The production of high polymer to surfactant microlatexes

Starved‐feed microemulsion polymerization of styrene was investigated. The influence of the type (SDS or Dowfax 2A1) and concentration of anionic surfactant on the final particle size of latex made by the polymerization of microemulsions of styrene was studied. In addition, the influence of 1‐pentanol and acrylic acid as cosurfactants was examined. Latexes with 20% solids content and polymer to surfactant ratio of 22 were produced, with a particle diameter of 42 nm and very low polydispersity indexes. Smaller particles are produced using SDS than Dowfax 2A1 for the same weight fraction of surfactant; however, similar particle sizes were obtained with the same molar concentrations of SDS and Dowfax 2A1. Further shot additions of monomer increased solids level as high as 40% and polymer to surfactant ratios greater than 40, with particles remaining monodisperse with average diameter smaller than 60 nm. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 48–54, 2010     

Effect of short-chain alcohols on the oil-in-water microemulsion polymerization of styrene

The influence of short-chain alcohols, 1-butanol (C₄OH), 2-pentanol (C₅OH) and 1-hexanol (C₆OH), on the formation of oil-in-water styrene microemulsions and the subsequent free-radical polymerization was studied. Sodium dodecyl sulfate was used as the surfactant. The overall performance of C₄OH as the cosurfactant is quite different from C₅OH and C₆OH. The range of the microemulsion region in decreasing order is C₄OH > C₅OH > C₆OH. The primary parameters selected for the microemulsion polymerization study were the concentrations of cosurfactant and styrene. Only a small fraction of microemulsion droplets initially present in the reaction system can be successfully transformed into latex particles and the remaining droplets serve as a reservoir to supply the growing particles with monomer. Limited flocculation of latex particles also occurs during polymerization and the degree of flocculation is most significant for the C₄OH system. Received: 24 August 1999/Accepted in revised form: 22 October 1999     

Emulsion copolymerization of styrene and methacrylic acid in the presence of a polyethylene oxide based-polymerizable stabilizer with a shorter chain length

The emulsion copolymerization of styrene and methacrylic acid (MAA) was performed in the presence of a relatively new macromonomer, poly(ethylene glycol) ethyl ether methacrylate (PEG-EEM) as a stabilizer. In contrast to similar studies, a macromonomer having relatively shorter polyethylene oxide chain length (i.e., M_n:246, n ≈ 3.0) was selected for this study. Highly uniform and carboxyl functionalized latex particles in the size range of 0.16–0.50 μm were obtained by changing MAA, PEG-EEM, total monomer, and initiator concentrations. The use of PEG-EEM as a stabilizer resulted in larger monodisperse particles relative to those obtained by the emulsifier-free emulsion copolymerization of styrene and MAA. The particle size decreased and the polymerization rate increased with the increasing MAA feed concentration. The application of power law model indicated that MAA concentration was more effective in the presence of PEG-EEM for control of particle size relative to similar systems. The latex particles with higher numbers of surface-carboxyl groups were obtained with the higher MAA feed concentrations. Although the particle size decreased and the polymerization rate increased with the increasing PEG-EEM concentration in the emulsion polymerization of styrene, both of them remained roughly constant with the increasing PEG-EEM concentration in the presence of MAA. Received: 21 December 2000 Accepted: 13 July 2000     

Convenient synthesis of novel fluorinated polyurethane hybrid latexes and core-shell structures via emulsion polymerization process with self-emulsification of polyurethane

Novel fluorinated polyurethane hybrid latexes in the size range of 40–50 nm, fluoroalkyl acrylate as fluorinated monomers, with various fluorine content (F% = 9∼26 wt%) were successfully prepared via emulsion polymerization process without traditional emulsifier. The waterborne polyurethane, which was synthesized by using isophronediisocyanate, dimethylol propionic acid, polyethylene glycols, etc., served not only as copolymerizable macromonomer but also as polymeric high molecular weight emulsifier. The structures of polyurethane macromonomer and fluorinated polyurethane were characterized by Fourier transform infrared and H¹-NMR. Particle size, zeta potential, micromorphology of the latex par.ticles, and surface properties were investigated by dynamic light scattering, potential particle size analyzer, transmission electron microscopy, and contact angle measurement, respectively. Results illustrated that the advantage of this process is that the size of fluorinated polyurethane hybrid particle is less sensitive to the composition. Furthermore, it was showed that fluorinated polyurethane latex particles had core-shell structures, especially when the content of fluorine was 26.08 wt%. Moreover, there was an obvious migration of fluorinated groups to the surface during the formation of fluorinated polymer films, although fluorinated groups were covered by polyurethane in latex particles.     

