Multiphase Polymer Dispersions and Nanocomposites by Catalytic/Free Radical Emulsion Polymerization

Summary: Free radical emulsion polymerization of styrene (S) or butyl acrylate (BA) in the presence of latices of linear polyethylene (PE) prepared by catalytic emulsion polymerization affords colloidally stable multiphase latices. Coagulation of a PE/PS latex affords nanocomposites composed of small PE phases dispersed in a PS matrix, as evidenced by the large supercoolings of PE crystallization (by DSC). TEM of PE/PBA latices indicates a PBA phase around the PE particles under the emulsion polymerization conditions investigated. Films formed from these dispersions exhibit homogeneously dispersed PE particles.

Multiphase latices are obtained by free radical emulsion polymerization of butyl acrylate in the presence of latices of linear polyethylene (PE) prepared by catalytic emulsion polymerization.     

Properties of polystyrene/poly(butyl acrylate) core/shell polymers modified with N‐methylol acrylamide

Polystyrene/poly(butyl acrylate) PS/PBA polymer dispersions with core/shell particles functionalized by N‐methylol acrylamide (N‐MA) were prepared through two‐step emulsion polymerization. The influence of N‐MA situated in shell and/or in core/shell of particles on the crosslinking reaction was studied to relate its mechanical properties and organic solvent resistance of films cast from basic and modified PS/PBA latexes. The changes in the phase arrangement of functionalized and unfunctionalized films after treatment with solvent and annealing were monitored. It was found that at the presence of N‐MA the crosslinking reaction occured already during the polymerization. Films from functionalized dispersions exhibit improved tensile strength and higher resistance against organic solvent.     

Preparation and application of cross-linked core-shell PBA/PS and PBA/PMMA nanoparticles

This paper reports the preparation of cross-linked core-shell poly(butyl acrylate)/polystyrene (PBA/PS) and poly(butyl acrylate)/poly(methyl methacrylate) (PBA/PMMA) nanoparticles via seeded emulsion polymerization and their application in nylon-based composites. A highly cross-linked structure was formed in both the cores and the shells by using a cross-linking agent, which could prevent the migration of hydrophobic PS shells to the inside of particles. There were covalent bonds on the interfaces between the cores and the shells of both particles. The average particle sizes were 40–50 nm, and the size distributions were narrow. The kinetics of polymerization was investigated. Well-defined core-shell structure and narrow particle size distribution could be achieved under starved conditions of monomer feeding. Furthermore, PBA/PMMA particles were used to fill nylon 6, good dispersion was obtained because of the strong interfacial interaction between the nanoparticles and the nylon 6 matrix and the good deformation ability of nanoparticles, and the toughness and rigidity of the composites were improved evidently. __________ Translated from Acta Polymerica Sinica, 2005, (6) (in Chinese)     

Morphology of micron-sized monodispersed composite polymer particles produced by seeded polymerization for the dispersion of highly monomer-swollen polymer particles

 Monodispersed polystyrene (PS)/poly(n-butyl methacrylate) (PBMA) composite particles having 9.4 μm in diameter were produced by seeded polymerization for the dispersion of highly n-butyl methacrylate (BMA)-swollen PS particles, and their morphologies were examined. The highly BMA-swollen PS particles (about 150 times the weight of the PS seed particles) were prepared by mixing monodispersed 1.8 μm-sized PS seed particles and 0.7 μm sized BMA droplets prepared with an ultrasonic homogenizer in ethanol/water (1/2, w/w) medium at room temperature. After NaNO₂ aqueous solution as inhibitor was added in the dispersion, the seeded polymerization was carried out at 70 °C. In an optical microscopic observation, one or two spherical high contrast regions which consisted mainly of PS were observed inside PS/PBMA composite particles. In the PS domain, there were many fine spherical PBMA domains. Such morphologies were based on the phase separation of PS and PBMA within the homogeneous swollen particles during the seeded polymerization. Received: 04 June 1997 Accepted: 27 August 1997     

