Emulsifier-free emulsion copolymerization of styrene and butyl acrylate. I. Kinetic studies in the absence of surfactant

Soapless emulsion copolymerization of styrene (S) and n-butyl acrylate (BuA) has been investigated using two types of initiator and different comonomer feed mixtures. When using K₂S₂O₈ as initiator, the particle size and size distribution of the final latexes (500 nm and 1.003, respectively) is not significantly affected by the comonomer feed composition, whereas the molecular weight and surface characteristics were found to sharply change at high butyl acrylate content. Based on the most probable particle nucleation mechanism and type of chain termination in the monomer swollen particles, a tentative explanation of these results has been proposed. Replacing persulfate by a carboxylic initiator (4-4′-azobiscyanopentanoic acid) results in the formation of stable particles as α observed with the persulfate, provided the aqueous phase pH is fixed in between 6 and 7. Results on the initiator residue location as a function of the conversion point out that the particle flocculation mechanism is strongly significant in the preparation of such latexes.     

Dispersion polymerization of 2-hydroxyethyl methacrylate (HEMA) using siloxane-based surfactant in supercritical carbon dioxide and in compressed liquid dimethyl ether

The free radical dispersion polymerization of 2-hydroxyethyl methacrylate (HEMA) has been carried out in supercritical carbon dioxide (scCO₂) and compressed liquid DME using several surfactants. The polymerization are performed in the presence of fluorine-based poly(3,3,4,4,5,5,6,6,7,7,8,8,9,9,10,10,10-heptadecafluorodecyl acrylate) [poly(HDFDA)], poly(3,3,4,4,5,5,6,6,7,7,8,8,9,9,10,10,10-heptadecafluorodecyl methacrylate) [poly(HDFDMA)], or poly(HDFDMA-co-MMA) and siloxane-based PDMS-g-pyrrolidonecarboxylic acid (Monasil PCA™) or PDMS modified surfactants, SS-5050K™ and KF6017™ as polymerization surfactants. When scCO₂ was used as a polymerization medium, the PHEMA were heavily agglomerated. However, the spherical and relatively uniform poly(2-hydroxyethyl methacrylate) (PHEMA) particles could be produced even at 20 bar, with a narrow particle size distribution in compressed liquid DME. It was observed that fluorine-based surfactants were not a good surfactant as siloxane-based surfactants for the dispersion polymerization of HEMA. The average particle size of PHEMA was shown to be dependent on the type of the surfactant, the amount of the surfactant and initiator added to the system. The effect of two continuous phases, which are scCO₂ and compressed liquid DME, as a polymerization medium, the surfactant types and the concentration, initiator concentration, and monomer concentration on the morphology and size of the polymer particles was also investigated.     

Dispersion polymerization of methyl methacrylate in supercritical CO2 in the presence of non-fluorous random copolymers

A series of non-fluorous random copolymers, composed of 3-[tris(trimethylsilyloxy)silyl] propyl methacrylate and 2-dimethylaminoethyl methacrylate, poly(SiMA-co-DMAEMA) with different comonomer ratios were prepared and utilized as stabilizers for the free radical dispersion polymerization of methyl methacrylate (MMA) in supercritical carbon dioxide (scCO₂). It was demonstrated that the composition and concentration of the stabilizer have a dramatic effect on the morphology of resulting poly methyl methacrylate (PMMA) latex. When the copolymeric stabilizer poly(SiMA-co-DMAEMA) (71:29) was employed, free-flowing spherical PMMA particles were produced in high yield. As the concentration of stabilizer increases, the resulting size of colloidal particles decreases. In addition, the monomer concentration and initial pressure affected the particle diameter of PMMA.     

Synthesis of cross-linked poly (<Emphasis Type="Italic">N</Emphasis>-isopropylacrylamide) microparticles in supercritical carbon dioxide

Herein, we report a new method that has been developed to prepare thermoresponsive polymers. The white, dry, fine powders were obtained directly from cross-linking polymerization of N-isopropylacrylamide in supercritical carbon dioxide (scCO₂) with N,N-methylenebisacrylamide as a cross-linker. The effects of the reaction pressure and time as well as the initial concentrations of the initiator, cross-linker, and monomer on the yield and morphology of the resulting polymer were investigated systematically. The polymer yield was increased with the concentrations of the cross-linker, monomer, and reaction time. Under the condition of using higher cross-linker concentrations, the cross-linked poly (N-isopropylacrylamide) microparticles with diameters of 50 nm were generated in scCO₂ in high-yield and short reaction times. These results suggest that the synthetic method using scCO₂ can be used to prepare biomedical materials such as the controlled drug-release system.     

