer‐swollen particles formed by the heteroagglomeration of unstable polymer particles and monomer droplets. The size of the “highly monomer” swollen particles continuously decreases with conversion, and they merge with the growing particles at about 40–50% conversion. The monomer droplets and/or large highly monomer‐swollen polymer particles also serve as a reservoir of monomer and emulsifier. The continuous release of nonionic (hydrophobic) emulsifier from the monomer phase increases the colloidal stability of primary particles and the number of polymer particles, that is, the particle nucleation is shifted to the higher conversion region. Variations of the square and cube of the mean droplet radius with aging time indicate that neither the coalescence nor the Ostwald ripening is the main driving force for the droplet instability. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 804–820, 2003     

Reversible‐addition fragmentation chain transfer radical emulsion polymerization by a nanoprecipitation process

Polymerizations of styrene under emulsion reversible‐addition fragmentation chain transfer polymerization conditions are reported. Using a recently developed nanoprecipitaiton process, emulsion particles were formed by the precipitation of an acetone solution of a macroRAFT agent into an aqueous solution of poly(vinyl alcohol). The particles were then swollen with monomer and subsequently polymerized. Emulsion polymerizations were performed at 65 and 75 °C in which either KPS, BPO, or a combination of both was used as an initiating source. Reactions were also performed at temperatures over 100 °C in which the thermal initiation of styrene was used as an initiating source. In all cases, the polymerizations proceeded in a living manner, yielding polymers that showed an incremental increase in molecular weight with time and had narrow molecular weight distributions. Plots of number‐ average molecular weight versus conversion were linear, indicating a controlled polymerization. The resulting latices were colloidally stable and gave particle size distributions with a typical average particle diameter in the 150 nm range. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 5708–5718, 2006     

The effect of cosurfactants and the initiator concentration on the polymer to surfactant concentration in nanolatexes

The effect of cosurfactant and initiator concentration on the ab initio production of nanolatexes using low surfactant levels was investigated. While the use of cosurfactants (acrylic acid and pentanol) increased the amount of monomer that can be used in styrene‐SDS microemulsion formulations to 13 wt %, high surfactant concentrations are still required, resulting in polymer‐to‐surfactant ratios (Pol/Surf) <1. Latexes with particle size of 30 ± 5 nm were produced upon polymerization of these microemulsions. The Pol/Surf can be significantly increased by increasing the initiator concentration of emulsion polymerization recipes. Particle sizes are comparable with microemulsion latexes, however, less surfactant is required. The reduction in the particle size with higher initiator concentration is attributed to a higher efficiency of particle nucleation and to a higher nucleation rate relative to the rate of monomer transfer. Nanolatexes (particle size < 30 nm) were obtained with 19 wt % solids content and Pol/Surf of 3.6 in ab initio. © 2011 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

Polymerization of oil (styrene and methylmethacrylate)-in-water microemulsions

 The polymerization of styrene-in-water and methylmeth-acrylate-in-water microemulsions stabilized by nonionic surfactants was investigated using different initiation techniques. Thermally induced initiation was carried out using potassium persulfate (water soluble) and azobisiso-butyronitrile (AIBN) (oil soluble) at 60° and 50°C, respectively. When the monomer concentration was kept below a certain limit, the particle size of the nanolatex was similar to the droplet size of the microemulsion precursor. At higher monomer concentrations, the latex produced was significantly larger than the microemulsion droplets, as a result of the possible coalescence of the microemulsion droplets during polymerization. By using chemically induced polymerization (hydrogen peroxide+ascorbic acid) at temperatures below the cloud point temperature of the microemulsion or by photochemically induced initiation at room temperature, it was possible to obtain nanolatex particles with similar size to the droplets up to 10% monomer content. In all cases, the particle size was determined using photon correlation spectroscopy (PCS). Electron micrographs of the microlatex particles were taken and these confirmed the measurements obtained by PCS. The molecular weight of the polymers produced was determined by gel permeation chromatography. The average number of polymer molecules per particle was calculated. It was shown in some cases that the nanolatex contained one polymer chain per particle. A mechanism was suggested for polymerization and particle growth. Received: 29 May 1997 Accepted: 28 May 1998     

Emulsion and controlled miniemulsion polymerization of the renewable monomer γ‐methyl‐α‐methylene‐γ‐butyrolactone

