Film formation of polymeric emulsions: Structure set-up and the pinhole effect characterized by microscopic techniques

Drying of emulsions of special polymeric core-shell latexes results in structured films and coatings with advantageous material properties. Here, we focus on so-called “container particles”, consisting of a low viscosity core with a low glass transition (poly(2-ethylhexyl methacrylate), PEtHMA), covered by a thin shell of a cross-linked rubber (poly(n-butyl acrylate), PBA). These particles can be regarded as model emulsions of reactive polymeric oils with a very high colloidal stability. The film formation of these latexes was studied by atomic force microscopy (AFM) in the tapping mode as well as by transmission electron microscopy (TEM). It is shown that the films stay nanostructured after the drying process, i. e. they exhibit both a controlled topography as well as a network superstructure originating from the characteristics of the original dispersions.

TEM allows to detect the whereabouts of the polar stabilizer. Both continous surfactant films as well as inverted micelles are found. A geometrically induced demixing phenomenon is found which enriches the polar components and might be the molecular reason for the so-called pinhole-effect, the failure of water-born coatings in contact with water.     

Synthesis and characterization of poly (n-butyl acrylate)-poly (methyl methacrylate) latex interpenetrating polymer networks by radiation-induced seeded emulsion polymerization

A series of latex interpenetrating polymer networks (LIPNs) were prepared via a two-stage emulsion polymerization of methyl methacrylate (MMA) or mixture of MMA and n-butyl acrylate (n-BA) on crosslinked poly(n-butyl acrylate)(PBA) seed latex using ⁶⁰Co γ-ray radiation. The particles of resultant latex were produced with diameters between 150 and 250 nm. FTIR spectra identified the formation of crosslinked copolymers of PMMA or P(MMA-co-BA). Dynamic light scattering (DLS) showed that with increasing n-BA concentration in second-stage monomers, the particle size of LIPN increased. Transmission electron microscope(TEM) photographs showed that the morphology of resultant acrylate interpenetrating polymer network (IPN) latex varied from the distinct core-shell structure to homogenous particle structure with the increase of n-BA concentration, and the morphology was mainly controlled by the miscibility between crosslinked PBA seed and second-stage copolymers and polarity of P(MMA-co-BA)copolymers. In addition, differential scanning calorimeter (DSC) measurements indicated the existence of reinforced miscibility between PBA seed and P(MMA-co-BA)copolymer in prepared LIPNs.     

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.     

Synthesis of poly(vinylidene chloride)-based composite latexes by emulsion polymerization from epoxy functional seeds for improved thermal stability

Poly(glycidyl methacrylate-co-butyl methacrylate)/poly(vinylidene chloride-co-methyl acrylate) (poly(GMA-co-BMA)/poly(VDC-co-MA)) composite latexes have been successfully synthesized via a two-stage emulsion polymerization process. In a first step, emulsion copolymerization of GMA and BMA was carried out in optimized conditions (low temperature, neutral pH, starved-feed conditions) to both limit the hydrolysis of epoxy groups and obtain small particle size (typically 30-50 nm size range). Composite latexes were then obtained by a second-stage seeded copolymerization of VDC and MA in the presence of tetrasodium pyrophosphate to control the pH and reach high molecular weight, leading to partial encapsulation of the seed particles (snow-man morphology, in agreement with theoretical expectations). Thermogravimetric analyses performed on the resulting composite particles showed that the epoxy-functionalized seed polymer behaved as an efficient thermal stabilizer of PVDC.     

