Unseeded semibatch emulsion polymerization of butyl acrylate: Bimodal particle size distribution

Unseeded semibatch emulsion polymerization of butyl acrylate (BA) using sodium lauryl sulfate as emulsifier and potassium persulfate as initiator was carried out at the conditions where secondary nucleation was probable. This was achieved by using no emulsifier in the initial reactor charge. The effects of changes in monomer emulsion feed rate, initiator concentration and distribution, emulsifier concentration in the feed, and temperature on the evolution of particle size averages and distribution were investigated. Bimodal particle size distributions (PSD) were obtained for most of the latexes. Inhibition effects were found to be important in the development of PSD. Primary particle formation occurred through micellar nucleation, whereas secondary nucleation probably occurred through homogenous nucleation. The polydispersity index (PDI) of the latexes increased with the decreasing monomer emulsion feed rate. The application of a larger amount of initiator to the reactor charge or using a higher temperature, reduced the formation of secondary particles and resulted in a formation of an unimodal PSD. The overall steady‐state rate of polymerization was found to approach the rate of monomer addition (R_p ≈ R_a ), if the emulsifier concentration in the aqueous phase was appreciable. This is different from the correlation 1/R_p = 1/K + 1/R_a obtained for the BA semibatch process with neat monomer feed. This suggests that different rate expressions can be used for BA semibatch emulsion polymerization at different conditions. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 528–545, 2000     

Emulsion procedures for thermally reversible covalent crosslinking of polymers

Quaternization and dequaternization of tertiary amine compounds were employed to obtain thermally reversible ionene networks from aqueous colloidal polymer dispersions prepared via emulsion polymerization. Chlorine‐functionalized polymers prepared via the emulsion copolymerization of styrene (St), butylacrylate (BA), or both with chloromethylstyrene, and amino‐functionalized polymers prepared via the emulsion copolymerization of St, BA, or both with 2‐(dimethylamino)ethylacrylate or 4‐vinylpyridine, were reacted without polymer separation, with a ditertiaryamine crosslinker and a dihalide crosslinker, respectively, to obtain crosslinked polymers. Crosslinked polymers were also obtained via the reaction of a chlorine‐functionalized polymer dispersion with an amino‐functionalized polymer dispersion or via the drying of the polymer blend prepared from the two kinds of dispersions. Reactive solubility experiments, flowability investigations (by thermocompression at ca. 215 °C), IR, and ¹H NMR analyses of the obtained crosslinked polymers indicated that the generated ionene bridges dequaternized on heating and requaternized on cooling. In comparison with solution crosslinking, no organic solvent was employed, and simple procedures were required for the preparation of the thermally reversible covalent crosslinked polymers. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 4373–4384, 2000     

Radical alternating copolymerization: A strategy for hyperbranched materials

Novel hyperbranched polymers were synthesized in a high yield without gelation through the free‐radical alternating copolymerization of an AB/B′ (allyloxy maleic acid/maleic anhydride) system, in which group B and monomer B′ both could only alternately polymerize with group A. The arm number of the produced highly branched polymers was equal to the product of the linear chain length and the probability of pendent B groups being growing centers. The molecular weight of these novel hyperbranched polymers increased with increasing initiator concentration and prolonged polymerization times. The AB/B′ system, used as described, provides a new general methodology for highly branched and functional polymers. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3074–3085, 2000     

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     

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     

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     

Properties of acrylic–polyurethane hybrid emulsions synthesized by the semibatch emulsion copolymerization of acrylates using different polyurethane particles

Aqueous acrylic–polyurethane hybrid emulsions were prepared by the semibatch emulsion copolymerization of methyl methacrylate and butyl acrylate in the presence of eight polyurethane dispersions. The polyurethane dispersions were synthesized with isophorone diisocyanate, 1000 and 2000 molecular weight polyester polyols, 1000 molecular weight polyether polyol, butanediol, and dimethylol propionic acid. Acrylic monomers were added in the monomer emulsion feed. We studied the effect of the use of different polyurethane seed particles and the effect of different weight ratios of methyl methacrylate to butyl acrylate on the emulsion properties, microphase structure, and mechanical properties of hybrid films. The average particle size and distribution were determined by photon correlation spectroscopy. The rheological properties of polyurethane dispersions and hybrid emulsions were tested under destructive conditions by an examination of flow curves and under nondestructive conditions of oscillatory shear in a range of linear viscoelastic responses. Differential scanning calorimetry was performed to characterize the thermal‐response properties of polymeric films. The relative average molecular weights were determined by gel permeation chromatography. The interactions between the acrylic and polyurethane components in hybrid particles and particle structure were studied with infrared spectroscopy and nuclear magnetic resonance spectroscopy. Mechanical properties such as the Koenig hardness, tensile strength, elongation at break, and Young's modulus were measured. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 4050–4069, 2005     

