High solids content latexes with low viscosity

The effect of particle size distribution (PSD) on the solids content and viscosity of the multi-sized latex was investigated by blending mono-sized latexes and measuring their rheological properties. The results showed that the maximum packing (highest solids content) was observed at a weight fraction 80% of large particles with respect to total solids content for both bi-modal and tri-modal latexes, and the lowest viscosity was obtained when the ratio of large to medium to small particles was approximately 80/10/10 (by weight). A two-stage technique to prepare high solids multi-sized polymer latex was developed by using a polymer latex previously made as seed and by adding small amount of additional surfactants and/or second group of polymer particles. The PSD of the latex was optimized by varying the amount of the seed, the additional surfactants, and the second group of particles. Film forming latexes with high solids (>65%) and low viscosity were obtained. Received: 18 February 2000 Accepted: 30 September 2000     

Seeded polymerization of vinyl acetate using monodisperse poly(vinyl acetate) latex particles

The seeded polymerizations of vinyl acetate, using monodisperse poly(vinyl acetate) latex particles prepared in the absence of emulsifiers with potassium persulfate, have been investigated at 70°C with potassium persulfate as an initiator. New small particles were formed in the system containing a small amount of seed particles, but were not observed in the system containing a large amount of seed particles. The size of the secondary particles increased, and their number decreased, with an increase in the seed particle number. The minimum diameter of PVAc particles, which are stabilized by the sulfate ion groups bound at the end of polymer chains during polymerization, was determined to be 0.12 μm diameter from the limiting total surface area of seed particles which prevented further secondary nucleation. The minimum diameter of the particles increased as the speed of the stirrer increased. The new small particle number calculated using this value agreed well with that formed in the seeded polymerization.     

Sterically and electrosterically stabilized emulsion polymerization. Kinetics and preparation

The principal subject discussed in the current paper is the radical polymerization in the aqueous emulsions of unsaturated monomers (styrene, alkyl (meth)acrylates, etc.) stabilized by non-ionic and ionic/non-ionic emulsifiers. The sterically and electrosterically stabilized emulsion polymerization is a classical method which allows to prepare polymer lattices with large particles and a narrow particle size distribution. In spite of the similarities between electrostatically and sterically stabilized emulsion polymerizations, there are large differences in the polymerization rate, particle size and nucleation mode due to varying solubility of emulsifiers in oil and water phases, micelle sizes and thickness of the interfacial layer at the particle surface. The well-known Smith-Ewart theory mostly applicable for ionic emulsifier, predicts that the number of particles nucleated is proportional to the concentration of emulsifier up to 0.6. The thin interfacial layer at the particle surface, the large surface area of relatively small polymer particles and high stability of small particles lead to rapid polymerization. In the sterically stabilized emulsion polymerization the reaction order is significantly above 0.6. This was ascribed to limited flocculation of polymer particles at low concentration of emulsifier, due to preferential location of emulsifier in the monomer phase. Polymerization in the large particles deviates from the zero-one approach but the pseudo-bulk kinetics can be operative. The thick interfacial layer can act as a barrier for entering radicals due to which the radical entry efficiency and also the rate of polymerization are depressed. The high oil-solubility of non-ionic emulsifier decreases the initial micellar amount of emulsifier available for particle nucleation, which induces non-stationary state polymerization. The continuous release of emulsifier from the monomer phase and dismantling of the non-micellar aggregates maintained a high level of free emulsifier for additional nucleation. In the mixed ionic/non-ionic emulsifiers, the released non-ionic emulsifier can displace the ionic emulsifier at the particle surface, which then takes part in additional nucleation. The non-stationary state polymerization can be induced by the addition of a small amount of ionic emulsifier or the incorporation of ionic groups onto the particle surface. Considering the ionic sites as no-adsorption sites, the equilibrium adsorption layer can be thought of as consisting of a uniform coverage with holes. The de-organization of the interfacial layer can be increased by interparticle interaction via extended PEO chains--a bridging flocculation mechanism. The low overall activation energy for the sterically stabilized emulsion polymerization resulted from a decreased barrier for entering radicals at high temperature and increased particle flocculation.     

