Kinetics of the potassium persulfate-initiated inverse emulsion polymerization of sodium acrylate solutions

The kinetics of the K₂S₂O₈-initiated inverse emulsion polymerization of aqueous sodium acrylate solutions in kerosene with Span 80 as the emulsifier has been studied. The conversion-time curves are S-shaped. The following expressions have been obtained for the maximum rate of polymerization and the molecular weight of the polymers under the experimental conditions investigated: R_max ∞ [K₂S₂O₈]^0.78[sodium acrylate]^1.5[Span 80]^0.1, (OVERLINE)M(/OVERLINE)_u ∞ [K₂S₂O₈]^−0.37[sodium acrylate]^2.9[Span 80]^−0.2. The activation energy for the maximum rate of polymerization is 94.8 kJ mol^−1. The results suggest a monomer–droplet–nucleation mechanism for the system studied. © 1996 John Wiley & Sons, Inc.     

Particle formation and coagulation in the seeded semibatch emulsion polymerization of butyl acrylate

Particle formation and coagulation in the seeded semibatch emulsion polymerization of butyl acrylate were studied under monomer‐starved conditions. To investigate the importance of the kinetics of the water phase in the nucleation process, the monomer feed rate was used as a variable to alter the monomer concentration in the aqueous phase. The emulsifier concentration in the feed was employed to alter the particle stability. Particle formation and coagulation were discussed in terms of critical surface coverage ratios. Particle coagulation occurred if the particle surface coverage dropped below θ_cr1 = 0.25 ± 0.05. The secondary nucleation occurred above a critical surface coverage of θ_cr2 = 0.55 ± 0.05. The number of particles remained approximately constant if the particle surface coverage was within θ_cr1 = 0.25 < θ < θ_cr2 = 0.55. This surface coverage band is equivalent to the surface tension band of 42.50 ± 5.0 dyne/cm that is required to avoid particle formation and coagulation in the course of polymerization. The kinetics of the water phase was shown to play an important role during homogeneous and micellar nucleations. For any fixed emulsifier concentration in the feed and above θ_cr2, the number of secondary particles increased with monomer concentration in the aqueous phase. Moreover, the presence of micelles in the reaction vessel is not the only perquisite for micellar nucleation to occur, a sufficient amount of monomer should be present in the aqueous phase to enhance the radical capture by partially monomer‐swollen micelles. The rate of polymerization increased with the surfactant concentration in the aqueous phase. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3612–3630, 2000     

Preparation of PEG-modified urethane acrylate emulsion and its emulsion polymerization

In order to improve stability and reduce droplet size, the PEG-modified urethane acrylates were synthesized by the reaction of polyethylene glycol (PEG) with residual isocyanate groups of urethane acrylate to incorporate hydrophilic groups into the molecular ends. The droplet sizes of the PEG-modified urethane acrylate emulsions were much smaller than those of unmodified urethane acrylate emulsions at the same surfactant composition, and the droplet sizes of these emulsions were significantly effected not by surfactant compositions and types, but by the reaction molar ratio of PEG, because the urethane acrylate containing polyoxyethylene groups as terminal groups aided the interfacial activity of surfactant molecules and acted as a polymeric surfactant. The actions of PEG-modified urethane acrylate were confirmed by the investigation of adsorption of urethane acrylate in a water/benzene interface.For polymerization of emulsions, the stability of emulsion in the process of emulsion polymerization was changed by the type of surfactant or initiator. In the case of emulsion polymerization with a water soluble initiator (K₂S₂O₈), the emulsions prepared using TWEEN 60 were broken in the process of polymerization. However, polymerization of these emulsions could be carried out using an oil soluble initiator (AIBN). The conversion of emulsion polymerization changed with the type of urethane acrylates, that is, the reaction molar ratio of PEG to 2-HEMA.     

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

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

Emulsion polymerization of butyl acrylate: Spin trapping and EPR study

The propagating radical in the emulsion polymerization reaction of butyl acrylate was detected by Electron Paramagnetic Resonance (EPR) spectroscopy using two spin-trapping agents, 2-methyl-2-nitrosopropane (MNP) and α-(4-pyridyl 1-oxide)-N-tert-butylnitrone (PyOBN). Through analysis of hyperfine structure of the spectra obtainedfrom the trapped radicals, the propagating radical is inferred to be the well known acrylate radical, ? [CH₂? CH(COOC₄H₉)]_n? CH₂? CH(COOC₄H₉)? . © 1994 John Wiley & Sons, Inc.     