Surface functionalization of polymer latex particles. III. A convenient method of producing ultrafine poly(methylstyrene) latexes with aldehyde groups on the surface

A convenient method of preparing ultrafine poly(methylstyrene) (PMS) latex particles with aldehyde groups on the surface is developed. PMS latexes in the size range 33–81 nm were prepared via microemulsion polymerization, using cetyltrimethylammonium bromide (CTAB) as surfactant. The surface of the PMS latexes was oxidized in the presence of tert-butyl hydroperoxide catalyzed by copper(II) chloride. As the degree of oxidation increased up to 6 h, the amounts of aldehyde group increased. Bigger particles were found to have a slightly higher rate of oxidation than small ones under the same oxidation conditions. The particle size underwent little change during oxidation; thus, the amounts of functional groups and the particle size could be controlled concurrently. Dialysis study of the oxidized PMS microlatexes indicated that the instability of highly oxidized PMS microlatexes was caused by the reduction of total surface charge density due to the presence of carboxylic acid groups. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 2103–2109, 1998     

Comparison of oil-soluble and water-soluble initiation of styrene polymerization in a three-component microemulsion

The polymerization of styrene in three-component oil-in-water microemulsions made with the cationic surfactant dodecyltrimethylammonium bromide is studied by dilatometry and quasielastic light scattering as a function of type and concentration of initiator. Fast polymerization rates, high conversions, and high molecular weight polymers are achieved with both oil-soluble (AIBN) and water-soluble (potassium persulfate) initiators. The rate of polymerization shows initiation and termination intervals, but no constant-rate interval is observed. Stable monodisperse microlatexes are obtained with both types of initiators. For both AIBN and potassium persulfate, polystyrene molecular weight is proportional to initiator concentration [I]^–0.4 and particle radii decrease as [I]^–0.2. Polymerization initiation occurs in or at the microemulsion droplets, and polymer particles grow by recruiting monomer and surfactant from uninitiated swollen micelles.     

Copolymerization of styrene and reactive surfactants in a microemulsion: control of copolymer composition by addition of nonreactive surfactant

The γ-ray-induced copolymerization of styrene and the surfactant monomer (surfmer) (11-acryloyloxy)undecyltrimethylammonium bromide, 1, – with and without the presence of the nonreactive surfactant N-dodecyltrimethyammonium bromide, 2, – was studied in a single-phase (1Φ) oil-in-water microemulsion. Upon exchange of 50 weight percent of 1 against 2 the 1Φ region could be increased to higher styrene content. Upon γ-ray irradiation a copolymer is formed: this copolymer exhibits a larger styrene-to-surfmer ratio than the original monomer mixture. This allowed the styrene-to-surfmer molar ratio in the resulting polymer to be varied from 0:1 to 4.3:1. The larger styrene-to-surfmer ratio originates from the simultaneous formation of homopolymer P-1, which is in accordance with the Candau–Leong–Fitch model of polymerization. Further information on particle size and material properties of the copolymers, which is not accessible by other preparation methods, is also given. Received: 30 July 1999 /Accepted: 24 November 1999     

Formations of polyvinyltoluene microlatexes in quaternary oil in water cetyltrimethylammonium bromide microemulsions

Polymerization of vinyltoluene (VT) in quaternary microemulsions containing cetyltrimethylammonium bromide (CTAB) as the cationic surfactant is studied using laser Raman spectroscopy (LRS) and dilatometry. The influences of water soluble (potassium peroxodisulphate, ammonium peroxodisulphate) and oil soluble (azobisisobutyronitrile, benzoyl peroxide) initiators, monomer, surfactant, cosurfactants (n-alcohol and bifunctional alcohols) and temperature on the rates of polymerization (R _p), energy of activation (Ea), particle diameter (D), number of polymer particles (N _p), molecular weight of polyvinyltoluene (M _v) and number of polymer chains per latex particle (N _pc) are investigated. The dependencies of the kinetic and latex size parameters on the initiators and cosurfactants are discussed in terms of the efficiency of the initiators in initiating the polymerization and on the interfacial partitioning behavior of various cosurfactants. The polymerization mechanism seems to follow Smith Ewart Case II hypothesis with two distinct rate regions. Final polymer microlatexes are found to lie within 10–50 nm as observed by transmission electron microscopy (TEM). Molecular weights are in the range of (1 to 5)×10⁶. Each latex particle contains one to three polymer chains.     