Synthesis of titania/polymer core-shell hybrid microspheres

Monodisperse titania/polymer core-shell microspheres were prepared by a two-stage reaction with titania as core and poly(ethyleneglycol dimethacrylate) (PEGDMA) as shell, in which the titania cores were synthesized by a sol-gel method and subsequently grafted with 3-trimethoxysilyl methacrylate as the first-stage reaction to incorporate the vinyl groups on the surface of inorganic core. The PEGDMA shell was then encapsulated over the MPS-modified titania core by distillation precipitation polymerization of ethyleneglycol dimethacrylate in neat acetonitrile during the second-stage polymerization via capture of the radicals of EGDMA with the aid of the reactive vinyl groups on the surface of inorganic core without any stabilizer or surfactant. The shell thickness of the core-shell hybrid microspheres was controlled by the feed of EGDMA monomer during the polymerization. The resultant titania particles and core-shell microspheres were studied by transmission electron microscopy, Fourier-transform infrared spectra, X-ray photoelectron spectroscopy, and thermogravimetric analysis.     

Morphology control of magnetic latex particles prepared from oil in water ferrofluid emulsion

The use of magnetic latex particles as solid support in biomedical applications is favourable when homogeneous and well-defined core–shell polymer particles are used. Accordingly, this paper concerns with the synthesis of magnetic poly(styrene–divinylbenzene) latex particles using emulsion polymerization of styrene (St) and divinylbenzene (DVB) monomers in the presence of preformed oil in water organic ferrofluid emulsion droplets as seed. The key parameters which affect on formation and morphology of the prepared magnetic latexes were investigated, including type of magnetic emulsion, St/DVB monomers ratio, DVB amount, type of initiator and surfactant nature. In this study, two different magnetic emulsions were used, low and high octane content magnetic emulsions. The magnetic emulsions were stabilized using different types of surfactants including AP, Triton X 405 and SDS. In addition, four different initiators, including AIBN, V50, ACPA and KPS were examined. The morphology of the prepared magnetic latexes was investigated using transmission electron microscopy. In addition, particle size and size distribution, magnetic content and magnetic properties of the prepared magnetic latexes were also examined, using various techniques, e.g. dynamic light scattering, thermal gravimetric analysis and vibrating sample magnetometer, respectively. The results showed that the morphology type (Janus like, moon like and/or core–shell) of the prepared magnetic latex particles could be controlled depending mainly on the used formulation. In fact, the use of styrene monomer leads to anisotropic morphology. Whereas, the progressive use of DVB in presence of KPS intiator leads to a well-defined magnetic core and polymer shell structure.

Mechanistic studies on particle nucleation in the batch emulsion polymerisation of<Emphasis Type="Italic"> n</Emphasis>-butyl acrylate containing multifunctional monomers

This paper reports the mechanistic details concerning the synthesis of crosslinked poly(n-butyl acrylate) dispersions intended to be used as seeds in the preparation of core-shell emulsions. The influence of crosslinking comonomers and the amount and type of surfactants on the kinetics, particle nucleation, particle size and particle size distribution in the batch emulsion polymerisation of n-butyl acrylate (BA) is explored. In the case of EGDA (ethylene glycol diacrylate) crosslinker the particle number decreased with increasing crosslink density, whereas the opposite trend was observed in the case of m-diisopropenylbenzene (m-DIPB) in the presence and absence of the surfactant sodium dodecyl sulfate (SDS). The observed behaviour is mainly attributed to the variation in the aqueous phase kinetics caused by the water solubility of the comonomer, which influences the formation rate of precursor particles during the nucleation stage. Only for the less water soluble crosslinker, DIPB, could the increase of particle number be explained within the Smith–Ewart theory by assuming prolonged nucleation due to reduced swelling of growing particles with monomer as a result of the crosslinking reaction.Abbreviations EGDA ethylene glycol diacrylate - m-DIPB meta-diisopropenylbenzene - SDS sodium dodecyl sulfate - PBA poly(n-butyl acrylate) - AFFF asymmetric field flow fractionation - MALLS multiangle laser light scattering - CMC critical micelle concentration     

Emulsifier-free emulsion copolymerization of styrene and butyl acrylate. I. Kinetic studies in the absence of surfactant