核/壳乳液聚合工艺中乳化剂的定量研究

以十二烷基硫酸钠(SDS)为乳化剂,采用多步种子乳液聚合方法制备了核/壳结构乳液,研究了乳化剂加入量以及加料速率对核壳乳液聚合的影响,并推导了核及壳乳液聚合阶段所需乳化剂量的计算公式.研究表明,当种子、核、壳乳液聚合阶段单体量分别为12g、50g和50g,种子乳液聚合阶段加入的乳化剂量为0.44g时,控制核、壳乳液聚合阶段乳化剂的加入量分别在0.64～2.07g及0.04～2.12g之间,且预乳化单体的滴加速度低于2.3g/min时,可以防止二次成核及新乳胶粒子的形成,制得粒径分布窄、核/壳结构明显的乳胶粒子.利用透射电镜(TEM)对所制备的核壳结构乳胶粒子的结构形态进行了验证,试验结果与理论预测结果一致.     

Effect of hydrophilic comonomer and surfactant type on the colloidal stability and size distribution of carboxyl- and amino-functionalized polystyrene particles prepared by miniemulsion polymerization

Carboxyl and amino-functionalized polystyrene latex particles were synthesized by the miniemulsion copolymerization of styrene and acrylic acid or 2-aminoethyl methacrylate hydrochloride (AEMH). The reaction was started by using an oil-soluble initiator, such as 2,2'-azobis(2-methylbutyronitrile) (V-59). The effect of the functional monomer content and type of surfactant (non-ionic versus ionic) on the particle size and particle size distribution was investigated by dynamic light scattering (DLS) and transmission electron microscopy (TEM). A bimodal particle size distribution was observed for functionalized latex particles prepared in the presence of the non-ionic surfactant (i.e., Lutensol AT-50) when 1 wt % of acrylic acid or 3 wt % of AEMH as a comonomer was employed. The copolymer particle nucleation was studied by using a highly hydrophobic fluorescent dye. From the obtained results, the formation of bimodal particle size distribution may be attributed to a budding-like effect, which takes place during the earlier stage of polymerization and is caused by the additional stabilizing energy originated from the ionic groups of a functional polymer. The reaction mechanism of particle formation in the presence of non-ionic and ionic surfactants has been proposed. The amount of the surface functional groups was determined from polyelectrolyte titration data.     

Preparation of nonspherical particles via dual-seeded dispersion polymerization in the presence of saturated hydrocarbon droplets

In this study, the effect of various polymerization conditions on the shape of the particles produced by dual-seeded dispersion polymerization of a second monomer with polystyrene (PS) and poly(methyl methacrylate) (PMMA) seed particles in the presence of saturated hydrocarbon droplets in a polar media was discussed. It was observed that with changing the affinity between the hydrocarbon and PS seed particles, second monomer type, polarity, and alcohol type of the medium nonspherical particles with a variety of shapes can be produced. Furthermore, we suggested that the presence of PMMA seed particles in the medium affects the distribution of the second polymer domains on the surface of the PS seed particles in addition to the absorbed amount of the hydrocarbon by PS particles and second polymer domains and the distribution of the hydrocarbon between them. Moreover, the experimental results showed that almond shell-like PS particles can be prepared under certain conditions.     

Polystyrene(1)/poly(butyl acrylate-methacrylic acid)(2) core-shell emulsion polymers. Part I. Synthesis and colloidal characterization