Nanostructured latexes made by a sequential multistage emulsion polymerization

A series of linear and lightly crosslinked nanostructured latices was prepared by a sequential multistage semicontinuous emulsion polymerization process alternating styrene (S) and n‐butyl acrylate (BA) monomer feeds five times, that is ten stages, and vice versa, along with several control latices. Transmission electron micrographs of the RuO₄‐stained cross sections of nanostructured and copolymer latex particles and films showed that their particle morphologies were not very different from each other, but the nanostructured latex particles were transformed into a nanocomposite film containing both polystyrene (PS) and poly(n‐butyl acrylate) (PBA) nanodomains interconnected by their diffuse polymer mixtures (i.e. interlayers). The thermal mechanical behaviors of the nanostructured latex films showed broad but single T_gs slightly higher than those of their counterpart copolymer films. These single T_gs indicated that their major component phases were the diffuse interlayers and that they behaved like pseudopolymer alloys. The minimum film formation temperatures of nanostructured latices capped with PBA and PS, respectively, were 15 °C lower than and equal to those of their counterpart copolymer latices, but their T_gs were about 10 °C higher. Consequently, nanostructured latices enabled us to combine good film formation with high strengths for adhesives and coatings applications. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 2826–2836, 2006     

Poly(acrylate‐b‐styrene‐b‐isobutylene‐b‐styrene‐b‐acrylate) Block Copolymers via Carbocationic and Atom Transfer Radical Polymerizations

A series of polyacrylate‐polystyrene‐polyisobutylene‐polystyrene‐polyacrylate (X‐PS‐PIB‐PS‐X) pentablock terpolymers (X=poly(methyl acrylate) (PMA), poly(butyl acrylate) (PBA), or poly(methyl methacrylate) (PMMA)) was prepared from poly (styrene‐b‐isobutylene‐b‐styrene) (PS‐PIB‐PS) block copolymers (BCPs) using either a Cu(I)Cl/1,1,4,7,7‐pentamethyldiethylenetriamine (PMDETA) or Cu(I)Cl/tris[2‐(dimethylamino)ethyl]amine (Me₆TREN) catalyst system. The PS‐PIB‐PS BCPs were prepared by quasiliving carbocationic polymerization of isobutylene using a difunctional initiator, followed by the sequential addition of styrene, and were used as macroinitiators for the atom transfer radical polymerization (ATRP) of methyl acrylate (MA), n‐butyl acrylate (BA), or methyl methacrylate (MMA). The ATRP of MA and BA proceeded in a controlled fashion using either a Cu(I)Cl/PMDETA or Cu(I)Cl/Me₆TREN catalyst system, as evidenced by a linear increase in molecular weight with conversion and low PDIs. The polymerization of MMA was less controlled. ¹H‐NMR spectroscopy was used to elucidate pentablock copolymer structure and composition. The thermal stabilities of the pentablock copolymers were slightly less than the PS‐PIB‐PS macroinitiators due to the presence of polyacrylate or polymethacrylate outer block segments. DSC analysis of the pentablock copolymers showed a plurality of glass transition temperatures, indicating a phase separated material.     

Influence of the swelling state of seed polymer particles with monomer on the morphology of micron-sized monodispersed composite polymer particles produced by seeded polymerization utilizing the dynamic swelling method

 Micron-sized mono-dispersed polystyrene (PS)/poly(n-butyl methacrylate) (PBMA) composite particles (PS/PBMA=2/1 by weight) having a heterogeneous structure in which many fine PBMA domains dispersed in a PS matrix near the particle surface were produced by seeded polymerization of n-butyl methacrylate (BMA) of which almost all had been absorbed by 1.8 μm-sized monodispersed PS seed particles utilizing the dynamic swelling method. The morphology was varied by changing the PS/BMA ratio and polymerization temperature. It was concluded that the swelling state of 2 μm-sized BMA-swollen PS particles in the seeded polymerization process is one of the important factors to control the morphology of the composite particles. Received: 27 November 1996 Accepted: 21 March 1997     

