Effects of 2‐hydroxyalkyl methacrylates on the styrene miniemulsion polymerizations stabilized by SDS and alkyl methacrylates

The effects of 2‐hydroxyalkyl methacrylates (HEMA and HPMA) on the styrene miniemulsion polymerizations stabilized by SDS/lauryl methacrylate (LMA) or SDS/stearyl methacrylate (SMA) were investigated. A mixed mode of particle nucleation (monomer droplet nucleation and homogeneous nucleation) is operative during polymerization. Homogeneous nucleation plays a crucial role in the polymerizations stabilized by SDS/LMA, whereas monomer droplet nucleation becomes more important in the polymerizations stabilized by SDS/SMA. The polymerization kinetics is insensitive to the type of 2‐hydroxyalkyl methacrylates, but the difference in the relative importance of monomer droplet nucleation and homogeneous nucleation is detected. Incorporation of 1‐pentanol (C₅OH) into the reaction mixture also shows a significant influence on the polymerizations stabilized by SDS/LMA or SDS/SMA. This is attributed to the formation of a close‐packed structure of SDS and C₅OH on the droplet surface, which acts as a barrier to the incoming oligomeric radicals. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3188–3199, 2000     

The effect of feed conditions in the emulsion catalytic chain transfer polymerization of alkyl methacrylates

([bis[μ-[(2,3-butanedione dioximato)(2-)-O:O′]] tetrafluorodiborato(2-)-N,N′,N″,N‴] cobalt), CoBF, has been used for the effective catalytic chain transfer of alkyl methacrylate homo- and copolymers under emulsion polymerization conditions. The catalytic chain transfer process reduces the rate of polymerization such that when the monomer is fed over 60 min the instantaneous conversion is low enough for the particle to be swollen with monomer, allowing diffusion of the catalysts between the aqueous and monomer phases. When the amount of the catalyst is reduced, the rate is increased, eventually leading to viscous, glassy particles that prevent catalyst mobility, which is observed as a breakdown in the polymerization mechanism. This can be circumvented by the addition of a 20% shot of monomer at the start of the reaction. The effective chain transfer coefficient decreases on increasing the length of the ester group of the methacrylate. The analysis of the polymers made by the technique described shows that the T_g of the polymers observe a broad transition due to the effect of chain length being pronounced at low molecular mass. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 3549–3557, 1999     

Thiol-ended polyethylene oxide as reactive stabilizer for dispersion polymerization of styrene

 Radical dispersion polymerization of styrene in aqueous ethanol solutions was performed in the presence of a new reactive polyethylene oxide stabilizer with thiol end groups. This reactive stabilizer was compared to the more conventional poly (N-vinyl pyrrolidone). Particles size distribution, molecular weights and kinetics were investigated. Monodispersed polymer particles with diameter in the range 200–2000 nm were obtained depending on the amount of stabilizer used. In all cases, the polyethylene oxide (PEO) sequence of the dispersant was partly incorporated at the surface of the latex particles, but the grafting yield of polyethylene oxide chains was always limited and did not exceed 15%. Part of the stabilizer being unreacted or reacted with low molecular weight polystyrene remained in the continuous phase. Received: 26 September 1996 Accepted: 4 March 1997     

Miniemulsion polymerization of methyl methacrylate with dodecyl mercaptan as cosurfactant

Miniemulsions of methyl methacrylate with sodium lauryl sulfate as the surfactant and dodecyl mercaptan (DDM) as the cosurfactant (or hydrophobe) were prepared and polymerized. The emulsions were of a droplet size range common to miniemulsions and exhibited long-term stability (greater than 3 months). Results indicate that DDM retards Ostwald ripening and allows the production of stable miniemulsions. When these emulsions were initiated, particle formation occurred predominantly by monomer droplet nucleation. The effects of the concentration of surfactant, cosurfactant and initiator were determined. Rates of polymerization, monomer droplet sizes, polymer particle sizes, molecular weights of the polymer, and the effect of initiator concentration on the number of particles vary systematically in ways that indicate predominant droplet nucleation in these systems. © 1996 John Wiley & Sons, Inc.     

Miniemulsion polymerization of styrene with chain transfer agent as cosurfactant

Miniemulsion polymerization of styrene with the chain transfer agent n-dodecyl mercaptan (DDM) used as cosurfactant was studied. Droplet size and shelf life for unpolymerized miniemulsions were measured and compared with those of equivalent macroemulsions. The miniemulsion monomer droplets with dodecyl mercaptan as cosurfactant were very stable. Shelf lives were from 17 h to 3 months. The kinetics of miniemulsion polymerization were studied. Unlike other miniemulsion systems where the cosurfactant does not act as a chain transfer agent, the polymerization rate falls with cosurfactant level because the chain transfer agent enhances radical desorption from the particles. The polymerization rate in all the miniemulsions was lower than that of the corresponding macroemulsions. Polymerized particles were larger than in the corresponding macroemulsions, but molecular weights were lower. Results indicate that DDM can serve as an effective cosurfactant as well as a chain transfer agent. The fact that the molecular weights are lower in the miniemulsion reactions indicates predominant droplet nucleation. © 1997 John Wiley & Sons, Inc.     