Synthesis of polystyrene/SiO2 composite microparticles by dispersion polymerization in supercritical fluid

A novel synthetic route to prepare polystyrene/SiO₂ composite microparticles in supercritical carbon dioxide (scCO₂) is presented. Silica particles with the size of 130 nm which were surface-modified with 3-(trimethoxysilyl) propyl methacrylate were used as seeds in the dispersion polymerization of styrene in the presence of a polymeric stabilizer, poly(1,1-dihydroheptafluorobutyl methacrylate-co-diisopropylaminoethyl methacrylate) to produce dry composite particles. The transmission electron microscopy analysis revealed that the composite microspheres contained several silica particles.     

Magnetically loaded poly(methyl methacrylate-co-acrylic acid) nano particles

Magnetically loaded polymeric nano-particles carrying functional groups on their surface were prepared by a two-stage process. In the first stage, super-paramagnetic magnetite (Fe₃O₄) nano-particles were produced by a co-precipitation method from the aqueous solutions of FeCl₂·4H₂O and FeCl₃·6H₂O using a NaOH solution. The smallest size obtained was 40.9 nm with poly-dispersity index of 0.194 obtained by using a Zeta Sizer. The effects of Fe²⁺/Fe³⁺ molar ratio, stirring rate, temperature, base concentration, and pH on the particle size/size distribution and stability of the dispersions were examined. Increasing the relative concentration of Fe²⁺ ion and decreasing the stirring rate and pH increased the particle size, while the concentration of NaOH and temperature did not change the particle size significantly. Polymer coating was achieved by emulsion polymerization at high surfactant to monomer ratio of methyl methacrylate (MMA) and acrylic acid which were used as comonomers (comonomer ratio: 90/10 weight) with high surfactant to monomer ratio. The surfactant and initiator were SDS and KPS, respectively. Nano-particles in the range of 115 and 300 nm in diameter were produced depending on recipe. Increasing the Fe₃O₄/monomer and surfactant/monomer ratios, the KPS concentration caused a decrease in the average diameter. Magnetic properties of the nano-particles were obtained by electron spin resonance and vibrating-sample magnetometer. Most of the polymer-coated nano-particles exhibited super paramagnetic behavior.An erratum to this article can be found at     

Synthesis of cross-linked poly(methyl methacrylate) via dispersion polymerization in supercritical carbon dioxide

Cross-linked poly(methyl methacrylate) particles were prepared via dispersion polymerization in supercritical carbon dioxide (scCO₂) using poly(heptadecafluorodecyl methacrylate) (PHDFDMA) and 2,2′-azobisisobutyronitrile as the dispersant and the initiator, respectively. The following chemicals were used as cross-linking agents: ethylene glycol dimethacrylate (EGDMA), 1,4-buthanediol di(meth)acrylate (1,4-BD(M)A), and trimethylolpropane trimethacrylate. PHDFDMA was synthesized by solution polymerization in scCO₂. We investigated the effect of the chemical structure, concentration of the cross-linking agents, reaction pressure, and CO₂ density on the morphology, the polydispersity, and the cross-linking density of polymer particles. The resulting polymer particle was characterized by field emission SEM, differential scanning calorimetry, and thermal gravimetric analysis. The cross-linked PMMA particles is more agglomerate as the cross-linking agent concentration increased and as pressure decreased at constant temperature. Glass-transition temperature (T _g) of the resulting polymer increased as the cross-linking agent increased with temperature and pressure increasing at the same CO₂ density. Decomposition temperature is slightly increased as 1,4-BDA concentration increased. From these results, we can confirm that the thermal stability of the polymer increased as the cross-linking agent and EGDMA is the best cross-linking agent in term of the thermal stability.     

