Emulsion and miniemulsion polymerizations with an oil‐soluble initiator in the presence and absence of an aqueous‐phase radical scavenger

Butyl acrylate conventional emulsion (macroemulsion) and miniemulsion polymerizations were carried out with an oil‐soluble initiator (azobisisobutyronitrile) in the presence or absence of an aqueous‐phase radical scavenger. For macroemulsion polymerization, in the presence of an aqueous‐phase radical scavenger, no particle nucleation occurred, whereas in the absence of an aqueous‐phase radical scavenger, particle nucleation proceeded as expected. For miniemulsion polymerization, the rate of polymerization was much higher in the absence of an aqueous‐phase radical scavenger than in its presence. Furthermore, in the absence of an aqueous‐phase radical scavenger, the miniemulsion polymerization rate increased with reduced droplet size, whereas in the presence of an aqueous‐phase radical scavenger, the trend was reversed. It is concluded that (1) for macroemulsion polymerization, the contribution from free radicals originating in the aqueous‐phase is predominant in the micellar nucleation of particles; (2) free radicals originating in the particle phase contribute to the rate of polymerization and the contribution increases with an increase in the particle size; and (3) for polymer particles with diameters of up to approximately 100 nm, polymerization is initiated from free radicals originating in the aqueous phase. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3200–3211, 2002     

Grafting of dodecyl methacrylate onto hydroxylated polybutadiene by miniemulsion polymerization

Homogeneous copolymer latex particles of dodecyl methacrylate (DMA) and low‐molecular‐weight hydroxy‐terminated polybutadiene (HTPB) oligomers were prepared by free‐radical polymerization using miniemulsion methods. Rate data and latex characteristics were consistent with the classical miniemulsion mechanism where nucleation of monomer droplets is the predominant pathway of particle formation. There is essentially no particle formation by secondary nucleation in the water phase. Characterization of the copolymer latex particles using transmission electron microscopy and modulated differential scanning calorimetry suggested that there is a significant amount of grafted poly(DMA)/HTPB polymer contributing to the miscibility of the HTPB and poly(DMA) phases. Particles were more homogeneous at increased HTPB composition, of relatively narrow polydispersity, and could be prepared reproducibly using a number of different initiation systems. The observed trends can all be rationalized in terms of conventional understanding of miniemulsion polymerization systems. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 3404–3416, 2004     

Synthesis of oily core‐hybrid shell nanocapsules through interfacial free radical copolymerization in miniemulsion: Droplet formation and nucleation

Nanocapsules with an oily core and an organic/inorganic hybrid shell were elaborated by miniemulsion (co)polymerization of styrene, divinylbenzene, γ‐methacryloyloxy propyl trimethoxysilane, and N‐isopropyl acrylamide. The hybrid copolymer shell membrane was formed by polymerization‐induced phase separation at the interface of the oily nanodroplets with water. It was shown that the size, size distribution, and colloidal stability of the miniemulsion droplets were extremely dependent on the nature of the oil phase, the monomer content and the surfactant concentration. The less water‐soluble the hydrocarbon template and the higher the monomer content, the better the droplet stability. The successful formation of nanocapsules with the targeted core‐shell morphology (i.e., a liquid core surrounded by a solid shell) was evidenced by cryogenic transmission electron microscopy. Both nanocapsules and nanoparticles were produced by polymerization of the miniemulsion droplets. The proportion of nanoparticles increased with increasing monomer concentration in the oil phase. These undesirable nanoparticles were presumably formed by homogeneous nucleation as we showed that micellar nucleation could be neglected under our experimental conditions even for high surfactant concentrations. The introduction of γ‐methacryloyloxy propyl trimethoxysilane was considered to be the main reason for homogeneous nucleation. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 593–603, 2010     

Morphology of PU/PMMA hybrid particles from miniemulsion polymerization: Thermodynamic considerations