Miniemulsion polymerization of styrene using well-defined cationic amphiphilic comblike copolymers as the sole stabilizer

Well-defined, positively charged, amphiphilic copolymers containing long alkyl side chains were used as stabilizers in the miniemulsion polymerization of styrene. The copolymers were prepared by controlled free-radical copolymerization of styrene and vinyl benzyl chloride using either the reversible addition-fragmentation chain transfer method or TEMPO-mediated polymerization. The benzyl chloride moities were modified by two different long alkyl chain tertiary amines (N,N-dimethyldodecyl amine and N,N-dimethylhexadecyl amine) to yield the amphiphilic copolymers with vinylbenzyl dimethyl alkyl ammonium chloride units. Owing to their high structural quality, only a small amount of these copolymers was required to stabilize the latex particles (0.5–2 wt% vs styrene). Moreover, in the absence of any hydrophobic agent, the amphiphilic comblike copolymer preserved the colloidal stability of both the initial liquid miniemulsion and the final latex. Ill-defined, analogous copolymers were synthesized by conventional free-radical polymerization and in comparison, exhibited poor stabilization properties.     

Miniemulsion polymerization of styrene with liquid polybutadiene as the sole co-stabilizer

A low-molecular-weight liquid polybutadiene (LPB) is employed as the sole co-stabilizer in miniemulsion polymerization of styrene in present work. Results indicate that the LPB can be used as an effective co-stabilizer to retard the diffusional degradation of monomer droplets in miniemulsion system and get stable miniemulsions. When the miniemulsions were initiated, particle formation occurred predominantly by monomer droplet nucleation. Moreover, the effects of various reaction parameters on the polymerization kinetics and the nucleation mechanisms were also investigated. These parameters include the level of LPB ([LPB]) and the concentrations of SDS ([SDS]) and potassium persulfate ([KPS]). It is shown that the polymerization rate indicates little dependence on [LPB], while increases with increasing [SDS] and [KPS]. Competition between droplet nucleation and homogeneous nucleation occur in the course of polymerization, but droplet nucleation becomes more important by increasing [LPB] or decreasing [SDS]. Furthermore, the result that the particle size is rather insensitive to changes in [KPS] provides the most compelling evidence for the dominant droplet nucleation.     

Emulsifier-free emulsion polymerization of the comonomer system styrene/tetrahydrofurfuryl metacrylate

 The emulsifier-free emulsion copolymerization of styrene and tetrahydrofurfuryl methacrylate (TMA) in aqueous phase is described. Monodisperse latex particles with diameters from about 280 to 620 nm are obtained consisting of a hydro-phobic polystyrene core and a hydrophilic poly-TMA shell. The influence of a variation of TMA, styrene and initiator (potassium persulfate) concentration in the original emulsion on particle size, molecular weight and composition of the copolymer is described. The concentration of TMA and initiator affects the number of primary particles but not the size of the final particles, whereas the styrene concentration strongly influences the particle diameter, a large size being favored by a high styrene concentration. The molecular weights of the polymers are between 6.2×10⁴ and 7.0×10⁵ g/mole. Size exclusion chromatography of polymer solutions in tetra-hydrofuran shows that high molecular weights are especially found in large particles, which are preferentially formed in emulsions with a high concentration of styrene. ¹H-NMR spectroscopy of the polymer shows that only about 50% of the initial TMA concentration are polymerized in the particles. Thus the copolymers prepared at increasing styrene concentration and constant initiator concentration of the emulsion show an increasing polystyrene content and are formed in particles of increasing size. Received: 4 June 1997 Accepted: 19 August 1997     

Reactive surfactants in heterophase polymerization. VIII. Emulsion polymerization of alkyl sulfopropyl maleate polymerizable surfactants (surfmers) with styrene

The copolymerization of styrene with two polymerizable surfactants (surfmers) based on maleic acid (dodecyl sodium sulfopropyl maleate and tetradecyl sodium sulfopropyl maleate) was studied in batch emulsion polymerizations. The surfmer conversion was obtained by serum replacement with water and subsequent analysis of the recovered, unreacted surfmers with two-phase titration. It was found that both surfmers copolymerized well with styrene and their partial conversion was higher than that of styrene. These results are contradictory to what was found before in the literature using ultrafiltration with methanol, and the differences are explained on the basis of oligomer formation: The oligomers formed are detected if the latices are washed with methanol. It was found that at the end of the polymerization (almost complete conversion of both styrene and surfmer) only 45% of the surfmer groups were present on the particle surface, which is in agreement with a high conversion of the surfmer at the beginning of the reaction. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35: 2561–2568, 1997     