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     

Polymer diffusion in high-M/low-M hard-soft latex blends

This paper describes experiments that investigate the use of low glass transition temperature (T _g) latex particles consisting of oligomer to promote polymer diffusion in films formed from high molar mass polymer latex. The chemical composition of both polymers was similar. Fluorescence resonance energy transfer (FRET) was used to follow the rate of polymer diffusion for samples in which the high molar mass polymer was labeled with appropriate donor and acceptor dyes. In these latex blends, the presence of the oligomer (with M _n = 24,000 g/mol, M _w/M _n = 2) was so effective at promoting the interdiffusion of the higher molar mass poly(butyl acrylate-co-methyl methacrylate; PBA/MMA = 1:1 by weight) polymer (with M _n = 43,00 g/mol, M _w/M _n = 3) that a significant amount of interdiffusion occurred during film drying. Additional polymer diffusion occurred during film aging and annealing, and this effect could be described quantitatively in terms of free-volume theory. This paper is dedicated to Professor Haruma Kawaguchi to honor his many contributions to the field of latex particles and their applications.     

Microemulsion polymerization of acrylamide and styrene: Effect of the structures of reaction media

Isothermal phase diagrams of the system cetyltrimethylammonium bromide (CTAB)/n‐butanol/n‐octane/water were constructed, and the effect of the oil (n‐octane) contents on the microemulsions was studied at 40 °C. We determined the microemulsion structures of two systems, CTAB/n‐butanol/10% n‐octane/water and sodium dodecyl sulfonate (As)/n‐butanol/20% styrene/water, by conductivity measurements to investigate the polymerization of acrylamide and styrene in the two microemulsion systems. The polymerization kinetics of the water‐soluble monomer acrylamide in CTAB micelles and the different CTAB/n‐butanol/10% n‐octane/water microemulsion media [water‐in‐oil (W/O), bicontinuous (BC), and oil‐in‐water (O/W)] were studied with water‐soluble sodium bisulfite as the initiator. The maximum polymerization rate in CTAB micelles was found at the second critical micelle concentration. A mechanism of polyacrylamide formation and growth was proposed. A connection between the structures of the microemulsions and the polymerization rates was observed; the maximum polymerization rate occurred at two transition points, from W/O to BC and from BC to O/W, and the polyacrylamide molecular weights, which depended on the structures of the microemulsions, were also found. A square‐root dependence of the polymerization rates on the initiator concentrations was obtained in CTAB micelles and O/W microemulsion media. The polymerization of the oil‐soluble monomer styrene in different As/n‐butanol/20% styrene/water microemulsion media (W/O, BC, and O/W) was also investigated with different initiators: water‐soluble potassium persulfate and oil‐soluble azobisisobutyronitrile. A similar connection between the structures of the microemulsions and the conversions of styrene in CTAB/n‐butanol/10% n‐octane/water for the polymerization of acrylamide was observed again. The structures of the microemulsions had an important role in the molecular weights and sizes of polystyrene. The polystyrene particles were 10–20 nm in diameter in BC microemulsion media and 30–60 nm in diameter in O/W microemulsion media according to transmission electron microscopy. We determined the solubilization site of styrene in O/W microemulsion drops by ¹H NMR spectra to analyze the results of the microemulsion polymerization of styrene. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3320–3334, 2001     

Ultrasonically induced microemulsion polymerization of styrene

In this paper, ultrasonically induced microemulsion polymerization of styrene was successfully performed, possessing many merits such as high polymerization rate, the formation of small latex particles with a narrow size distribution, the absence of initiator and relatively low surfactant concentration. The monomer conversion reached 70% in 1 h, and the average diameter of polystyrene (PS) latex was about 30 nm which could be prepared with 3% surfactant (sodium dodecyl sulfate, SDS) concentration. The molecular weight of PS was around 10⁶ and the poly-distribution index was 1.06, indicating a very narrow distribution. Several influencing factors were investigated in detail, showing that ultrasonically induced microemulsion polymerization is a new route to prepare PS nanoparticles.     