Soapless emulsion copolymerization of styrene (S) and n-butyl acrylate (BuA) has been investigated using two types of initiator and different comonomer feed mixtures. When using K₂S₂O₈ as initiator, the particle size and size distribution of the final latexes (500 nm and 1.003, respectively) is not significantly affected by the comonomer feed composition, whereas the molecular weight and surface characteristics were found to sharply change at high butyl acrylate content. Based on the most probable particle nucleation mechanism and type of chain termination in the monomer swollen particles, a tentative explanation of these results has been proposed. Replacing persulfate by a carboxylic initiator (4-4′-azobiscyanopentanoic acid) results in the formation of stable particles as α observed with the persulfate, provided the aqueous phase pH is fixed in between 6 and 7. Results on the initiator residue location as a function of the conversion point out that the particle flocculation mechanism is strongly significant in the preparation of such latexes.     

Synthesis of hydroxy- and dihydroxy-end-capped poly(<Emphasis Type="Italic">n</Emphasis>-butyl acrylate)s and their use as reactive stabilizers for the preparation of polyurethane latexes

Well-defined hydroxy end-functionalized poly(n-butyl acrylate)s (PBA-OH and PBA-(OH)₂), were prepared by atom transfer radical polymerization (ATRP) and used as reactive stabilizers for the preparation of polyurethane in dispersed medium. PBA-OH was obtained by end-capping the growing poly(n-butyl acrylate) chains with allyl alcohol added in excess at the end of the polymerization. The two hydroxyl functions of PBA-(OH)₂ were fixed at one end of the poly(n-butyl acrylate) chains either by initiation or by chain-end functionalization reactions. The latter were protected under the form of cyclic acetal and attached either to the initiator bearing a secondary bromine or to the terminating agent carrying a poorly reactive vinylic unsaturation. PBA-OH and PBA-(OH)₂ have been successfully used as reactive stabilizers (surfmers) to prepare core-shell polyurethane particles in dispersed medium. The final particle size was found to be very much dependent to parameters such as the molar mass, concentration and valence of the reactive stabilizer as well as the manner of addition of the reactants during the procedure.     

Kinetic studies on the n-alkyl acrylate polymerization

Kinetic studies on the polymerization of n-butyl acrylate and n-octadecyl acrylate in toluene at 70°C with benzoyl peroxide as initiator are reported. High monomer orders of 1.55 and 1.75 were obtained for n-butyl and n-octadecyl acrylates, respectively. Though the initiator order in butyl acrylate polymerization was 0.5, the octadecyl acrylate polymerization showed less than square root initiator order. The activation energy for the polymerization of both the acrylates was determined. Autoacceleration was found even at low conversions. The autoacceleration was influenced by both monomer and initiator concentration. Molecular weight data was presented in support of the gel effect. © 1992 John Wiley & Sons, Inc.     

Synthesis of SiO2/poly(styrene‐co‐butyl acrylate) nanocomposite microspheres via miniemulsion polymerization

A series of SiO₂/poly(styrene‐co‐butyl acrylate) nanocomposite microspheres with various morphologies (e.g., multicore–shell, normal core–shell, and raspberry‐like) were synthesized via miniemulsion polymerization. The results showed that the morphology of the composite latex particles was strongly influenced by the presence or absence of the soft monomer (butyl acrylate), the particle sizes of the silica, and the emulsifier concentrations. The incorporation of the soft monomer helped in forming the multicore–shell structure. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 3202–3209, 2006     

Synthesis and characterization of a novel silane-based vinylic monomer and its application in the multilayer core-shell latex