Mechanism of emulsion polymerization of styrene using a reactive surfactant

The emulsion polymerization of styrene using the reactive surfactant sodium dodecyl allyl sulfosuccinate (TREM LF‐40) was studied. The polymerization kinetics were found to be unusual in that R_p was not directly proportional to N_p (R_p ∝ N_p^0.67). Several reasons are stated to explain the unusual kinetics, including chain transfer to TREM LF‐40, copolymerization of styrene with TREM LF‐40, and the influence of the homopolymer of TREM LF‐40 [poly(TREM)] and/or the copolymer [poly(TREM‐co‐styrene)] on the entry and exit rates of free radicals. The possibility of both chain transfer and copolymerization exists primarily at the oil/water interface, whereas both can also occur in the aqueous and monomer phases. Bulk polymerizations of styrene in the presence of TREM LF‐40 and poly(TREM) were conducted, and the results show that the reaction rate decreased for the styrene/TREM LF‐40 system. Latex characterization by serum replacement and titration measurements provided evidence for the chemical bonding of TREM LF‐40 to the polymer particles. The fraction of chemically bound reactive surfactant decreased with increasing surfactant concentration and increased with increasing initiator concentration. Relatively high contact angles of water on films cast from the latexes showed that TREM LF‐40 did not migrate significantly to the surface of the film, which was consistent with the latex‐surface characterization results. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3093–3105, 2001     

Details of the emulsion polymerization of styrene using a reaction calorimeter

An automated reaction calorimeter was used to directly monitor the rate of emulsion polymerization of styrene using different emulsifier (sodium lauryl sulfate) and initiator (potassium persulfate) concentrations. By using this technique in conjunction with off-line measurements of the evolution of the particle size distributions, important details of the process were observed. The classical constant rate period (Interval II) often reported for the batch emulsion polymerization of styrene was not seen in this work. Instead, the experimental results suggest that the end of nucleation and the disappearance of monomer droplets take place at approximately the same conversion (36–40%). From the polymerization rate data, important parameters such as the monomer concentration in the polymer particles and the average number of radicals per particle were calculated. © 1996 John Wiley & Sons, Inc.     

Kinetics of the microemulsion polymerization of styrene with short‐chain alcohols as the cosurfactant

The kinetics of styrene microemulsion polymerization stabilized by sodium dodecyl sulfate (SDS) and a series of short‐chain alcohols (n‐C_iH_2i+1OH, abbreviated as C_iOH, where i = 4, 5, or 6) at 60 °C was investigated. Sodium persulfate was used as the initiator. The microemulsion polymerization process can be divided into two intervals: the polymerization rate (R_p) first increases to a maximum at about a 20% conversion (interval I) and thereafter continues to decrease toward the end of the polymerization (interval II). For all the SDS/C_iOH‐stabilized polymerization systems, R_p increases when the initiator or monomer concentration increases. The average number of free radicals per particle is smaller than 0.5. The molecular weight of the polymer produced is primarily controlled by the chain‐transfer reaction. In general, the reaction kinetics for the polymerization system with C₄OH as the cosurfactant behaves quite differently from the kinetics of the C₅OH and C₆OH counterparts. This is closely related to the different water solubilities of these short‐chain alcohols and the different concentrations of the cosurfactants used in the preparation of the microemulsion. © 2001 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 39: 898–912, 2001     

Poly(propene-co-maleic acid) with lateral perester groups as initiator in the emulsion polymerization of styrene

The influence of the initiator structure on the reaction process was investigated. In addition to the initiator concentration, its molar mass and the content of perester groups in the single molecule are determining factors that influence the course of reaction. Quantitative relationships are shown. The initiator is bonded by grafting reactions on the surface of the latex particles. The grafted moiety is dependent on the initiator structure and reaction temperature. Latices with polydispersities lower than 1.1 are obtained. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2045–2054, 1999     

Miniemulsion polymerization of styrene costabilized with polyurethane via <Superscript>60</Superscript>Co γ-ray radiation initiation

Polyurethane (PU) was successfully synthesized and used as costabilizer in the miniemulsion polymerization of styrene (St) initiated by ⁶⁰Co γ-ray radiation at room temperature. Only 2 wt% PU based on the monomer was enough to prepare a stable miniemulsion with a shelf life of more than 12 months. Preservation of original particle size and distribution throughout the polymerization observed from dynamic light scattering measurements indicates the predominance of monomer droplet nucleation. Kinetic analysis shows that there is no constant rate stage, which also suggests a droplet nucleation mechanism. Polystyrene (PS) nanoparticles with relatively small diameters (40–70 nm) and narrow size distribution could be easily prepared. The effects of surfactant, costabilizer, and absorbed dose rate on the miniemulsion polymerization were discussed.     