Semicontinuous heterophase copolymerization of styrene and acrylonitrile

The synthesis of styrene‐acrylonitrile copolymers by semicontinuous heterophase polymerization is reported here. The effect of feed composition at a fixed addition rate of monomer mixture on kinetics, particle size, polymer content, and molar masses, was studied. This process permits the synthesis of nanolatexes containing narrow size‐distribution particles with number‐average diameter (D_n) of about 18 nm, polymer content as high as 23 wt %, and copolymer‐to‐surfactant weight ratios between 23 and 25, depending on monomer feeding rate, which are larger than those reported for microemulsion copolymerization of several comonomers. Copolymers with homogeneous composition similar to the feeding monomers composition were obtained thorough the reaction, which is difficult to achieve by batch polymerization. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

Polymerization of styrene with ionic comonomer,nonionic comonomer,or both

Nanosized polystyrene latexes with high polymer contents were obtained from an emulsifier-free process by the polymerization of styrene with ionic comonomer, nonionic comonomer, or both. After seeding particles were generated in an initial emulsion system consisting of styrene, water, an ionic comonomer [sodium styrenesulfonate (NaSS)] or nonionic comonomer [2-hydroxyethyl methacrylate (HEMA)], and potassium persulfate, most of the styrene monomer or a mixture of styrene and HEMA was added dropwise to the polymerizing emulsion over 6 h. Stable latexes with high polystyrene contents (≤25%) were obtained. The latex particle weight-average diameters were largely reduced (41 nm) by the continuous addition of monomer(s) compared with those (117 nm) obtained by the one-pot polymerization method. Latex particles varied from about 30 to 250 nm in diameters, whereas their molar masses were within 10⁴ to 10⁵ g/mol. The effect of the comonomer concentration on the number of polystyrene particles per milliliter of latex and the weight-average molar masses of the copolymers during the polymerization are discussed. The surface compositions of the latex particles were analyzed by X-ray photoelectron spectroscopy, which indicated that the surface of the latex particles was significantly enriched in NaSS, HEMA, or both. © 2001 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 39: 1634–1645, 2001     

Styrene polymerization in ternary microemulsions: effects of water-soluble and oil-soluble initiators

The polymerization of styrene in ternary microemulsions stabilized by the cationic surfactant tetradecyltrimethylammonium bromide was studied as a function of concentrations of water-soluble (potassium persulfate, KPS) and oil-soluble (AIBN) initiators. At a particular molar ratio of the initiators, similar maximum rates of polymerization can be achieved from using both types of the initiators. In addition, both initiated systems produced microlatexes with similar hydrodynamic radius, number of polymer particles, molecular weight of polystyrene and number of polymer chain per latex particle. But the dependencies of these latex parameters on concentrations of KPS and AIBN may not be the same. The polymerization mechanism appears to be similar, irrespective of using KPS or AIBN. It is discussed in terms of effective radicals produced for the polymerization. While the different dependencies of some latex parameters on concentrations of the initiators are attributed to the different efficiencies of the initiators in producing effective radicals.     

Preaparation of cationic latexes of poly(styrene-CO-butyl acrylate) and their properties evolution in latex dilution

Cationic latexes were prepared through emulsion copolymerization of styrene(St) and butyl acrylate(BA) with a cationic surfactant,cetyl trimethyl ammonium bromide(CTAB).Latex properties,including particle size,size distribution,ζpotential,surface tension and monomer conversion,were determined for latexes prepared with different CTAB amounts. Evolution of these properties during emulsion polymerization was followed in order to understand the mechanism of the particles formation.Results showed that both particle size andζpotential were function of polymerization time and latex solids.Parallel emulsion polymerizations with cationic,anionic charged initiator and charge-free initiators were also carried out,the latex properties were determined at different polymerization time.All these results were attentively interpreted based on the mechanisms of emulsion polymerization,surfactant adsorption and latex particle stabilization.     