Crosslinking network structure governing particle shape and size distribution by one-step emulsion polymerization in the presence of particle coagulation

In this study, sub-200?nm, crosslinked latex particles with a narrow particle size distribution were prepared by one-step emulsion polymerization in the presence of particle coagulation. The relationship between the particle shape and particle coagulation was investigated by varying the time of crosslinking network structure formation and particle coagulation. Particles with irregular shapes such as doublet, triplet, and ellipsoid were obtained using divinylbenzene (DVB) and ethylene glycol dimethacrylate (EGDMA) as the crosslinking agents, because the crosslinking network structure of particles was formed before the particle coagulation. In contrast, latex particles with a uniform spherical shape were also prepared using triallyl isocyanurate (TAIC) or dihydrodicyclopentadienyl acrylate (DCPA) as the crosslinking agents by delaying the time of crosslinking network structure formation. Alternatively, uniform spherical latex particles were prepared by bringing forward the particle coagulation time using cationic initiator, 2, 2′-azobis (2-methylpropionamidine) dihydrochloride (AAPH). This study presents a new idea that would further broaden the application of particle coagulation in emulsion polymerization.     

Butyl acrylate and vinyl acetate semicontinuous emulsion copolymerizations: study of stabilization performance

The use of small amounts of carboxylic monomers in industrial recipes with high solids content enhances colloidal stability due to the presence of carboxylic groups on the outer surface of the polymer particles. Understanding the relationship between several different but interdependent phenomena, including particle nucleation, kinetics, particle aggregation, monomer type, solids content, the role of the carboxylic monomer and the influence of reaction temperature may improve the control over particle size and latex stability. In this work, the kinetics and stabilization performance of semicontinuous vinyl acetate (VA) and butyl acrylate (BA) emulsion copolymerization reactions are studied under different reaction temperatures, acrylic acid (AA) concentrations, solids contents and monomer feed compositions. Results show that choosing optimal AA concentrations and reaction temperatures are key factors in order to enhance the stabilization performance in semicontinuous VA/BA emulsion copolymerization.     

Butyl acrylate RAFT polymerization in miniemulsion

Few successes about butyl acrylate (BA) RAFT miniemulsion homopolymerization were reported, even though styrene, methyl methacrylate, and vinyl acetate had been successfully applied in reversible addition fragmentation transfer (RAFT) miniemulsion polymerization. In this article, four types of RAFT agent with various designed R and Z groups [benzyl dithioisobutyrate (BDIB), 1-phenylethyl phenyldithioacetate (PEPDTA), cumyl dithioisobutyrate (CDIB), benzyl dithiobenzoate] were used to mediate BA miniemulsion polymerization using the conditions (5 wt % hexadance and sodium dodecyl sulfate) effective for styrene and methyl methacrylate systems. All four types of the RAFT agents effectively control over the bulk polymerization. In contrast, only BDIB resulted in a rather narrow molecular weight distribution in the miniemulsion polymerization. A pronounced inhibition and rate retardation were observed in both bulk and miniemulsion polymerizations mediated by CDIB and benzyl dithiobenzoate. When compared with the bulk polymerization, a much longer inhibition period (over eight times) was observed in the CDIB-mediated miniemulsion polymerization. It was concluded that only the RAFT agent with the primary R group and Z group with less stabilizing ability to the intermediate radicals is effective to mediate BA miniemulsion polymerization in terms of achieving a narrow molecular weight distribution and short inhibition period. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 2304–2315, 2007     

On the evolution of the rate of polymerization,number and size distribution of particles in styrene emulsion polymerization above CMC

This work is an extension of a communication reported by two of the authors [Carro and Herrera‐Ordoñez, Macromol Rapid Commun 2006, 27, 274], where bimodal particle size distributions (PSD), obtained by asymmetric flow‐field flow fractionation (AFFF, AF⁴), were taken as evidence of certain degree of stability of primary particles. Now, emulsion polymerizations of styrene were performed under conditions employed before by other researchers, intending to examine if the behavior observed is general. The number of particles (N) and PSD were studied by means of dynamic light scattering and AF⁴. By the later, bimodal PSDs were detected in all cases, where the population corresponding to primary particles (diameter <20 nm) depends on reaction conditions. Regarding N, AF⁴ results show that it is constant during interval II, in contrast to DLS results. Primary particle coagulation was evidenced as minimums in N evolution and the rate of polymerization curves, monitored by calorimetry and gravimetry, which are enhanced when higher particle number is generated and/or the ionic strength is increased. These results suggest that particle coagulation is not as extensive as it would be expected according to the coagulative theory. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 3152–3160, 2010     

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.     