The kinetics of free‐radical emulsion polymerization of γ‐methyl‐α‐methylene‐γ‐butyrolactone (MeMBL), a renewable monomer related to methyl methacrylate, are presented in detail for the first time, and stable polymer latices are prepared. The effects of different reaction parameters on free‐radical emulsion polymerization of MeMBL are presented. Homogeneous nucleation is asserted to be the dominant path for particle formation. Miniemulsion copolymerization of MeMBL and styrene is also reported. In this case, the homogeneous nucleation process appears limited when using an oil soluble initiator. Both the RAFT miniemulsion polymerizations and RAFT bulk polymerizations are well controlled and narrow polydispersity copolymers are produced. Rate retardation is observed in the RAFT miniemulsion polymerizations compared with the free‐radical polymerization and RAFT bulk polymerizations and the possible causes of the retardation are discussed. The reactivity ratios of MeMBL and styrene in RAFT bulk copolymerization are also determined. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 5929–5944, 2008     

Emulsifier‐free,organotellurium‐mediated living radical emulsion polymerization (emulsion TERP): Effect of monomer hydrophilicity

Emulsifier‐free, organotellurium‐mediated living radical emulsion polymerizations (emulsion TERPs) of methyl methacrylate (MMA) and n‐butyl methacrylate (BMA) with dimethyl ditelluride were carried out at two different stirring rates (220 rpm and 1000 rpm). In the emulsion TERP of MMA as a hydrophilic monomer, the molecular weight distribution (MWD) controls with both stirring rates were good with high polymerization rate (100% conversion at 1.5 h). On the other hand, in the emulsion TERP of BMA as a hydrophobic monomer, at 220 rpm the polymerization rate was much slow (～50% conversion at 22 h) and the MWD control was bad, but at 1000 rpm the polymerization was completed within 7 h and MWD control was good. These results suggest that monomer transportation from droplets to polymerizing particles via aqueous medium is important for good MWD control and steady polymerization in the emulsion TERP. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

TEMPO‐Mediated Emulsion Polymerization

While miniemulsion polymerization has proven to be well‐suited for conducting living/controlled radical polymerizations, emulsion polymerizations have proven to be far more challenging. Ab initio emulsion polymerizations, in which monomer droplets are present during polymerization, have thus far not been successful with TEMPO‐mediated polymerizations, as a result of colloidal instability and coagulum formation. By selectively inhibiting polymerization in the monomer droplets, it is demonstrated that droplet polymerization is responsible for the formation of large (>1 µm) particles that can lead to coagulum formation. Furthermore, we show that coagulum‐free latexes can be produced using a TEMPO‐mediated ab initio emulsion polymerization by suppressing droplet polymerization.

     

Microemulsion polymerization of styrene

Initiation of polymerization in styrene oil-in-water microemulsions by water-soluble potassium persulfate of oil-soluble 2,2′-azobis-(2-methyl butyronitrile) at 70°C gave stable latexes which were bluish and less translucent than the original microemulsions. The effects of initiator concentration, polymerization temperature, and monomer concentration on the kinetics, particle size distributions, and molecular weight distributions were investigated. The kinetics of polymerization were measured by dilatometry. In all cases, the polymerization rate shows only two intervals, which increased to a maximum and then decreased. There was no apparent constant rate period and no gel effect. A longer nucleation period was found for polymerizations initiated by potassium persulfate as compared to 2,2′-azobis-(2-methyl butyronitrile). The small latex particle size (20–30 nm) and high polymer molecular weight (1–2 × 10⁶) implies that each latex particle consists of two or three polystyrene molecules. The maximum polymerization rate and number of particles varied with the 0.47 and 0.40 powers of potassium persulfate concentration, and the 0.39 and 0.38 powers of 2,2′-azobis-(2-methyl butyronitrile) concentration, respectively. This is consistent with the 0.4 power predicted by Smith–Ewart Case 2 kinetics. Microemulsion polymerizations of styrene–toluene mixtures at the same oil-water phase ratio gave lower polymerization rates and lower molecular weights, but the same latex particle size as with styrene alone. A mechanism is proposed, which comprised initiation and polymerization in the microemulsion droplets, by comparing the kinetics of microemulsion polymerization with conventional emulsion and miniemulsion polymerization systems.     