A novel monomer methacrylamidophenoxy dimethylsiloxy phenylphthalimide was obtained by a reaction of 4,4′-bis-aminophenoxy dimethylsilane, phthalic anhydride and methacryloyl chloride. Then it has been used in the synthesis of phase-separated polymer latex with a multilayer core-shell morphology by surface cross-linking emulsion polymerization. Poly(butyl acrylate) was used for the seed and the core of the latex, the inner shell was poly(butyl acrylate/styrene) cross-linked with divinylbenzene to avoid phase inversion, and the poly(methyl methacrylate/butyl acrylate/methacrylamidophenoxy dimethylsiloxy phenylphthalimide) was the outer shell. The structural elucidation of monomer was carried out by elemental analysis, FTIR, ¹H NMR, and ¹³C NMR spectroscopic techniques. The morphology and glass transition temperatures of the synthesized product were investigated by transmission electron microscopy and differential scanning calorimetry, respectively. The multilayer core-shell structure was clearly shown in TEM micrographs, and the three-phase separation was confirmed by DSC analysis. The obtained results demonstrated that the average particle size is 81.8, 108 and 132 nm for the core, core-shell and multilayer core-shell particles, which agrees with the TEM micrograph measurement of 75, 103, and 131 nm, respectively.     

Synthesis and characterization of core-shell latexes with microscopic and solid-state NMR methods

Core-shell latexes based on poly (butyl acrylate) and poly(methyl methacrylate) were synthesized with varying shell content at high and low temperature. Electron microscopy combined with advanced solid-state NMR techniques have been used to investigate the entire structure and the interphase morphology in these core-shell particles depending on the reaction conditions. Distinct differences of the interphase morphology were found for particles synthesized at high and low temperature.     

Synthesis of tertiary-butyl acrylate polymers and preparation of diblock copolymers using atom transfer radical polymerization

The synthesis of tert-butyl acrylate by atom transfer radical polymerization (ATRP) is reported. This polymer was prepared using FeCl₂ · 4H₂O(PPh₃)₂ catalyst system in conjunction with methyl 2-bromopropionate as initiator, in bulk and in solution using acetone as a solvent. The addition of solvent was necessary in order to decrease the polymerization rate and to afford low polydispersity polymers. The number-average molecular weights of the resulting polymers increased in direct proportion to the monomer conversion, and the polydispersities (M_w/M_n) were as low as 1.2. In addition, the preparation of an AB diblock copolymer of poly (n-butyl methacrylate)-block-poly (tert-butyl acrylate) by ATRP is reported. The resulting polymers and copolymers were characterized by means of size exclusion chromatography and ¹H-NMR Spectroscopy.     

Shape of the particles produced by seeded dispersion polymerization of styrene

In this work, seeded dispersion polymerization of styrene was carried out in the presence of various types of seed particles. We found that in the case of polystyrene and poly(methyl methacrylate) seeds, the shape of the resulting particles remained spherical. For styrene/poly(nbutyl methacrylate) (PnBMA) and styrene/poly(lauryl methacrylate) seeding particles, raspberry like particles were produced along with those of occluded morphology. We studied the effects of various polymerization factors such as concentrations of a stabilizer, an initiator, and a monomer, a weight ratio of methanol to water, a type of initiator, weight ratio of styrene to Pn-BMA seed particles, and polymerization temperature on the formation of these raspberry-like particles. The experimental results showed that the increase of concentrations of the initiator and the stabilizer as well as that of methanol favors the formation of such particles by increasing their surface roughness. An increase of the temperature of polymerization had the same effect on the morphology of resulting product. We hypothesized that the nucleation and growth of specifically fine-structured polystyrene domains on the surface of the Pn-BMA particles guides the formation of non-linear morphology during seeded polymerization in colloidal solution.     

“Reviews in Macromolecular Chemistry”

Abstract

In the homopolymerization and copolymerization of vinyl acetate with dibutyl maleate in the presence of the sodium salt of sulfosuccinic acid semiester with nonylphenol ethoxylated with 25 mol ethylene oxide, the initiator, potassium persulfate (KPS), has a higher decomposition rate than in water even after consumption of monomer. The value of the initiator productivity, P, defined as the ratio of the formed polymer over the decomposed KPS, decreases as the batch stage of the semicontinuous process proceeds. The initiator reacts either with free surfactant molecules or with those grafted on poly(vinyl acetate) chains. During the stage of continuous addition of monomers and KPS, a smaller initiator concentration no longer provides proportionality between the added and decomposed amounts of initiator. The increased monomer concentration at the beginning of continuous addition causes the rate of KPS splitting to decrease as most of the surfactant is bound to the surface monomer/polymer particles.     