The morphology of PU/PMMA hybrid particles prepared by miniemulsion polymerization was predicted through the consideration of their Gibbs free energy changes. Five morphological states of PU/PMMA hybrid particles were proposed and their Gibbs free energy changes were calculated. Before the formation of hybrid particles, the initial state included a monomer mixture of PU prepolymer, MMA, a chain extender, TMP, and an initiator, which was in droplets suspended in water containing SDS. Two assumptions were made. First, the densities of all states were the same. Secondly, secondary nucleation of particles was negligible. Thus the size of initial droplet and final particle was unchanged through miniemulsion polymerization. The interfacial tensions were measured by a pendant drop method and were used for calculation. The preferred morphology of PU/PMMA hybrid particle had the minimum value of ΔG_phase. Different NCO/OH ratios of PU and initiators of MMA were used to study the morphological change of PU/PMMA hybrid particles. When BD was used as the chain extender of PU, the hybrid particles showed the PU‐rich phase as the shell and PMMA‐rich as the core. When incorporating bisphenol A into PU polymer, the homogeneous structure of hybrid particle was preferred. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 3359–3369, 2007     

Hybrid Miniemulsion Polymerization of Acrylate/Oil and Acrylate/Fatty Acid Systems

Acrylate–alkyd hybrid latex via miniemulsion polymerizations show promise as water‐borne coating systems. However, poor homogeneity of the particles caused by the immiscibility of the alkyd in polyacrylate limits monomer conversion and film formation. To resolve this problem, the hybrid miniemulsion polymerization of acrylate in the presence of linoleic acid and sunflower seed oil was carried out. Products were characterized by solvent extraction, dynamic light scattering, gel permeation chromatography (GPC), differential scanning calorimeter (DSC), and transmission electron microscopy (TEM). The results provide clear evidence that substituting a fatty acid or natural oil with smaller molecular size (weight) for a conventional alkyd improves the grafting efficiency, and enhances the homogeneity of the hybrid polymer particles in water‐borne latex systems.

     

Polymerization kinetics and microstructure of waterborne acrylic/alkyd nanocomposites synthesized by miniemulsion

Waterborne acrylic‐alkyd nanocomposites are expected to combine the positive properties of alkyd resins and acrylic polymers. In this work, the kinetics of the miniemulsion polymerization used to synthesize these nanocomposites and the effect of the process variables on the polymer architecture and particle morphology was investigated. It was found that resin hydrophobicity and the type of initiator strongly affected the microstructure of these materials. The mechanisms responsible for these effects were discussed. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 4871–4885, 2009     

Particle nucleation in high solids batch miniemulsion polymerization stabilized with a polymeric surfactant

The nucleation of polymer particles in the miniemulsion polymerization of vinyl acetate/VeoVa10 (VAc/VeoVa10) stabilized with PVOH was studied. The effect of costabilizer type, PVOH concentration, and type (thermal water‐soluble and oil‐soluble; and redox water‐soluble) and concentration of initiator on the extent of droplet nucleation were studied. Droplet nucleation was maximized by improving miniemulsion stability and using efficient initiators. These high solids dispersions could not be obtained by using a conventional batch emulsion polymerization. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 6407–6415, 2008     

Emulsion and controlled miniemulsion polymerization of the renewable monomer γ‐methyl‐α‐methylene‐γ‐butyrolactone

The kinetics of free‐radical emulsion polymerization of γ‐methyl‐α‐methylene‐γ‐butyrolactone (MeMBL), a renewable monomer related to methyl methacrylate, are presented in detail for the first time, and stable polymer latices are prepared. The effects of different reaction parameters on free‐radical emulsion polymerization of MeMBL are presented. Homogeneous nucleation is asserted to be the dominant path for particle formation. Miniemulsion copolymerization of MeMBL and styrene is also reported. In this case, the homogeneous nucleation process appears limited when using an oil soluble initiator. Both the RAFT miniemulsion polymerizations and RAFT bulk polymerizations are well controlled and narrow polydispersity copolymers are produced. Rate retardation is observed in the RAFT miniemulsion polymerizations compared with the free‐radical polymerization and RAFT bulk polymerizations and the possible causes of the retardation are discussed. The reactivity ratios of MeMBL and styrene in RAFT bulk copolymerization are also determined. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 5929–5944, 2008     

Synthesis of large,high‐solid‐content latexes by miniemulsion polymerization

Multiple and diverse applications have been recently found for miniemulsions and miniemulsion polymerization. In this work, miniemulsion polymerization is presented as a suitable technique for the preparation of high‐solid‐content latices with large particle sizes. Monomer miniemulsions were prepared with a high‐pressure homogenizer, and droplet sizes of 200–700 nm were obtained. Latexes with particle sizes larger than the sizes commonly accepted for miniemulsion polymerization were obtained. With fixed operational conditions of the homogenizer, the type of stabilizer was the key parameter determining the droplet size and the droplet size distribution. The particle size of the latices obtained by miniemulsion polymerization indicated that the particles were mainly formed by droplet nucleation. Latexes obtained by this process have multiple applications, including use as seeds in the polymerization of high‐solid‐content latices. This article shows that potential new applications for miniemulsion polymerization are far from being exhausted. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 4222–4227, 2004     