Effect of temperature on styrene emulsion polymerization in the presence of sodium dodecyl sulfate. II

The batch emulsion polymerization kinetics of styrene initiated by a water‐soluble peroxodisulfate at different temperatures in the presence of sodium dodecyl sulfate was investigated. The curves of the polymerization rate versus conversion show two distinct nonstationary‐rate intervals and a shoulder occurring at a high conversion, whereas the stationary‐rate interval is very short. The nonstationary‐state polymerization is discussed in terms of the long‐term particle‐nucleation period, the additional formation of radicals by thermal initiation, the depressed monomer‐droplet degradation, the elimination of charged radicals through aqueous‐phase termination, the relatively narrow particle‐size distribution and constant polydispersity index throughout the reaction, and a mixed mode of continuous particle nucleation. The maximum rate of polymerization (or the number of polymer particles nucleated) is proportional to the rate of initiation to the 0.27 power, which indicates lower nucleation efficiency as compared to classical emulsion polymerization. The low activation energy of polymerization is attributed to the small barrier for the entering radicals. The overall activation energy was controlled by the initiation and propagation steps. The high ratio of the absorption rate of radicals by latex particles to the formation rate of radicals in water can be attributed to the efficient entry of uncharged radicals and the additional formation of radicals by thermally induced initiation. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 1477–1486, 2000     

Kinetics of styrene emulsion polymerization in the presence of montmorillonite

The effect of the pristine sodium montmorillonite (Na⁺-MMT) on the styrene emulsion polymerizations with different concentrations of SDS ([SDS]) was investigated. At constant [SDS], the polymerization rate is faster for the run with 1 wt.% Na⁺-MMT compared to the counterpart without Na⁺-MMT. Micelle nucleation predominates in the polymerizations with [SDS] ≧ 13 mM. On the other hand, the contribution of the polymerization associated with the Na⁺-MMT platelets increases significantly when [SDS] decreases from 13 to 9 mM. At [SDS] (e.g., 2 mM) < CMC, homogeneous nucleation controls the particle formation process and polymerization kinetics. Moreover, the contribution of the Na⁺-MMT platelets that act as extra reaction loci to the polymerization kinetics is even comparable to the run in the absence of Na⁺-MMT. The resultant polymer particle size, polymer molecular weight and zeta potential were characterized and a preliminary model was developed to qualitatively study the differences between the polymerizations in the presence and absence of 1 wt.% Na⁺-MMT.     

Emulsion copolymerization of butyl acrylate with cationic monomer using interfacial redox initiator system

The polymerization kinetics of butyl acrylate/[2‐(methacryloyoxy)ethyl]trimethyl ammonium chloride (BA/MAETAC) macroemulsion and miniemulsion copolymerizations was investigated with cumene hydroperoxide/tetraethylenepentamine as a redox initiator system. The postulate of an interfacial copolymerization with the two‐component redox initiator system (one hydrophobic and the other hydrophilic) was confirmed. Adding MAETAC had a complex effect on the polymerization kinetics of BA. The influence was ascribed to variations in the nucleation mechanism, which were dependent on the level of MAETAC, and the polymerization method (macroemulsion vs miniemulsion). It was proposed that at the beginning of a macroemulsion copolymerization with high MAETAC composition the micellar copolymerization occurred, which controlled the nucleation process. The hydration properties of the latex were used to characterize the copolymer composition. The composition of the copolymer from the interfacial polymerization was very heterogeneous. The copolymer composition was lower in BA when there was an increase in BA conversion or the particle size. Adding salt increased the MAETAC content and decreased the BA content in the copolymer. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2696–2709, 2001     

Branched polymers through redox emulsion polymerization using peroxide monomer as the branching agent

Redox emulsion polymerization to branched vinyl polymers in the presence of 2-(tert-butylperoxy)ethyl methacrylate (BPEMA), ferrous sulfate, and sodium formaldehyde sulfoxylate (SFS) is reported in this paper. The peroxide monomer BPEMA containing alkyl peroxide was designed for high stability during preparation and storage. Nuclear magnetic resonance spectroscopy (NMR), Raman, and triple-detection size-exclusion chromatography (TD-SEC) measurements were used to reveal the polymerization procedure and provide evidence of branching structure. In the case of polymerization at St₁₀₀-BPEMA_1.0-FeSO_{4 0.5}-SFS_0.2, the molecular weight increased and decreased with conversion below and above 75% monomer conversion, respectively. The decreasing of molecular weight with monomer conversion came from the increased viscosity of the micelle, which makes it difficult for the formed macromolecules containing vinyl group to participate into polymerization. Finally, the molecular weight reached a value of M_{n. SEC} = 439,200 g/mol at 92.2% conversion. In addition, the Zimm branching factor, g', also decreased and increased with conversion below and above 60% conversion, respectively, and then the g' finally attends a value of 0.41, showing high degree of branching. Branched poly(methyl methacrylate) was also prepared through this strategy, showing a versatile approach to branched vinyl polymers.     