交联核壳结构PBA/PS和PBA/PMMA纳米微球的制备与应用

考察了聚丙烯酸丁酯/聚苯乙烯(PBA/PS)以及聚丙烯酸丁酯/聚甲基丙烯酸甲酯(PBA/PMMA)交联核壳结构纳米高分子微球的制备方法,并对其在尼龙复合材料中的应用进行了初步研究.结果表明,通过交联剂的引入使粒子核层和壳层内部均形成了高度交联的结构,可以限制亲水性较小的聚苯乙烯(PS)壳层向粒子内部迁移的趋势;制备出的微球平均粒径为40~50 nm,粒径分布很窄.采用饥饿态加料方式加入第二单体不仅可以使微球具有较高的产率和凝胶率,而且可以使其具有更理想的核壳结构和更窄的粒径分布.此外,将合成出的PBA/PMMA核壳粒子对尼龙6基体进行复合的结果表明,由于该微球表面与尼龙6基体之间具有较强的界面相互作用且微球具有较大的形变能力,可以在基体中形成良好的分散,在保持材料强度的同时有效地提高了其刚性和韧性.     

Thermodynamic aspects of the heterogeneous structure of “golf-ball-like” polymer particles

Recently, we found that “golf-ball-like” polystyrene (PS)/poly(butyl acrytlate) composite particles could be produced by seeded emulsion polymerization of butyl acrylate with PS seed particles. In this article, the theoretical and experimental thermodynamic instabilities of the golf-ball-like structure are discussed and are compared with core-shell and hemispherical morphologies. Received: 2 February 1999 Accepted in revised form: 3 June 1999     

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.     

Structural morphology of poly(styrene)-poly(butyl acrylate) polymer-polymer composites studied by dynamic mechanical measurements

The emulsion polymerization process allows production of polymer particles with different structural morphologies. Films obtained after coalescence keep some memory of this morphology, but large modifications can occur during coalescence. In the present case, one of the polymers, polystyrene (PS), exhibits a glass temperature (Tg) much higher than the filmification temperature (close to room temperature), while the other one, poly(butyl acrylate) (PBA), has a much lowerTg. Furthermore, it is well known that dynamic mechanical measurements can be very helpful in providing information on the morphology of polymer materials, i.e., on geometrical and topological arrangement of homopolymer domains. At first, this method was used for comparison of two types of films: i) the first one obtained from structured-core (PS)-shell (PBA) particles, ii) the second one obtained from a blend of homopolymer particles (PS and PBA). It appears that the expected core-shell particles lost their geometric structure in the second film. Second, comparison of the predicted dynamic modulus and experimental data shows that i) strong interactions exist between PS nodules unless their coalescence has occured, leading to an abnormally high modulus at room temperature, ii) after achieving their coalescence, PS forms a more or less continuous phase. Both phenomena strongly depend on the particle size and their respective volume fractions.     

Modified suspension‐PVC particles as absorbents of ortho‐dichlorobenzene from water

Modified porous PVC particles are studied as absorbents of o‐dichlorobenzene (DCB), from water. The modified particles were produced by an in‐situ stabilizer‐free polymerization/crosslinking of a monomer/crosslinker/peroxide solution absorbed within commercial porous suspension‐type PVC particles. The modifying monomers used include styrene with divinyl benzene (DVB) as a crosslinking comonomer, methyl methacrylate (MMA), butyl acrylate (BA), or ethylhexyl acrylate (EHA) with ethylene glycol dimethacrylate (EGDMA) as a crosslinking comonomer. The effect of the nature of the monomers, morphology, porosity, surface area and composition of the modified PVC particles on DCB absorption was studied. Batch experiments (absorption rate and isotherms) were used to screen the PVC absorbents on the basis of absorption rate and absorption capacity. Continuous absorption column experiments were conducted to study the parameters characterizing the absorption process. Both the unmodified and modified PVC particles absorb DCB from water. The PBA and PEHA‐modified PVC particles approach equilibrium capacity faster and have greater absorption capacity than neat PVC, PS‐modified PVC and PMMA‐modified PVC particles. The absorption characteristics are influenced by the modifying polymer's T_g. The rubbery nature of PBA and PEHA yields better absorption in spite of the significantly lower surface area and porosity obtained in the modified PVC particles. Thus, indicating that fast adsorption followed by bulk absorption of DCB is taking place. A clear influence of the crosslinking effect was not established. The continuous absorption experiments were found more efficient than the batch absorption experiments. Copyright © 2003 John Wiley & Sons, Ltd.     