Towards a consistent mechanism of emulsion polymerization—new experimental details

The application of atypical experimental methods such as conductivity measurements, optical microscopy, and nonstirred polymerizations to investigations of the ‘classical’ batch ab initio emulsion polymerization of styrene revealed astonishing facts. The most important result is the discovery of spontaneous emulsification leading to monomer droplets even in the quiescent styrene in water system. These monomer droplets with a size between a few and some hundreds of nanometers, which are formed by spontaneous emulsification as soon as styrene and water are brought into contact, have a strong influence on the particle nucleation, the particle morphology, and the swelling of the particles. Experimental results confirm that micelles of low-molecular-weight surfactants are not a major locus of particle nucleation. Brownian dynamics simulations show that the capture of matter by the particles strongly depends on the polymer volume fraction and the size of the captured species (primary free radicals, oligomers, single monomer molecules, or clusters).     

Semicontinuous heterophase polymerization under monomer starved conditions to prepare nanoparticles with narrow size distribution

The semicontinuous polymerization of methyl methacrylate (MMA) in heterogeneous medium under monomer‐starved conditions is reported here. The effect of monomer addition rate on kinetics, particle size, particle number, and PMMA average molar masses are reported. This process permits the synthesis of high‐solid content latexes containing nano‐sized particles (<40 nm) with narrow particle size distributions [(D_w/D_n) < 1.1]. Moreover, the molar masses (M_n ≈ 0.3–1.2 × 10⁶ g/mol) are much lower than those expected by chain transfer to monomer, which is the typical termination mechanism in 0–1 emulsion and microemulsion reactions. Both particle size and average molar masses decrease as the rate of monomer addition is diminished. Possible explanations for this process are provided. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 1463–1473, 2007     

苯乙烯微乳液种子聚合

通过观测苯乙烯微乳液种子聚合前后体系内聚合物粒子大小及其分布的变化发现,无论是γ射线还是KPS引发,聚合过程中都没有新的聚合物粒子生成。尽管聚合前体系中存在单体溶胀的胶束,但在聚合过程中这些胶束主要充当单体仓库,自己成核聚合的几率很低。由于微乳液种子聚合体系内,单体量相对较低,聚合物粒子数目很大,其聚合动力学明显不同于常规乳液种子聚合。     

Photoinduced cationic ring‐opening frontal polymerizations of oxetanes and oxiranes

The photoinitiated cationic ring‐opening polymerizations of certain epoxides and 3,3‐disubstituted oxetanes display the characteristics of frontal polymerizations. When irradiated with UV light, these monomers display a marked induction period, during which little conversion of the monomer to the polymer takes place. The local application of heat to an irradiated monomer sample results in polymerization that occurs as a front propagating rapidly throughout the entire reaction mass. For the characterization of these frontal polymerizations, the use of a new monitoring technique, employing optical pyrometry, has been instituted. This method provides a simple, rapid means of following these fast polymerizations and quantitatively determining their frontal velocities. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1630–1646, 2004     

Reversible addition–fragmentation chain transfer polymerization of methyl methacrylate in suspension

The reversible addition–fragmentation chain transfer polymerization of methyl methacrylate mediated by 2‐cyanoprop‐2‐yl dithiobenzoate (CPDB) in bulk (60 and 70 °C) and suspension (70 °C) was studied, and in both polymerization systems, a good control of the molecular weight and polydispersity was observed. Stable suspension polymerizations were carried out over a range of CPDB concentrations, and with increasing CPDB concentration, the particle size and polydispersity index of the produced polymer decreased. The former was ascribed to the lower viscosities of the monomer and polymer droplets at low conversions, which caused easier breakup with the applied shear stresses. Lower polydispersity indices at higher CPDB concentrations were probably caused by a diminished gel effect, which was observed at lower CPDB concentrations at high conversions, causing a broadening of the molecular weight distribution. The livingness of the polymers formed in suspension was proven by successful chain extensions with methyl methacrylate, styrene, and 2‐hydroxyethyl methacrylate. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 2001–2012, 2005     

Evolution of multimodal particle size distribution in vinyl acetate/butyl acrylate emulsion copolymerizations