Electrosteric stability of styrene/acrylic acid copolymer latices under emulsion polymerization reaction conditions

Acrylic acid (AA) is used in many emulsion polymerization formulations to improve the colloidal stability during and after the production of latex products. Theoretically, the improved stability originates from electrostatic repulsion complemented with steric repulsion. The objective of this work was to study the contribution of AA to the colloidal stability of polystyrene and styrene/AA copolymer latices under simulated reaction conditions. The strength of electrostatic and steric repulsion forces as a function of the electrolyte concentration, pH, and temperature was investigated via coagulation experiments with monomer‐swollen latices in stirred tank reactors. Transmission electron microscopy pictures and dynamic light scattering measurements provided an understanding of the conditions and mechanisms leading to coagulation. The experiments demonstrated that the presence of surface‐bound carboxylic groups only improved the colloidal stability if the carboxylic groups were charged, that is, at a high pH. At a low pH, the copolymer latices were even less stable than the homopolymer latex, and this indicated that the addition of AA did not improve the colloidal stability of a growing polystyrene latex. With respect to emulsion polymerization process operations, insufficient mixing and a highly concentrated electrolyte feed were found to be sources of fouling and enhanced macroscopic coagulation. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 726–732, 2005     

Miniemulsion polymerization of styrene: Evolution of the particle size distribution

The mechanism of the miniemulsion polymerization of styrene was investiaged through a combination of calorimetry to monitor the polymerization rate and transmission electron microscopy (TEM) to follow the evolution of the particle size distribution. These techniques proved to be a powerful combination for gaining detailed mechanistic information regarding these polymerizations. Particle size analysis of the latexes withdrawn during the course of the reaction revealed that most of the polymer particles were formed by a relatively low conversion (i.e., 10% conversion). However, nucleation continued well past this point (to 40-60% conversion). In fact, it was observed that nucleation in miniemulsion polymerizations using cetyl alcohol continued past the maximum in the rate of polymerization. As a result of these long nucleation periods, the latex particle size distributions produced from these miniemulsion polymerizations were broader than their conventional emulsion polymerization counterparts, and were negatively skewed with a tail of small particles. The amount of negative skewing of the particle size distributions was found to decrease with increasing initiator (potassium persulfate) concentration. Finally, a correlation was observed between the length of time to the maximum polymerization rate and the breadth of the particle size distribution as reflected in the standard deviation. © 1995 John Wiley & Sons, Inc.     

Effect of dose rate on emulsion and microemulsion polymerization of styrene

Emulsion and microemulsion polymerization of styrene were initiated with a gamma ray to study the effect of dose rate on polymerization. In both systems, there is an apparent plateau of polymerization rate in the curve of reaction rate vs. conversion. It was shown that emulsion polymerization conformed to the Smith–Ewart theory very well. Changing the dose rate in interval 2 had no great influence on polymerization rate, but it changed the average lifetime of radicals in polymer particles and affected the molecular weight of polymer produced. For microemulsion polymerization it was assumed that in the plateau it is the number of growing polymer particles being kept constant, not the number of polymer particles. When the dose rate was changed while the polymerization came into the constant period, the polymerization rate and the molecular weight of the polymer varied with the dose rate. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 257–262, 1998     

On the emulsion polymerization of styrene in the presence of a nonionic emulsifier

The batch emulsion polymerization kinetics of styrene (St) initiated by a water-soluble peroxodisulfate in the presence of a nonionic emulsifier was investigated. The polymerization rate versus the conversion curves showed two nonstationary rate intervals, two rate maxima, and Smith–Ewart Interval 2 (nondistinct). The rate of polymerization and number of nucleated polymer particles were proportional to the 1.4th and 2.4th powers, respectively, of the emulsifier concentration. Deviation from the micellar nucleation model was attributed to the low water solubility of the emulsifier, the low level of the micellar emulsifier, and the mixed modes of particle nucleation. In emulsion polymerizations with a low emulsifier concentration, the number of radicals per particle and particle size increased with increasing conversion, and the increase was more pronounced at a low conversion. By contrast, in emulsion polymerizations with a high emulsifier concentration, the number of radicals per particle decreased with increasing conversion. This is discussed in terms of the mixed models of particle nucleation, the gel effect, and the pseudobulk kinetics. The formation of monodisperse latex particles was attributed to coagulative nucleation and droplet nucleation for the polymerizations with low and high emulsifier concentrations, respectively. The effects of the continuous release of the emulsifier from nonmicellar aggregates and monomer droplets, the close-packing structure of the droplet surface, and the hydrophobic nature of the emulsifier on the emulsion polymerization of St are discussed. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4422–4431, 1999