Kinetics and mechanism of emulsifier-free emulsion polymerization. III. Styrene/nonionic comonomer (2-hydroxyethyl methacrylate) system

The emulsifier-free emulsion polymerizations of styrene in the presence of about 0.33–2.7% (relative to styrene) of the water soluble comonomer, 2-hydroxyethyl methacrylate (HEMA), and of the initiator, potassium persulfate (KPS), were carried out. It was found that KPS plays a predominant role in the particle nucleation process, since the number density of polymer particles (N_p) was dependent on the 0.97-power of [KPS]. The nucleation ability of HEMA was weak, since N_p was dependent only on the 0.17-power of [HEMA]. The particle nucleation stage ceased quite early before 1% conversion, leading to nearly monodispersed polymer particles. The nucleation is suggested to be via the homogeneous nucleation mechanism. The particles grow via the core-shell structure mechanism (shell region polymerization), since the particle size is rather large—from 1500 to 6000 Å. The amount of HEMA can affect the shell thickness and physical properties of the shell, such as the monomer swelling capacity and monomer diffusion rate.     

Synthesis of Latex Particles with Surface Functional Groups and Their Applications for the Fabrication of Porous Materials

In this study, monodisperse latex particles with specific surface functional groups were synthesized by emulsifier-free emulsion polymerization. Amidine or carboxylated polystyrene nanospheres with narrow size distribution were prepared by emulsion polymerization using AIBA (α,α′-zodiisobutyramidine dihydrochloride) as amine-containing initiator or acrylic acid as carboxyl-containing comonomer, respectively. Factors affecting the particle size and distribution were systemically studied by changing the amount of initiator or monomer, the polymerization temperature, and the stirring speed of emulsion polymerization reactor. Monodisperse polymethylmethacrylate beads were also synthesized by soapless emulsion polymerization using methacrylic acid or aminoethylmethacrylate hydrogen hydrochloride as comonomer for the surface functionalization of the particles. As applications of the latex beads, the polymeric particles were adopted as templating materials for the fabrication of macroporous titania film and meso-macroporous silica particles by colloidal templating method.     

Synthesis of thermo‐responsive microgels in supercritical carbon dioxide using ethylene glycol dimethacrylate as a cross‐linker

Herein, we report the preparation of thermo‐responsive polymers in a green medium. The white, dry, fine powders were obtained directly from the cross‐linking polymerization of N‐isopropylacrylamide (NIPA) in supercritical carbon dioxide (scCO₂) at pressures ranging from 10 to 28 MPa utilizing ethylene glycol dimethacrylate (EGDMA) as a cross‐linker. The effects of reaction pressure, cross‐linker ratio, initiator concentration, and reaction time were investigated. In the presence of this cross‐linker (26.4% w/w), much smaller poly(N‐isopropylacrylamide) (PNIPA) microgels (<0.2 µm diameter) were formed, and it was shown that the particle size and the morphology of the polymer were strongly dependent on the cross‐linker ratio in scCO₂. Copyright © 2009 John Wiley & Sons, Ltd.     

Continuous reaction system to investigate the dispersion polymerization of vinyl monomers in supercritical carbon dioxide

A laboratory‐scale continuous reaction system using a stirred tank reactor was assembled in our laboratory to study the dispersion polymerization of vinyl monomers in supercritical carbon dioxide (scCO₂). The apparatus was equipped with a suitable downstream separation section to collect solid particles entrained in the effluent stream from the reactor, whose monomer concentration could be measured online with a gas chromatograph. The dispersion polymerization of methyl methacrylate in scCO₂ was selected as a model process to be investigated in the apparatus. The experiments were performed at 65 °C and 25 MPa with 2,2′‐azobisisobutyronitrile as the initiator and a reactive polysiloxane macromonomer as a surfactant to investigate the effect of the mean residence time of the reaction mixture on the monomer conversion, polymerization rate, polymer molecular weight, and particle size distribution. The results were compared with those obtained in batch polymerizations carried out under similar operative conditions. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 4122–4135, 2006     

In situ generation of biodegradable poly(p-dioxanone) micro-particles by polymerization in supercritical carbon dioxide

Ring-opening suspension polymerization of p-dioxanone（PDO） in supercritical carbon dioxide（scCO₂） was investigated in the presence of poly（caprolactone）-perfluropolyether-poly（caprolactone）（PCL-PFPE-PCL）.The molecular weight,yield and particle morphology of poly（p-dioxanone）（PPDO） were studied.The stabilizer was effective to stabilize the ring-opening polymerization（ROP） of PDO in scCO₂,leading to the formation of resorbable microparticles in a"one pot"procedure.The mean size of PPDO microparticles obtained from suspension polymerizations was sensitive to the rate of agitation and the stabilizer concentration.The method to generate PPDO microparticles has overcome its unprocessable drawback with common organic solvents and provided new product form for biomedical applications.     