Increasing Solid Content in Latexes of Polyacrylamide Nanoparticles Made by Semi-continuous Inverse Heterophase Polymerization

The synthesis of polyacrylamide nanoparticles by semi-continuous inverse heterophase polymerization as a function of feeding rate of monomer aqueous solution is reported here. In this process, a concentrated acrylamide aqueous solution is dosed semi-continuously at various rates over an AOT-toluene solution containing the initiator. Our results indicate that particle size and the viscosimetric molar masses diminish as the dosing rate is slowed down and that smaller particles, as well as lower molar masses, are obtained compared to those produced by batch and semi-continuous microemulsion polymerizations, employing the same concentration of surfactant. Moreover, higher polymer/surfactant ratios are higher compared to those obtained in batch microemulsion polymerization and similar or slightly higher than that in semi-continuous microemulsion polymerization.     

Effect of the structures of microemulsions on chemical reactions

Two kinds of chemical reactions were studied in two different microemulsion systems: cetyltrimethylammonium bromide/1-butanol/10 and 25% n-octane/water and sodium dodecyl sulfonate/1-butanol/20% styrene/water. One reaction is a hydrolysis reaction, in which aspirin and 2,4-dinitrochlorobenzene were used as the hydrolysis substrates. The second reaction is the polymerization of styrene, which was initiated by using two initiators, water-soluble K₂S₂O₈ and oil-soluble 2,2′-azobis(isobutyronitrile), and, at the same time, the polymerization of acrylamide, which was initiated by NaHSO₃, was also studied. All the hydrolysis reaction experimental results show that the hydrolysis is greatly affected by the structures and the structural transitions of microemulsions. The hydrolysis rates are higher in water-in-oil (W/O) microemulsion media and decrease with the addition of water. The rates increase in bicontinuous (BC) microemulsions and decrease in oil-in-water (O/W) microemulsions. The transition points of the hydrolysis rates occurred at the two microemulsion structural transition points from W/O to BC and from BC to O/W. The polymerization relationships between the conversions of styrene, the molecular weights of polystyrene and the water contents of the microemulsion system were obtained. The effects of microemulsion structures on the sizes of the polystyrene particles and on the molecular weights of the polymers are discussed. Polystyrene particles with diameters of 10–60 nm were observed by microscopy. Our experimental polymerization results show that microemulsions are suitable as media for the production of polymers, the molecular weights and the particle sizes of which can be controlled and predicted by variations in microemulsion structures. Received: 11 July 1999/Accepted: 26 July 1999     

The effect of cosurfactants and the initiator concentration on the polymer to surfactant concentration in nanolatexes

The effect of cosurfactant and initiator concentration on the ab initio production of nanolatexes using low surfactant levels was investigated. While the use of cosurfactants (acrylic acid and pentanol) increased the amount of monomer that can be used in styrene‐SDS microemulsion formulations to 13 wt %, high surfactant concentrations are still required, resulting in polymer‐to‐surfactant ratios (Pol/Surf) <1. Latexes with particle size of 30 ± 5 nm were produced upon polymerization of these microemulsions. The Pol/Surf can be significantly increased by increasing the initiator concentration of emulsion polymerization recipes. Particle sizes are comparable with microemulsion latexes, however, less surfactant is required. The reduction in the particle size with higher initiator concentration is attributed to a higher efficiency of particle nucleation and to a higher nucleation rate relative to the rate of monomer transfer. Nanolatexes (particle size < 30 nm) were obtained with 19 wt % solids content and Pol/Surf of 3.6 in ab initio. © 2011 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

High monomer content batch microemulsion polymerization of butyl acrylate initiated with gamma ray

Radiation polymerization of butyl acrylate was performed in a microemulsion stabilized with a mixture of sodium of 12-acryloxy-9-octadecenoic acid and sodium dodecyl sulfate in a weight ratio of 2 at room temperature. BA content in microemulsion can be successfully improved up to 40 wt% with low surfactant concentration (lower than 10 wt%). The resulted stable, translucent microlatex contain particles with average diameter from 28.1 to 38.1 nm with different monomer content. Particle size depends on the dose rate and surfactant concentration. Effects of monomer content and dose rate on the maximum polymerization rate are discussed.