Polystyrene (PS) (1)/Poly(n-butyl acrylate (BA)-methacrylic acid (MAA)) (2) structured particle latexes were prepared by emulsion polymerization using monodisperse polystyrene latex seed (118 nm) and different BA/MAA ratios. Three main aspects have been investigated: i) the polymerization kinetics; ii) the particle morphology as a function of reaction time; iii) the distribution of MAA units between the water phase and the polymer particles.The amount of MAA in the shell copolymer was found to be the main factor controlling the particle shape and morphology. The shape of the structured particles was, generally, non-spherical, and the shape irregularities increased as a particles was, generally, non-spherical, and the shape irregularities increased as a function of reaction time. At the beginning of the second stage reaction, new small particles were observed, which coalesced onto the PS seed as the polymerization proceeded. The distribution of the MAA groups in the latex particles and the serum was analyzed by alkali/back-acid titration, using ionic exchanged latexes. No MAA groups were detected in the latex serum. Due to the lowTg of the BA-MAA copolymers, alkali conductimetric titrations accounted for all the MAA groups on and within the polymer particles. Therefore, for these systems, this method is not only limited to a thin surface layer, as it is often assumed.     

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     

聚合物纳米微粒静电组装行为及其表征

使用2,2′-偶氮二异丁基脒二盐酸盐自由基引发剂,改变甲基丙烯酰氧乙基十六烷基二甲基溴化铵阳离子功能单体的量与苯乙烯进行乳液聚合获得不同粒径的阳离子乳胶粒,使用十二烷基硫酸钠为乳化剂和过硫酸钾为引发剂制备阴离子聚合物乳胶粒.采用基于静电相互作用的异凝聚法将以上2种带有相反电荷的乳胶粒组装,获得了表面粗糙程度不同的复合微粒.对异凝聚过程中复合液透光率和微粒大小及分布进行跟踪测试,并用透射电子显微镜表征了阳离子微粒、阴离子微粒以及复合微粒的形态和大小.结果表明,在一定范围内可以通过控制阴离子乳胶粒与阳离子乳胶粒的复合比例改变单个复合微粒表面阳离子小微粒的数目.     

PARTICLE SIZE DISTRIBUTION IN CONTINUOUS EMULSION POLYMERIZATION WITH FREE RADICAL DESORPTION

A mathematical model of particle size distribution in continuous emulsion polymerization which accounts for the free radical desorption from polymer particles is presented. The desorption rate is based on the diffusion theories which suggest the rate coefficient should be inversely proportional to the surface area of the polymer particles. The number density and total particle number are estimated by our model.

The average number of radicals per particle approaches Smith-Ewart case II In the range of large particle sizes. A means for predicting the nature of average desorption rate is proposed, and it seems to be influenced by concentrations of emulsifier and initiator, and residence times as well     

The influence of surfactant coverage of the minidroplets on RAFT miniemulsion polymerization

The surfactant coverage of minidroplets was tuned by postaddition of more surfactants after preparation of the miniemulsion of styrene. The influence of surfactant coverage on reversible addition‐fragmentation chain transfer (RAFT) miniemulsion polymerization of styrene was investigated. When the surfactant (sodium dodecyl sulfate; SDS) coverage was as low as 40%, two kinds of particles, denoted as polymer and oligomer particles, were formed in the early stage of the polymerization. Polymer chains within two kinds of particles grew in a parallel way during the rest period of the polymerization. The oligomer particles contributed less than 10% to the final monomer conversion but consumed over one in third the original RAFT agent molecules. Oligomer particles were larger in size but much lower in molecular weight. Both the particle size and molecular weight distributions were bimodal. With increase of SDS coverage, the formation of oligomer particles was suppressed. As a result, the nucleation efficiency of the minidroplets was greatly enhanced and the molecular weight and particle size distributions were dramatically narrowed. The formation of the oligomer particles was ascribed to the superswelling occurring in the beginning stage of the polymerization. The experimental observations are in excellent accord to the superswelling theory. Postaddition of surfactant presents a novel method to narrow particle size and molecular weight distributions in RAFT miniemulsion polymerization. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 2293–2306, 2006     

Synthesis and properties of soap-free poly(methyl methacrylate-ethyl acrylate-methacrylic acid) latex particles prepared by seeded emulsion polymerization