Emulsion terpolymerization of butyl acrylate/methyl methacrylate/vinyl acetate: Experimental results

A systematic study of the terpolymerization of butyl acrylate/methyl methacrylate/vinyl acetate (BA/MMA/VAc) was conducted. In this stage of the study, batch emulsion terpolymerizations were performed in a 5 L stainless steel pilot plant reactor. The experiments were designed using a Bayesian (optimal) technique. The polymers produced were characterized for conversion, composition, molecular weight, and particle size. Conversion, terpolymer composition, number- and weight-average molecular weight, and average particle size results are discussed in light of the influence of seven factors and the interaction of these factors. The factors studied include monomer feed composition, initiator concentration, chain transfer agent concentration, impurity concentration, initiator type, emulsifier concentration, and temperature. A “two-stage rate” phenomenon, similar to that occurring in bulk co- and terpolymerization and emulsion copolymerization of acrylic/vinyl acetate systems was observed in the conversion, composition and molecular weight data. Furthermore, an interesting yet often ignored effect of impurities on emulsion polymerization kinetics was explained. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35 : 1659–1672, 1997     

Emulsion copolymerization of substituted acetylenes for constructing optically active helical polymer nanoparticles. Synergistic effects and helicity inversion

Copolymerizations of substituted acetylenes have been intensively studied in solution polymerization for constructing chirally helical polymers, while emulsion copolymerizations of the kind of monomers have been only scarcely reported. In the present study, chiral substituted acetylene monomer containing cholic acid group underwent emulsion copolymerizations with an achiral acetylenic monomer in the presence of rhodium catalyst, providing optically active helical copolymer nanoparticles. Synergistic effects were found in the resulting helical copolymers, enabling one certain copolymer to show the maximum CD signal intensity. Moreover, the helicity of the helical copolymers in nanoparticle state was opposite to that in solution state. This is the first demonstration that synergistic effects and helicity inversion simultaneously occurred in helical copolymers prepared by emulsion copolymerization process. To deepen the understanding of the unique phenomena, corresponding solution copolymerization and emulsification process were also investigated. Different from “Sergeant and Soldiers rule” approach, the present study provides a new strategy for preparing chirally helical polymer particles by making full use of achiral monomers. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016 , 54, 1679–1685     

Cross‐linking emulsion copolymerization of butyl acrylate with diallyl maleate

The emulsion copolymerization of butyl acrylate (BA) with a trifunctional cross‐linker, diallyl maleate (DAM), was investigated. The effect of the monomer feeding time and the amount of cross‐linker on the microstructural properties (branching, cross‐linking, gel formation, and sol MWD) of the seeded semicontinuous emulsion copolymerization of BA with DAM was investigated. It was found that the gel content was not significantly affected by increasing feeding time, but the level of quaternary carbons (an indication of the branching density) increased. On the other hand, increasing the amount of DAM in the feed composition caused gel content, level of quaternary carbons, and the cross‐linking density to increase. Interestingly, the level of quaternary carbons and the cross‐linking density sharply increased during the cooking period. The molecular weight of the sol decreased as DAM increased in the feed. In addition, the effect of process type, batch versus semibatch, was also considered and important differences in the level of quaternary carbons, cross‐linking, and gel content were found. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 4684–4694, 2005     

Styrenic surfmer in emulsion copolymerization of acrylic monomers. II. Copolymerization and film properties

Polymerizable styrenic surfactants (surfmers) and nonreactive analogs, have been applied in emulsion copolymerization of acrylic monomers in a seeded semibatch process. Stable core-shell latexes with low levels of coagulum and controlled particle size have been obtained; some of them, with either steric or electrosteric stabilization, display excellent stability to electrolytes, freeze–thaw cycles, and shear flocculation. In addition, the reactive surfactants lead to films with superior performance due to reduced migration of surfactant to the surface (contact angle measurements) and dimensional stability when the films are dipped in water, as well as less water uptake. Some differences also appear in particle morphologies. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4205–4217, 1999     

“Continuous” emulsifier‐free emulsion polymerization for the synthesis of monodisperse polymeric latex particles

A “continuous” emulsifier‐free emulsion copolymerization (CEFEP) of styrene and divinylbenzene (DVB) or methyl methacrylate (MMA) and ethylene glycol dimethacrylate (EGDMA) has been devised to produce uniform polymeric microspheres of narrow size distribution from 74 nm to 2 μm, depending on reaction time. Monomer and crosslinker vapors were fed continuously into a small reactor. We suggest that after initial nucleation, subsequent CEFEP proceeds near the surfaces of growing particles in a monomer‐swollen outer shell. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3181–3187, 2000     