Emulsifier-free emulsion polymerization with ionic comonomer

Emulsion polymerization of styrene in the absence of emulsifier with K₂S₂O₈ as initiator produced uniform latices. Incorporation of ca. 0.5% ionic comonomer (sodium styrenesulfonate) reduced the particle size from the range 0.5–1.0 μm achieved in prior emulsifier free formulations to a range of 0.15–0.40 μm. Some advantages achieved by incorporation of ionic comonomer were higher polymer content and independently controllable surface charge density. Particle diameter varied as the 0.64 power of the ratio of ionic strength to comonomer, as the ?0.20 power of initiator concentration, and as the 0.46 power of monomer content. Kinetic data suggest that copolymerization takes place in the aqueous phase, and that nuclei for particle growth are formed by precipitation of the initially water-soluble copolymer. The latex is stabilized by sulfonic acid groups of the comonomer, as well as by sulfate end groups from the initiator.     

Study on soap‐free P(MMA‐EA‐AA or MAA) latex particles with narrow size distribution

Soap‐free poly(methyl methacrylate‐ethyl acrylate‐acrylic acid or methacrylic acid) [P(MMA‐EA‐AA or MAA)] particles with narrow size distribution were synthesized by seeded emulsion polymerization of methyl methacrylate (MMA), ethyl acrylate (EA) and acrylic acid (AA) or methacrylic acid (MAA), and the influences of the mass ratio of core/shell monomers used in the two stages of polymerization ([C/S]_w) and initiator amount on polymerization, particle size and its distribution were investigated by using different monomer addition modes. Results showed that when the batch swelling method was used, the monomer conversion was more than 96.0% and particle size distribution was narrow, and the particle size increased first and then remained almost unchanged at around 600 nm with the [C/S]_w decreased. When the drop‐wise addition method was used, the monomer conversion decreased slightly with [C/S]_w decreased, and large particles more than 750 nm in diameter can be obtained; with the initiator amount increased, the particle size decreased and the monomer conversion had a trend to increase; the particle size distribution was broader and the number of new particles was more in the AA system than in the MAA system; but the AA system was more stable than the MAA system at both low and high initiator amount. Copyright © 2006 John Wiley & Sons, Ltd.     

Controlled/living heterogeneous radical polymerization in supercritical carbon dioxide

Supercritical carbon dioxide (scCO₂) is an inexpensive and environmentally friendly medium for radical polymerizations. ScCO₂ is suited for heterogeneous controlled/living radical polymerizations (CLRPs), since the monomer, initiator, and control reagents (nitroxide, etc.) are soluble, but the polymer formed is insoluble beyond a critical degree of polymerization (J_crit). The precipitated polymer can continue growing in (only) the particle phase giving living polymer of controlled well‐defined microstructure. The addition of a colloidal stabilizer gives a dispersion polymerization with well‐defined colloidal particles being formed. In recent years, nitroxide‐mediated polymerization (NMP), atom transfer radical polymerization (ATRP), and reversible addition fragmentation chain transfer (RAFT) polymerization have all been conducted as heterogeneous polymerizations in scCO₂. This Highlight reviews this recent body of work, and describes the unique characteristics of scCO₂ that allows composite particle formation of unique morphology to be achieved. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 3711–3728, 2009     

Pickering emulsion polymerization kinetics of styrene: Comparison of bare and surface modified SiO2 nanoparticles

A step towards the understanding of some mechanistic events occurring in the styrene Pickering emulsions, using a SiO₂ dispersion, is presented. Polymerizations at 80°C with different levels of a water soluble initiator were performed. The emulsion polymer content was ca. 15% with conversions close to 90%. With conversion and particle size measurements, the particle density was estimated for bare and surface modified SiO₂ particles. Then, the average number of radicals per particle was inferred, yielding a pseudo-bulk type polymerization. It was found that bare SiO₂ nanoparticles do not participate in the nucleation mechanism; however, they, along with the initiator, promote an enhanced oligomer coagulation. On the other hand, the hexadecyltrimethylammonium bromide modified SiO₂ nanoparticles do participate in the nucleation and coagulation mechanisms, yielding more stable and smaller poorly-covered polymer particles. This approach allowed untangling some events such as: particle nucleation, radical entry to particles, particle density, coagulation and vitreous and Trommsdorff effects.     

