Particle Growth during the Polymerization of Olefins on Supported Catalysts. Part 2: Current Experimental Understanding and Modeling Progresses on Particle Fragmentation,Growth, and Morphology Development

The morphology of the growing polymer particles is important in olefin polymerisation on supported catalysts. It has a significant impact on the rate of mass and energy transport, and consequently on the polymerisation rate, comonomer incorporation, and the molecular weight distribution. The ability to quantify the evolution of morphology during the polymerisation process à priori would therefore be quite useful. The morphology itself is a direct product of the fragmentation step and concurrent/subsequent expansion of the particle, both caused by the build‐up and dissipation of hydraulic forces due to the accumulation of polymer in the particle. It is influenced by the initial morphology of the support, as well as the reaction conditions and local polymer properties. The single particle models developed to describe the morphology evolution in a growing particle are reviewed here. The main assumptions, abilities, and limitations of the models are evaluated and the issues which face developing a completely predictive model are finally discussed. Despite some very interesting attempts at morphology modelling in recent years, significant progress still needs to be made in order to develop a fully predictive model of the sort.     

New Millable Polyurethane/Organoclay Nanocomposite: Preparation,Characterization and Properties

The preparation, characterization and properties of novel millable polyurethane/organoclay nanocomposites are reported. Clay treated with methyl tallow bis(2‐hydroxyethyl) quaternary ammonium chloride was used as an organoclay for nanocomposite preparation. X‐ray diffraction indicated the intercalation of polymer chains inside the interlayer spacings of the clay. Dynamic mechanical analysis showed a significant increase in storage modulus, and tensile strength increases with increased organoclay loading.

X‐ray diffraction patterns of millable polyurethane/organoclay nanocomposites.     

Optimizing Melt‐Processing Conditions for the Preparation of iPP/Fumed Silica Nanocomposites: Morphology,Mechanical and Gas Permeability Properties

A series of iPP/SiO₂ nanocomposites, containing 1, 2.5, 5, 7.5, and 10 wt.‐% fumed silica nanoparticles, were prepared by melt mixing in a twin screw co‐rotating extruder. The effect of different extrusion parameters was evaluated. The size of aggregates increased with increase in SiO₂ content and repetition of the mixing process improved the filler's dispersion. A similar effect was also exhibited by either increasing the rotor speed or the mixing temperature, with the latter being more pronounced at the ranges studied. The mechanical properties of the prepared nanocomposites were evaluated and various models used to explain the observed enhancements. However, only the three‐phase model could provide some correlation with the experimental results. All nanocomposites displayed lower permeability to gases.

     

Polyurethane/polyaniline and polyurethane‐poly(methyl methacrylate)/polyaniline conductive core‐shell particles: Preparation,morphology, and conductivity

Polyurethane/polyaniline (PU/PANI) and polyurethane‐poly(methyl methacrylate)/polyaniline (PU‐PMMA/PANI) conductive core‐shell particles were synthesized by a two‐stage polymerization process. The first stage was to produce a core of PU or PU‐PMMA via miniemulsion polymerization using sodium dodecyl sulfate (SDS) as the surfactant. The second stage was to synthesize the shell of polyaniline over the surface of core particles. Hydrogen chloride (HCl) and dodecyl benzenesulfonic acid (DBSA) were used as the dopant agents. Ammonium persulfate (APS) was used as the oxidant for the polymerization of ANI. Different concentrations of HCl, DBSA, and SDS would cause different conformations of PANI chains and thus different morphologies of PANI particles. UV–visible spectra revealed that the polaron band was blue‐shifted because of the more coiled conformation of PANI chains by increasing the concentration of DBSA. Besides, with a high concentration of DBSA, both spherical‐ and rod‐shape PANI particles were observed by transmission electron microscope, and the coverage of PANI particles onto the core surfaces was improved. The key point of formation of rod‐type PANI particles was that DBSA was served with a high concentration accompanied with the existence of HCl or SDS. The better coverage of PANI particles over the core surfaces by charging higher DBSA concentrations resulted in a higher conductivity of hybrid particles. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 3902–3911, 2007     

Polystyrene (1)/poly(butyl acrylate/amide type functional monomer) (2) two-stage emulsion polymers. Synthesis and thermomechanical properties of latex films

Polystyrene (PS) (1)/Poly (n-butyl acrylate (BA)/amide type functional monomer) (2) structured latex particles were prepared through emulsion polymerization varying the hydrophilicity of the functional monomer employed. The second-stage polymerization kinetics, the size and morphology of latex particles, and the location of the functional groups in the final latexes were studied, in order to relate them to the thermomechanical properties of films cast from these latexes. It has been shown that, as expected, increasing the hydrophobicity leads to a better homogeneity in the copolymer formed during the second-stage polymerization, while the more hydrophilic functional monomer partly homopolymerizes in a separate phase. However, the functionalization by all the monomers used in this work, prevents the PS seed particles to form a continuous skeleton (percolated network). Further heat treatments at 140°C do not lead to the formation of a continuous PS phase as for pure BA/pure PS two-stage particles. In addition, some thermally induced crosslinking effects are discussed in relation with the functional monomer location within the particles. © 1995 John Wiley & Sons, Inc.