This article presents a study on the engineering of multimodal distributions in semibatch emulsion polymerizations with nonionic surfactants. Various methods of producing multimodal distributions are demonstrated, and the sensitivity of the process to the properties of the reagents are analyzed. A test‐bed emulsion polymerization system, equipped with instrumentation to measure particle size distribution (capillary hydrodynamic fractionator) and monomer conversion (densitometer and flow meters), is used for this purpose. The process is monitored and controlled with an industrial distributed control system, which enables the automated operation of the process through sequential or logic controllers operating over lower level proportional integral derivative controllers. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 2232–2249, 2003     

Kinetic model of reversible addition‐fragmentation chain transfer polymerization in microemulsions

A simplified kinetic model for RAFT microemulsion polymerization has been developed to facilitate the investigation of the effects of slow fragmentation of the intermediate macro‐RAFT radical, termination reactions, and diffusion rate of the chain transfer agent to the locus of polymerization on the control of the polymerization and the rate of monomer conversion. This simplified model captures the experimentally observed decrease in the rate of polymerization, and the shift of the rate maximum to conversions less than the 39% conversion predicted by the Morgan model for uncontrolled microemulsion polymerizations. The model shows that the short, but finite, lifetime of the intermediate macro‐RAFT radical (1.3 × 10^?4–1.3 × 10^?2 s) causes the observed rate retardation in RAFT microemulsion polymerizations of butyl acrylate with the chain transfer agent methyl‐2‐(O‐ethylxanthyl)propionate. The calculated magnitude of the fragmentation rate constant (k_f = 4.0 × 10¹–4.0 × 10³ s^?1) is greater than the literature values for bulk RAFT polymerizations that only consider slow fragmentation of the macro‐RAFT radical and not termination (k_f = 10^?2 s^?1). This is consistent with the finding that slow fragmentation promotes biradical termination in RAFT microemulsion polymerizations. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 604–613, 2010     

Molecular Watchmaking: ab initio Emulsion Polymerization by RAFT-controlled Self-assembly

Controlled radical polymerization using RAFT has the potential to make polymers with virtually any desired molecular architecture. For this to be implemented on an industrial scale, it must be performed by polymerization in disperse media. However, simply adding a RAFT agent to a conventional emulsion polymerization recipe leads to a loss of molecular weight control and formation of coagulum, probably because of nucleation in droplets, which is normally an unlikely phenomenon in emulsion polymerizations. Recently, a method has been devised for implementing RAFT in ab initio emulsion polymerization that avoids droplets in the particle formation stage. The molecular weight distribution of the polymer thus formed shows that molecular weight control is maintained throughout the polymerization. A model is developed to predict the particle size formed in this new type of emulsion polymerization. The new methodology enables synthesis of novel dispersions where molecular architecture can be precisely controlled, such as structured core-shell particles.     

Synthesis of iron oxide/poly(methyl methacrylate) composite latex particles: Nucleation mechanism and morphology

A magnetic poly(methyl methacrylate) (PMMA) composite latex was prepared by soapless emulsion polymerization in the presence of ferrofluid, and the ferrofluid was prepared by means of a coprecipitation method. The effects of various polymerization parameters, such as the monomer concentration, ferrofluid content, and initiator concentration, on the conversion curve and particle size of the magnetic composite latex particles were examined in detail. The results showed that two nucleation mechanisms were involved according to the polymerization conditions. In the monomer‐rich and less ferrofluid system, self‐nucleation of PMMA was dominant over the entire course of emulsion polymerization. In the ferrofluid‐rich system, seeded emulsion polymerization was the main course to form the magnetic composite latex particles. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 5695–5705, 2004     

Multistep and semibatch nitroxide‐mediated controlled free‐radical emulsion polymerization: A significant step toward conceivable industrial processes

Nitroxide‐mediated emulsion polymerizations of n‐butyl acrylate and styrene were performed with a monofunctional, water‐soluble alkoxyamine initiator and a difunctional one. Two different processes were applied, either in two steps or under semibatch conditions. In particular, the polymerization times were strongly reduced, while high conversions and good control over the polymer characteristics were maintained. In all cases, stable latexes were recovered; with the difunctional initiator in particular, they exhibited small particles and narrow particle size distributions. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 4142–4153, 2006