Evolution of multimodal particle size distribution in vinyl acetate/butyl acrylate emulsion copolymerizations

This article presents a study on the engineering of multimodal distributions in semibatch emulsion polymerizations with nonionic surfactants. Various methods of producing multimodal distributions are demonstrated, and the sensitivity of the process to the properties of the reagents are analyzed. A test‐bed emulsion polymerization system, equipped with instrumentation to measure particle size distribution (capillary hydrodynamic fractionator) and monomer conversion (densitometer and flow meters), is used for this purpose. The process is monitored and controlled with an industrial distributed control system, which enables the automated operation of the process through sequential or logic controllers operating over lower level proportional integral derivative controllers. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 2232–2249, 2003     

The polymerization rate of freshly nucleated particles during emulsion polymerization with micellar nucleation

A simple procedure was developed to account for the contribution of freshly nucleated particles to the total polymerization rate during micellar nucleation. It has been shown that the polymerization rate of the freshly nucleated particles cannot be described by a steady-state solution for a radical population balance over the particle size distribution, i.e., the classical Smith-Ewart recursion relation. Once nucleated, the particles grow for a significant period of time with one radical before either radical desorption or radical absorption, followed by instantaneous bimolecular termination, occur. For most emulsion polymerizations, radical desorption is the dominant process for radical loss of the freshly nucleated particles. A relation for the mean time that the freshly nucleated particles grow with one radical was derived. © 1996 John Wiley & Sons, Inc.     

An isotachophoresis for the microdetermination of potassium persulphate as initiator in emulsion polymerization

An isotachophoresis (IP) was applied to determine the decomposition rate of potassium persulphate (KPS) as initiator in emulsion polymerization, in comparison with conventional iodometry and ferrometry. For the exact determination, the latter methods needed several milliliters of the emulsion pipetted from the polymerization system, whereas IP did only a few microliters. Moreover, the amount of sulphuric acid produced as the decomposition by-product was simultaneously determined by IP, which is impossible for iodometry and ferrometry.Part CIV of the series Studies on Suspension and Emulsion.     

Kinetics of the seeded semicontinuous emulsion copolymerization of methyl methacrylate and butyl acrylate

The effect of a chain‐transfer agent (CTA) on the kinetics and molecular weight distribution of the methyl methacrylate/butyl acrylate semicontinuous emulsion polymerization was investigated. The dodecanethiol had a slight effect on the reaction rate but significantly affected the secondary nucleation. The effect of the CTA concentration on the gel formation and the effect of the reaction conditions on the mass‐transfer limitations of the CTA are discussed. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 367–375, 2000     

Effect of solvent on the rate constants in solution polymerization. Part I. Butyl acrylate

An experimental study was performed to estimate the value of the lumped kinetic constant k_p/k. This quantity was evaluated using the well‐known conversion vs. time approach in dilute solutions using both azo‐bis‐isobutyronitrile and benzoyl peroxide (AIBN and BPO), and two different solvents (toluene and ethyl acetate) at 60°C. It was demonstrated that if one uses the classic model for homopolymerization kinetics, the value of the lumped rate constant depends very strongly on the concentration of the monomer in the solution, decreasing as the solution becomes more and more dilute. This result was observed for both initiators and both solvents, and found to be independent of initiator type, but slightly more pronounced for toluene than for ethyl acetate. The number‐ and weight‐average molecular weights of the different polymers were also measured, and excellent agreement was found between the measured and modeled values. It was demonstrated that there was a practically linear relationship between the value of the lumped constant and the square root of the number‐average chain length. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 571–588, 1999     

On the emulsion polymerization of styrene in the presence of a nonionic emulsifier

The batch emulsion polymerization kinetics of styrene (St) initiated by a water-soluble peroxodisulfate in the presence of a nonionic emulsifier was investigated. The polymerization rate versus the conversion curves showed two nonstationary rate intervals, two rate maxima, and Smith–Ewart Interval 2 (nondistinct). The rate of polymerization and number of nucleated polymer particles were proportional to the 1.4th and 2.4th powers, respectively, of the emulsifier concentration. Deviation from the micellar nucleation model was attributed to the low water solubility of the emulsifier, the low level of the micellar emulsifier, and the mixed modes of particle nucleation. In emulsion polymerizations with a low emulsifier concentration, the number of radicals per particle and particle size increased with increasing conversion, and the increase was more pronounced at a low conversion. By contrast, in emulsion polymerizations with a high emulsifier concentration, the number of radicals per particle decreased with increasing conversion. This is discussed in terms of the mixed models of particle nucleation, the gel effect, and the pseudobulk kinetics. The formation of monodisperse latex particles was attributed to coagulative nucleation and droplet nucleation for the polymerizations with low and high emulsifier concentrations, respectively. The effects of the continuous release of the emulsifier from nonmicellar aggregates and monomer droplets, the close-packing structure of the droplet surface, and the hydrophobic nature of the emulsifier on the emulsion polymerization of St are discussed. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4422–4431, 1999