Styrene miniemulsion polymerization initiated by 2,2′-azobisisobutyronitrile

The effects of various parameters on the dodecyl methacrylate (DMA) or stearyl methacrylate (SMA) containing styrene miniemulsion polymerizations were investigated. These parameters include the type of initiators [2,2′-azobisisobutyronitrile (AIBN) vs. sodium persulfate (SPS)], the size of the homogenized monomer droplets, the AIBN concentration, and the SDS concentration. A small quantity of a water-insoluble dye was also incorporated into the polymerization system to study the related particle nucleation mechanisms. The oil-soluble AIBN promotes nucleation in the monomer droplets, whereas homogeneous nucleation predominates in the reaction system with the water-soluble SPS. Homogeneous nucleation, however, cannot be ruled out in the DMA or SMA containing polymerizations with AIBN as the sole initiator. Increasing the level of AIBN or SDS enhances formation of particle nuclei via homogeneous nucleation. The reaction kinetics is primarily controlled by the competitive events of monomer droplet nucleation and homogeneous nucleation. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2537–2550, 1999     

Kinetics and mechanism of emulsifier-free emulsion copolymerization: Styrene-methyl methacrylate-acrylic acid system

The emulsifier-free emulsion copolymerization of styrene (St) and methyl methacrylate (MMA) in the presence of functional monomer acrylic acid (AA) was carried out in batch process. The kinetics was investigated in detail using model function, Integrated Gamma Function. The morphology and size of particles were monitored continuously by TEM all along the polymerization. It was found that the nucleation, polymerization rate increase with increasing concentration of the functional monomer AA, initiator ammonium persulfate (APS), and polymerization temperature T, and APS plays a predominant role in the particle nucleation process. The particle nucleation stage ceased at about 10% conversion and the steady stage can be extended to about 70% conversion. The particle nucleation is likely to yield primary particle via the mechanism of homogeneous coagulative nucleation and coagulation of the primary particle to yield uniform particles. The particle growth in the postnucleation stage is via a shell growth mechanism. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2649–2656, 1999     

Miniemulsion polymerization of styrene using the oil-soluble initiator AMBN

The Mettler RC1 calorimeter was used to measure the rate of polymerization of conventional emulsion, homogenized emulsion, and miniemulsion polymerizations of styrene initiated with 2,2′-azobis(2-methylbutyronitrile). It was noted that the rate of polymerization significantly increased as the surface area of the monomer droplets increased. This was taken as strong evidence that in the miniemulsion and homogenized emulsion polymerizations, the fraction of the initiator soluble in the oil phase was responsible for single radical generation. The partitioning of AMBN at 70 °C was measured by high-pressure liquid chromatography to be 134 parts in the oil : 1 part in the water. Predissolving polystyrene in the miniemulsion prior to homogenization resulted in an enhancement in the rate of polymerization, although to a lesser extent than what has been previously noted for parallel miniemulsion polymerizations initiated with potassium persulfate. It was also noted that the method of addition of the oil-soluble initiator (either predissolved in the monomer prior to homogenization or dissolved in a small separate phase of monomer and added directly to the reactor) has a measurable effect on the kinetics in the miniemulsion polymerization of styrene. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4449–4457, 1999     

Miniemulsion polymerization of styrene using alkyl methacrylates as the reactive cosurfactant

 Stable styrene miniemulsions were prepared by using alkyl methacrylates as the reactive cosurfactant. Like conventional cosurfactants (e.g., cetyl alcohol (CA) and hexadecane (HD)), alkyl methacrylates (e.g., dodecyl methacrylate (DMA) and stearyl methacrylate (SMA)) may act as a cosurfactant in stabilizing the homogenized miniemulsions. Furthermore, the methacrylate group may be chemically incorporated into latex particles in subsequent miniemulsion polymerization. The data of the monomer droplet size, creaming rate and phase separation of monomer as a function of time were used to evaluate the shelf-life of miniemulsions stabilized by sodium dodecyl sulfate in combination with various cosurfactants. Polystyrene latex particles were produced via both monomer droplet nucleation and homogeneous nucleation in the miniemulsion polymerization using CA or DMA as the cosurfactant, with the result of a quite broad particle size distribution. On the other hand, the miniemulsion polymerization with HD or SMA showed a predominant monomer droplet nucleation. The resultant particle size distribution was relatively narrow. In miniemulsion polymerization, the less hydrophobic DMA is similar to CA, whereas the more hydrophobic SMA is similar to HD. Received: 19 November 1996 Accepted: 20 February 1997     