Production of micron-sized monodispersed core/shell polymethyl methacrylate/polystyrene particles by seeded dispersion polymerization

 Micron-sized monodispersed polymethyl methacrylate (PMMA)/polystyrene (PS) (PMMA/PS=2/1, wt ratio) composite particles consisting of PMMA-core and PS-shell were successfully produced by seeded dispersion polymerization of styrene in a methanol/water medium in the presence of about 2 μm-sized monodispersed PMMA particles. From the view point of thermodynamic equilibrium, such a morphology is difficult to form by usual seeded polymerization in a polar medium such as water. It is concluded that seeded dispersion polymerization in which almost all monomers and initiators exist in the medium has an advantage to produce core/shell polymer particles in which polymer layers accumulate in their order of the production regardless of the hydrophobicity of polymers, because of high viscosity in polymerizing particles. Received: 9 December 1996 Accepted: 26 February 1997     

Formation mechanism of micron-sized monodispersed polymer particles having a hollow structure

 Recently, the authors reported that micron-sized monodispersed cross-linked polymer particles having a single hollow in the inside were produced by seeded polymerization for the dispersion of (toluene/divinylbenzene)-swollen polystyrene (PS) particles prepared utilizing the dynamic swelling method which the authors had proposed. In this article, the particles at various conversions of the seeded polymerization were observed with an optical microscope in detail. From the obtained results, the formation mechanism of the hollow structure is suggested as follows. As seeded polymerization proceeds, poly-divinylbenzene (PDVB) molecules precipitated in the swollen particle are trapped near the interface and gradually pile at the inner surface, which results in a cross-linked PDVB shell. PS which dissolves in the swollen particles is repelled gradually to the inside. After the completion of the polymerization, toluene in the hollow evaporates by drying, and PS clings to the inner wall of the shell uniformly. Received: 14 February 1997 Accepted: 16 April 1997     

Modification of porous suspension‐PVC particles by stabilizer‐free aqueous dispersion polymerization of absorbed acrylate monomers

The present study describes modification of porous PVC particles by polymerization of a monomer/crosslinker/peroxide solution absorbed within the PVC particles. The modifying crosslinked polymers include butyl acrylate (BA) crosslinked with ethylene glycol dimethacrylate (EGDMA) and ethylhexyl acrylate (EHA) crosslinked with EGDMA. The monomer solution is blended with the PVC particles by dry‐blending. The monomer absorbed particles are then polymerized in a stabilizer‐free aqueous dispersion‐polymerization. The modified semi‐IPN PVC particles have better stability than the neat PVC particles in packed columns for absorption of halo‐organics from water, etc. The modified semi‐IPN PVC particles are melt processable and thus have the potential of being interesting and useful modified rigid PVC materials. The modified PVC particles characterization includes polymerization yield, non‐extractables and porosity measurements and also morphology and dynamic mechanical behavior (DMTA). PBA and PEHA polymerization has shown high yield levels. The high conversion of BA and EHA within the particle, is partly due to their low solubility in water. The levels of non‐extractable fractions found are indicative of low chemical interaction between the polyacrylate/PVC phases in the particle. The modified PVC particle's porosity levels indicate that BA and EHA partly polymerize within the PVC particles' bulk and partly in the pores as crusts covering the PVC pore surfaces. This finding is supported by SEM observations of unetched and etched freeze fractured surfaces. Higher crosslinking levels of the polyacrylate modification promote compatibility with the PVC particles' bulk. DMTA measurements show two loss modulus peaks for the 0.5%EGDMA blends in the glass transition temperature region, suggesting imcompatibility. However, at 5%EGDMA a single transition is found exhibiting enhanced compatibility owing to the high degree of crosslinking, which prevents phase separation. Copyright © 2002 John Wiley & Sons, Ltd.     