Dispersion copolymerization of methyl methacrylate and n-butyl acrylate

In the dispersion copolymerization of methyl methacrylate (MMA) and n-butyl acrylate (BA), the particle size increases with an increasing MMA fraction in the comonomer. The power dependence of the particle size on the initiator concentration also increases with an increasing MMA concentration. Similar to what can be found in the homopolymerizations, two populations can be observed in the molecular weight distributions of the copolymers. Core–shell structured particles with a poly(methyl methacrylate)-rich core and a poly(n-butyl acrylate)-rich shell result from the copolymerizations because of the significantly different reactivity ratios. The reaction rates of the dispersion copolymerization are lower than those of the homopolymerization of BA and close to or lower than those of the homopolymerization of MMA, depending on the ratio of the monomers. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 2105–2112, 2007     

The formation of “inverted” core-shell latexes

It has been found that when hydrophobic monomers are polymerized in the presence of highly hydrophilic polymer seed particles, the second-stage hydrophobic polymers form cores surrounded by the first-stage hydrophilic polymers, resulting in “inverted” core-shell latexes. The formation of core-shell morphology by this inversion process has been found to be dependent on the hydrophilicity and molecular weight of the first-stage hydrophilic polymers and the extent of phase separation between the two polymers involved. Particle morphology has been examined by electron microscopy, surface acid titration, alkali swelling of particles, and surface reactivity.     

Adding magnetic ionic liquid monomers to the emulsion polymerization tool‐box: Towards polymer latexes and coatings with new properties

Magnetic ionic liquid monomers were synthesized and then polymerized to get magnetic polymer latexes and films. First, a series of 1‐vinyl‐3‐dodecyl‐imidazolium monomers having metal halides counter‐anions such as FeCl₃Br^?, CoCl₂Br^?, and MnCl₂Br^? were synthesized. These ionic liquid monomers were first homopolymerized to lead to magnetic poly(ionic liquids) and characterized. Secondly, magnetic latexes were synthesized by using the magnetic ionic liquids as surfmers (surfactant + monomer) in the emulsion polymerization of methyl methacrylate/n‐butyl acrylate. It was found that the powders obtained by freeze‐drying the latexes presented a paramagnetic behavior with weak antiferromagnetic interactions between the adjacent metal ions. Although the ratio of magnetic ionic liquid/monomer was only 2% these poly(methyl methacrylate‐co‐butyl acrylate) powders and latexes responded to a magnetic field due to the surfmer paramagnetic nature. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016 , 54, 1145–1152     

Synthesis of urethane—acrylic multi-block copolymers via electrochemically mediated ATRP

The electrochemically mediated atom transfer radical polymerisation (eATRP) of n-butyl acrylate was investigated under a variety of catalyst concentrations. Poly(n-butyl acrylate)-block-polyurethane-block-poly(n-butyl acrylate) copolymers were prepared via electrochemically mediated atom transfer radical polymerisation (eATRP) using only 7 × 10^?6 mole % of Cu^II complex. The successful chain extension and formation of penta-block copolymers confirmed the living nature of the poly(alkyl acrylates) prepared by eATRP. In this work, the tri-block and penta-block urethane-acrylate copolymers were synthesised for the first time by using tertiary bromine-terminated polyurethane macro-initiators as transitional products reacting with n-butyl acrylate, and subsequently with tert-butyl acrylate in the presence of the Cu^IIBr₂/TPMA catalyst complex. The results of ¹H NMR spectral studies support the formation of tri-block poly(n-butyl acrylate)-block-polyurethane-block-poly(n-butyl acrylate) copolymers, and penta-block poly(tert-butyl acrylate)-block-poly(n-butyl acrylate)-block-polyurethane-block-poly(n-butyl acrylate)-block-poly(tert-butyl acrylate) copolymers.