In order to obtain functional polymer latex particles with clean surface and with surface carboxyl groups, P(MMA-EA) seed particles with the diameter of 335 nm were first synthesized via soap-free batch emulsion polymerization of methyl methacrylate (MMA) and ethyl acrylate (EA), and then the seeded emulsion copolymerization of MMA, EA and MAA (methacrylic acid) onto the seed particles were performed in the absence of emulsifier. Influences of ingredients and conditions on polymerization, latex particle size (D_p) and its distribution were investigated. Results showed that most of the monomers polymerized onto the seed latex particles in the second step of polymerization by using drop-wise addition method, and D_p increased from 483 nm to 829 nm with the mass ratio of core/shell monomers [C]/[S] decreased from 1:2 to 1:15. It was found that D_p decreased with the increase of MAA and initiator amounts, and the size of the latex particles became uniform with the decrease of MAA amount and with the increase of [C]/[S] value.     

Kinetics of the batch cationic emulsion polymerization of styrene: A comparative study with the anionic case

An in‐depth study on the kinetics of the cationic emulsion polymerization of styrene in a batch reactor is presented. This study is focused on the effect of the amount of the cationic surfactant dodecyltrimethylammonium bromide (DTAB), using two different cationic initiators: 2,2′‐azobisisobutyramidine dihydrochloride (AIBA), 2,2′‐azobis (N,N′‐dimethyleneisobutyramidine) dihydrochloride (ADIBA), on kinetics and colloidal features such as conversion, number of particles, number average of radicals per particle, mean particle diameter, and particle size distribution (PSD) of the polystyrene latices obtained by emulsion polymerization in a batch reactor. Furthermore, the results of the cationic emulsion polymerization were compared with its homologous anionic case. Using DTAB as cationic surfactant an expected increase in the total rate of polymerization was observed when the DTAB concentration increased. However, the total number of particles increased much more than in the anionic system. On the other hand, a dependence on the particle size of the rate of polymerization per particle together with the average number of radicals per particle was found. These differences between cationic and anionic emulsion polymerizations were explained taking into account the limited particle coagulation observed with cationic surfactants, and the high rate of radical formation of cationic initiators. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 4461–4478, 2006     

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.     

Influence of the seed polymer on the chromatographic properties of size monodisperse polymeric separation media prepared by a multi-step swelling and polymerization method

Monodisperse polymer particle-based separation media were prepared by a multi-step swelling and polymerization method with two pairs of monomers and two porogenic solvents. Their chromatographic properties were compared to those of beads prepared by a corresponding suspension polymerization method without the use of seed polymer to ascertain the influence of the seed polymer on their porous structures. A large change in porous structure was observed when the swollen particle consisting of monomers and porogenic solvents contained at least one good solvent for the polystyrene seed polymer, allowing it to remain in the polymerizing medium. In contrast, when the polystyrene seed particle was excluded from the swollen oil droplets, due to its poor solubility in the monomers and the porogenic solvents, there was no difference in the chromatographic properties such as pore volume, pore size, pore size distribution, or retention selectivity between the multi-step swelling and polymerization method and the suspension polymerization method. Since the only difference between the multi-step swelling and polymerization method and the suspension method is the use of the seed polymer, it appears that a very small amount (< 1% v/v) of seed polymers in the enlarged swollen droplets plays an important role as a porogen and affects the porous structure as well as the chromatographic properties of the monodisperse polymer particle-based separation media. © 1993 John Wiley & Sons, Inc.     

苯乙烯和N-乙烯基吡咯烷酮共聚物/Ag复合微球的制备及性能研究

首先用无皂乳液聚合法制备了单分散聚苯乙烯(PSt)乳液,以此为种子乳液,使用N,N-亚甲基双丙烯酰胺(MBA)为交联剂,过硫酸钾(KPS)为引发剂,进行苯乙烯和N-乙烯基吡咯烷酮(NVP)共聚合制备了以PSt为核、St和NVP共聚物为壳的具有核-壳结构的聚合物微球(P(St-NVP)).以此微球为模板通过化学沉积法得到了粒径分布均匀、单分散的P(St-NVP)/Ag复合微球.傅里叶红外光谱、X-射线衍射、扫描电镜、透射电镜、激光粒度仪和紫外-可见光谱对复合微球的结构、形貌、物相及催化性能进行了表征.结果表明,P(St-NVP)/Ag复合微球具有规则的球形结构,粒径在400～700 nm之间,随交联剂浓度或种子乳液浓度的增加,复合微球粒径减小.粒径在十几个纳米左右的银粒子均匀分布在微球表面和内部.载银复合微球在NaBH4还原4-硝基苯酚为4-氨基苯酚的模型反应中表现出较高的催化活性.     