Production of hollow polymer particles by suspension polymerization

 Polymer particles having single hollow in the inside were successfully prepared by suspension polymerization for divinylbenzene/ toluene droplets dissolving polystyrene (PS) in an aqueous solution of poly(vinyl alcohol). Such a hollow polymer particle was not obtained without PS. The hollow structure was affected by the molecular weight and the concentration of PS. Received: 3 December 1997 Accepted: 27 March 1998     

胶乳接枝插层法天然橡胶/蒙脱土/聚丙烯酸丁酯纳米复合材料结构与性能的研究

采用胶乳接枝插层法,引入单体,制备了天然橡胶蒙脱土聚丙烯酸丁酯纳米复合材料.X射线衍射(XRD)和透射电镜(TEM)结果表明,在单体丙烯酸丁酯(BA)的作用下,改性蒙脱土片层被进一步撑大,并在橡胶基体中以纳米级分散;动态粘弹谱(DMA)测定结果显示,该体系的玻璃化温度有所提高,且60℃时具有较低的tanδ值,说明具有较小的滚动阻力;物理机械性能测试表明该方法有效地实现了对天然橡胶的补强.     

Emulsifier for microemulsion polymerization

 By introducing an hydroxyl group and a lipophilic branch into the middle of lipophilic head of emulsifier 12-oxy-9-octadecenoic acid, a new emulsifier was synthesized and applied in microemulsion polymerization. When the emulsifier content in the microemulsion was kept to about 12%, the highest monomer content in microemulsion could achieve 35% for BA, 20% for St and MMA. The microemulsion with high monomer content remained clear after polymerization, and the average diameters of polymer particles were 38.9 nm for St microemulsion, 47.4 nm for BA, and 50.7 nm for MMA. Received: 18 November 1997 Accepted: 16 January 1998     

Dendrimers as scaffolds for multifunctional reversible addition–fragmentation chain transfer agents: Syntheses and polymerization

The synthesis and characterization of novel first‐ and second‐generation true dendritic reversible addition–fragmentation chain transfer (RAFT) agents carrying 6 or 12 pendant 3‐benzylsulfanylthiocarbonylsulfanylpropionic acid RAFT end groups with Z‐group architecture based on 1,1,1‐hydroxyphenyl ethane and trimethylolpropane cores are described in detail. The multifunctional dendritic RAFT agents have been used to prepare star polymers of poly(butyl acrylate) (PBA) and polystyrene (PS) of narrow polydispersities (1.4 < polydispersity index < 1.1 for PBA and 1.5 < polydispersity index < 1.3 for PS) via bulk free‐radical polymerization at 60 °C. The novel dendrimer‐based multifunctional RAFT agents effect an efficient living polymerization process, as evidenced by the linear evolution of the number‐average molecular weight (M_n) with the monomer–polymer conversion, yielding star polymers with molecular weights of up to M_n = 160,000 g mol^?1 for PBA (based on a linear PBA calibration) and up to M_n = 70,000 g mol^?1 for PS (based on a linear PS calibration). A structural change in the chemical nature of the dendritic core (i.e., 1,1,1‐hydroxyphenyl ethane vs trimethylolpropane) has no influence on the observed molecular weight distributions. The star‐shaped structure of the generated polymers has been confirmed through the cleavage of the pendant arms off the core of the star‐shaped polymeric materials. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 5877–5890, 2004     

Synthesis and characterization of new flame-retardant microspheres by dispersion polymerization of pentabromobenzyl acrylate

New flame-retardant nano/micro particles of sizes ranging between 0.06 ± 0.01 and 1.70 ± 0.23 μm were formed by dispersion polymerization of the pentabromobenzyl acrylate monomer (PBBA) in methyl ethyl ketone as a continuous phase. The effect of various polymerization parameters, e.g., monomer concentration, initiator type and concentration, stabilizer concentration and crosslinker monomer concentration, on the size, size distribution and polymerization yield of the produced poly(pentabromobenzyl acrylate) particles has been elucidated. Poly(pentabromobenzyl acrylate)/polystyrene (PPBBA/PS) nano/micro blends of the contents of different PPBBA particles were prepared by mixing the PPBBA particles with a PS solution in methylene chloride, followed by evaporation of the methylene chloride from the mixture. The thermal stability of these blends was also studied.