EFFECT OF 2—HYDROXYETHYL METHACRYLATE ON SEMIBATCH EMULSIFIER—FREE EMULSION COPOLYMERIZATION OF METHYL METHACRYLATE AND BUTYL ACRYLATE

The semibatch emulsifier-free emulsion copolymerization of methyl methacrylate (MMA) and butyl acrylate(BA) in the presence of 2-hydroxyethyl methacrylate(HEMA) initiated by K2S2O8(PSP) was studied.The latex particles can maintain an appreciable stability during the emulsifier-free emulsion copolymerization of MMA and BA in the presence of HEMA.The average particle diameter increase with an increase of total solids content,HEMA content,PSP content,ionic strength of the system and monomer feed rate,and decrease with the monomer feed ration from 3/1 (MMA/BA:molar ration).to 1/3.The stability of this reaction system is improved by adding HEMA as nonionic comonomer,High solids content (50%) latex with monodisperse particle can be obtained using this process.     

Semibatch emulsion polymerization of methyl methacrylate using different polyurethane particles

Aqueous acrylic‐polyurethane (AC–PU) hybrid emulsions were prepared by semibatch emulsion polymerization of methyl methacrylate (MMA) in the presence of four polyurethane (PU) dispersions. The PU dispersions were synthesized with isophorone diisocyanate (IPDI), 1000 and 2000 molecular weight (MW) poly(neopentyl) adipate, 1000 MW polytetramethyleneetherglycol, butanediol (BD), and dimethylol propionic acid (DMPA). MMA was added in the monomer emulsion feed. We studied the effect of the use of different PU seed particles on the rate of polymerization, the particle size and distribution, the number of particles, and the average number of radicals per particle. The PU rigidity was controlled by varying the polyol chemical structure, the polyol MW (M_n), and by adding BD. The monomer feed rate was varied to study its influence on the process. It was observed that the PU particles that had been prepared with a higher MW polyol swelled better with MMA before the monomer‐starved conditions occurred. There seemed to be no significant discrepancies between the series with different PU seeds in the monomer‐starved conditions. The overall conversion depended on the monomer addition rate, and the polymerization rate acquired a constant value that was comparable to the value of the monomer addition rate. The instantaneous conversion increased slightly. The average particle size increased, and the total particle number in the reactor was constant and similar to the number of PU particles in the initial charge. The average number of radicals per particle increased. The differences between the system with a constant particle number and average number of radicals per particle and the system with a fixed radical concentration are discussed. The semibatch emulsion polymerization of MMA in the presence of PU particles studied was better compared to the system with a fixed radical concentration. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 844–858, 2005     

Miniemulsion Copolymerization of Ethylene and Vinyl Acetate

The copolymerizations of a gaseous monomer (ethylene) and a liquid monomer (vinyl acetate) via emulsion and miniemulsion polymerizations are reported. Reactions in which the vinyl acetate was introduced in both batch and semibatch modes are carried out. (Ethylene introduction is always in a semibatch model since the polymerization is carried out under a constant pressure of ethylene in the reactor headspace.) The results are compared, drawing the conclusion that miniemulsion copolymerization has an advantage over conventional emulsion polymerization for monomers with very low water solubility (including gaseous monomers) due to their nucleation in monomer droplets without transport through the aqueous phase.

     

Amphiphilic polymethacrylates as crosslinked polymer precursors obtained by free‐radical monomethacrylate/dimethacrylate copolymerizations

As an extension of our work on the elucidation of the mechanism and control of 3‐dimensional network formation in the free‐radical crosslinking polymerization and copolymerization of multivinyl compounds with the aim to molecularly design vinyl‐type network polymers, novel amphiphilic polymers were prepared as crosslinked polymer precursors. Thus, benzyl methacrylate, a nonpolar monomer, was copolymerized radically with 5 mol % of triicosaethylene glycol dimethacrylate [CH₂C(CH₃)CO(OCH₂CH₂)₂₃OCOC(CH₃)CH₂], a polar monomer, in the presence of lauryl mercaptan as a chain transfer agent. The resulting prepolymers (i.e., vinyl‐type network‐polymer precursors or amphiphilic polymers) were characterized mainly by viscometry using t‐butylbenzene (t‐BB) and a t‐BB/MeOH (80/20) mixture as solvents. The viscosities in the t‐BB/MeOH (80/20) mixture were quite high compared with those in t‐BB, and completely reversed concentration dependencies were observed in the solvents. These are discussed by considering the difference in conformation and the shrinkage of polar, flexible polyoxyethylene units or the entanglement of nonpolar, rigid primary chains. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 4396–4402, 2000     

Model‐based design and synthesis of gradient MMA/tBMA copolymers by computer‐programmed semibatch atom transfer radical copolymerization