Kinetics and mechanism of emulsifier-free emulsion polymerization. II. Styrene/water soluble comonomer (sodium methallyl sulfonate) system

The emulsifier-free emulsion polymerizations of styrene in the presence of about 1 wt% (related to styrene) of the water soluble comonomer, sodium methallyl sulfonate (NaMS), which has short hydrophobic group and strong hydrophilic ionic group, and of the initiator, potassium persulfate, are carried out. Under constant ionic strength, the number density of polymer particles (N_p) is found to depend on 0.5-power of the initiator concentration and shows a minimum in the comonomer concentration plot. Under constant concentration of monomer, comonomer and initiator, N_p is found to depend on ?1.1-power of the ionic strength. In the earlier period, the presence of styrene oligomer having MW about 1000 and water soluble poly(NaMS) or copolymer with high NaMS content suggests a micellar nucleation mechanism, by which the styrene oligomer behaves as emulsifier and the poly(NaMS) can either stabilize or destabilize the existing particles, depending on its concentration in the aqueous phase. The particle size is rather uniform having an uniformity very close to 1 (ca. 1.001) throughout the entire process. It is much larger than that of the conventional emulsion polymerization or emulsifier-free emulsion polymerization with the other comonomers by about 3 to 4 times in diameter or 27 to 64 times in volume, leading to that the average radical number in the particle could be much greater than 0.5. The (conversion)^2/3 versus time plot is found to be linear from 6 to 50% conversion. During this period, for the conversion from 10 to 40% the polymerization rate increases twice but the particle volume increases four-fold. In addition, MWD shows bimodal (excluding the styrene oligomer peak in the earlier period) during the growth period. But the lower MW peak shifts to higher MW and become larger, while the higher MW peak decreases, and finally the MWD becomes single mode after 58.6% conversion. These results suggest a “gradient polymerization” or “transition stage to core-shell structure” in the earlier stage of particle growth and a “shell part polymerization” in the later stage.     

Size-controlled synthesis of monodisperse core/shell nanogels

Small, monodisperse nanogels (∼50-nm radius) were synthesized by free-radical precipitation polymerization and were characterized using a suite of light scattering and chromatography methods. Nanogels were synthesized with either N-isopropylacrylamide or N-isopropylmethacrylamide as the main monomer, with acrylic acid or 4-acrylamidofluorescein as a comonomer and N,N′-methylenebis(acrylamide) as a cross-linker. By varying the surfactant and initiator concentrations, particle size was controlled while maintaining excellent monodispersity. An amine-containing shell was added to these core particles to facilitate subsequent bioconjugation. Successful conjugation of folic acid to the particles was demonstrated as an example of how such materials might be employed in a targeted drug delivery system.     

Synthesis of highly cross-linked poly(diethylene glycol dimethacrylate) microparticles in supercritical carbon dioxide

Herein we report the synthesis of poly(diethylene glycol dimethacrylate), poly(DEGDMA), by free-radical heterogeneous polymerization in supercritical carbon dioxide (scCO₂), using a commercially available carboxylic acid end-capped perfluoropolyether oil (Krytox 157FSL) as stabiliser. The effect of initial concentration of stabiliser, monomer and initiator on the yield and morphology of the resulting polymer has been investigated. Krytox worked effectively as a stabiliser and discrete poly(DEGDMA) particles with diameters ranging from 1.28 to 2.08 μm and narrow particle size distribution were produced in supercritical carbon dioxide, in high yield and in short reaction times, without making use of harmful organic solvents.     

Synthesis and emulsion copolymerization of amphiphilic poly(2-oxazoline) macromonomer possessing a vinyl ester group

The present article describes the synthesis and emulsion copolymerization of a block-type amphiphilic poly(2-oxazoline) macromonomer possessing a polymerizable vinyl ester group. The macromonomer was synthesized by one-pot two-stage block copolymerization of 2-oxazolines using vinyl iodoacetate as initiator. 2-Methyl- and 2-n-butyl-2-oxazolines were employed for the construction of hydrophilic and hydrophobic segments, respectively. The surface activities evaluated by the surface tension of the macromonomer in water were fairly good. Emulsion copolymerization of vinyl acetate with the macromonomer was carried out. The macromonomer acted as a polymeric surfactant, as well as a comonomer. The resulting copolymer latex particles were spherical and their diameter was in the sub-micron range. The effects of the composition of the macromonomer on the emulsion copolymerization and the resulting latex particles were examined. © 1993 John Wiley & Sons, Inc.