Fabrication of hierarchical microparticles by depositing the in situ synthesized surface nanoparticles on microspheres during the seed emulsion polymerization

A general strategy for the synthesis of polymeric hierarchical microparticles containing surface nanoparticles through modified seed emulsion polymerization is proposed. This modified seed emulsion polymerization has a character that suitable amount of monomer miniemulsion is added during the polymerization. The in situ synthesized surface nanoparticles which are resulted from the monomer miniemulsion as well as the shell-forming polymer coagulate on the seed particles and therefore hierarchical microparticles are fabricated. Various polymeric hierarchical microparticles containing 20-36 nm poly(styrene-co-acrylamide), poly(styrene-co-acrylic acid), and polystyrene surface nanoparticles are synthesized following the proposed method. The advantages in the present synthesis including both the well controls in the size, the composition, and the number of the surface nanoparticles and the convenience are demonstrated. The proposed strategy is anticipated to be a general method to fabricate hierarchical microparticles and is believed to have promising application in particle surface modification.     

Model filled polymers. VIII. Synthesis of crosslinked polymeric beads by seed polymerization

Monodisperse crosslinked polystyrene (PS) and polymethacrylate (PMA) beads of sizes greater than 1 μm in diameter are prepared by particle nucleation onto pre-existing polymer seeds in a multistage emulsion polymerization, in the absence of emulsifier. An adequate seed number concentration, which decreases with increasing seed size, is necessary to achieve monodisperse beads. Monodisperse multicomposition beads are prepared by polymerizing styrene onto PMA seeds, but not by polymerizing methyl methacrylate onto PS seeds. Phase separation in growing seed particles or surface polymerization following free radical capture may lead to the formation of asymmetric shaped particles.     

单分散、大粒径聚苯乙烯微球的制备

以聚乙烯基吡咯烷酮为分散剂、偶氮二异丁腈为引发剂、醇／水混合物为分散介质进行了苯乙烯的分散聚合，讨论了初始单体浓度、分散剂用量、引发剂浓度、分散介质组成和反应温度等反应条件对所得聚合物颗粒直径和直径分布的影响．通过大量的试验，筛选出了较为理想的分散聚合的条件及配方，制备出了粒径为４８μｍ的单分散聚苯乙烯微球．然后，以分散聚合所制得的聚合物颗粒为种子，用动力学溶胀法制成了粒径增大近四倍的单分散、大粒径聚苯乙烯微球，并讨论了滴水速度和补加分散剂对溶胀的影响     

Monodisperse glycidyl-functional polymer particles in the micron-size range by seeded polymerization

Polymer particles having glycidyl ether groups were prepared through seeded polymerization in aqueous medium. The polystyrene seed particles were swollen with a mixture of n-butyl methacrylate, glycidyl methacrylate, ethylene glycol dimethacrylate, and benzoyl peroxide initiator. The particles produced after polymerization were characterized regarding the particle morphology and functionality. Optical microscopy and scanning electron microscopy showed that the particles are in the size range of 13–14 μm and are highly monodisperse with heterophase structures. Actually, the high content of glycidyl methacrylate in the second monomer mixture caused the particle phase to be homogeneous. This effect was explained in terms of the surface tension of each polymer phase. Moreover, the cross-linking of the seed particles had a significant effect on the final particle morphology. From the HCl–dioxane back titration method, it was found that about 20–30% of glycidyl ether groups still remained on the final particles. Received: 25 February 2000 Accepted: 10 November 2000