Methyl methacrylate (MMA)/tert‐butyl methacrylate (tBMA) gradient copolymers having linear and hyperbolic composition profiles were synthesized. These special copolymer products were achieved via a model‐based computer‐controlled semibatch atom transfer radical copolymerization (ATRcoP) process. A simple ATRcoP model was developed based on the terminal model. The equilibrium constants in the ATRP of MMA and tBMA were estimated by the data correlation. The model was verified by batch experiments and was found to give good correlation for the polymerization rate, molecular weight, and copolymer composition data. The model coupled with a reactor model was then applied to the semibatch ATRcoP and was used to calculate comonomer feeding rates for the targeted gradient composition profiles. It was found that the experimental monomer conversion, molecular weight, and cumulative copolymer composition were in good agreement with their targeted theoretical values. The gradient copolymers had low polydispersities close to 1.1. This work demonstrated the feasibility of the model‐based semibatch ATRcoP in fine‐tuning gradient copolymer composition profiles. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 69–79, 2009     

Organic solvent‐free catalytic hydrogenation of diene‐based polymer nanoparticles in latex form: Part I. Preparation of nano‐substrate

Poly(butadiene‐co‐acrylonitrile) (NBR) nanoparticles were synthesized in a semibatch emulsion polymerization system using Gemini surfactant trimethylene‐1,3‐bis (dodecyldimethylammonium bromide), referred to as Gemini‐type surfactant (GS) 12‐3‐12, as the emulsifier. In this polymerization system, an enhanced decomposition rate of initiator ammonium persulfate was achieved even under the low temperature of 50 °C which is attributed to the acidic initiation environment provided using GS 12‐3‐12. The microstructure and copolymer composition of the polymer nanoparticles were characterized by Fourier‐transformed infrared and ¹H nuclear magnetic resonance spectroscopy. The effects of the surfactant concentration on the particle size, zeta potential, polymerization conversion, copolymer composition, molecular weight, and glass transition temperature (T_g) were investigated. It was found that the particle diameter can be controlled by the surfactant concentration and monomer/water ratio and particle sizes below 20 nm can be reached. The obtained latex particles exhibit a spherical morphology. A kinetic study of the copolymerization reaction was carried out, which indicated that an azeotropic composition was produced. The synthesized fine NBR nanoparticles can be employed as the nano substrate for a subsequent hydrogenation process so as to overcome the challenge involved in the field of latex hydrogenation of polymers, which can be found in a related report: Organic Solvent‐Free Catalytic Hydrogenation of Diene‐based Polymer Nanoparticles in Latex Form: Part II. Kinetic Analysis and Mechanistic Study. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

Influence of hydrophobic monomers on secondary nucleation of hydroxyl‐functionalized latexes

The influence of butyl acrylate (BA) and methyl methacrylate (MMA) on hydroxyl functionalized latexes was investigated. The hydrophobicity of the monomer feed was varied via the BA/MMA ratio. In addition to monitoring the effect of hydrophobic monomer feed on secondary nucleation, the polymerization kinetics and final latex properties were also obtained for comparison. Five different BA to MMA molar ratios were combined with five 2‐hydroxyethyl methacrylate (HEMA) concentrations (0, 10, 20, 30 and 40 mol% in monomer composition). All latexes were synthesized through seeded semibatch emulsion polymerization process. Particle size distributions and average particle sizes of the latexes were determined by dynamic light scattering (DLS) and qualitatively compared with transmission electron microscope (TEM) images. The BA to MMA ratio significantly influences the boundary HEMA concentration at which homogeneous secondary nucleation occurs. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 2190–2202     

High solids TEMPO‐mediated radical semibatch emulsion polymerization of styrene

A bicomponent initiation system consisting of 2,2,6,6‐tetramethylpiperidine‐N‐oxyl (TEMPO) and the water soluble initiator potassium persulfate (KPS) was used to develop a robust and versatile semibatch emulsion polymerization process to obtain polystyrene (PS) latexes with solids contents of 5–40 wt %. A window of operating conditions was found that yielded high conversion (>95%) stable latexes and well controlled polymers, overcoming limitations found in previous attempts at developing similar processes using TEMPO. The critical parameters studied were surfactant concentration, monomer concentration in the nucleation step and the monomer feed rate in the semibatch step. Methyl acrylate (MA) was used in the nucleation step to improve the nitroxide efficiency (N_Eff). Latexes having molecular weight distribution (MWD) with dispersity (?) lower than 1.5, average particle size (D_p) from ≈32 to ≈500 nm, nitroxide efficiencies N_Eff up to ≈1.0 and monomer conversions >90% were obtained in less than 12 h with solids contents up to 40 wt %. These results constitute a significant advance over prior efforts in TEMPO‐mediated polymerization in aqueous dispersions. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016 , 54, 49–62