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     

Hybrid free radical/cationic frontal photopolymerizations

The irradiation of hybrid photopolymer systems consisting of a free radically polymerizable multifunctional acrylate monomer and a cationically polymerizable epoxide or oxetane monomer was conducted under conditions where only the free radical polymerization takes place. This results in the formation of a free‐standing polyacrylate network film containing quiescent oxonium ions along with the unreacted cyclic ether monomer. The subsequent application of a point source of heat to the film ignites a cationic ring‐opening frontal polymerization that emanates from that site and propagates to all portions of the irradiated sample. This article examines the impact of various molecular structural and experimental parameters on these novel hybrid frontal polymerizations that produce interpenetrating network polymers. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 4331–4340, 2007     

Synthesis of raspberry‐like silica/polystyrene/silica multilayer hybrid particles via miniemulsion polymerization

Organic–inorganic hybrid particles have many potential applications, but almost all research has been focused on hybrid particles with one kind of inorganic nanoparticle. This article presents a novel and facile preparation approach for raspberry‐like silica/polystyrene/silica multilayer hybrid particles via miniemulsion polymerization. In this method, larger, surface‐modified silica particles are first dispersed into monomer droplets to form a miniemulsion, and then raspberry‐like silica/polystyrene/silica multilayer hybrid particles are directly obtained when miniemulsion polymerization is performed in the presence of smaller, unmodified silica particles with 4‐vinylpyridine as an auxiliary monomer. Influential parameters such as the amount of 4‐vinylpyridine, the surfactant concentration, and the pH value of the system have been investigated. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 1028–1037, 2007     

Miniemulsion polymerization of styrene with a block copolymer surfactant

A series of miniemulsion systems based on styrene/azobisisobutyronitrile in the presence of poly(methyl methacrylate‐b‐2‐(dimethylamino)ethyl methacrylate) as a surfactant and hexadecane (HD) as a cosurfactant were developed. For comparison, a series of pseudoconventional emulsions also were carried out with the same procedure used for the aforementioned series but without the cosurfactant (HD). Both the droplet size and shelf life were also measured. Experimental results indicate that it is possible to slow the effect of Ostwald ripening and thereby produce a stable miniemulsion with the block copolymer as the surfactant and HD as the cosurfactant. In addition, the extent to which varying the surfactant concentration and copolymer composition could affect both the polymer particle size during the polymerization and the polymerization rate was examined. Variation in the polymer particle sizes during polymerization indicates that droplet and aqueous (micellar or both homogeneous) nucleation occurs in the miniemulsion polymerization. With the same concentration of the surfactant used in the miniemulsion polymerization, the polymerization rates of systems with M₁₂B₃₆ are faster than those of systems with M₁₂B₁₂. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 1818–1827, 2000     

Controlled,radical reversible addition–fragmentation chain‐transfer polymerization in high‐surfactant‐concentration ionic miniemulsions

Living free‐radical polymerization of methacrylate and styrenic monomers with ionic surfactants was carried out with reversible addition–fragmentation chain transfer in miniemulsion with different surfactant types and concentrations. The previously reported problem of phase separation was found to be insignificant at higher surfactant concentrations, and control of the molar mass and polydispersity index was superior to that of published miniemulsion systems. Cationic and anionic surfactants were used to examine the validity of the argument that ionic surfactants interfere with transfer agents. Ionic surfactants were suitable for miniemulsion polymerization under certain conditions. The colloidal stability of the miniemulsions was consistent with the predictions of a specific model. The living character of the polymer that comprised the latex material was shown by its transformation into block copolymers. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 960–974, 2004     

Evolution of particle morphology during the synthesis of hybrid acrylic/CeO2 nanocomposites by miniemulsion polymerization

The evolution of the morphology of an acrylic/CeO₂ hybrid latex synthesized by a two step seeded semibatch emulsion polymerization process was investigated. The seed was produced by batch miniemulsion polymerization and in the second step a neat monomer preemulsion was fed to the seed to increase the solids content and encapsulate the inorganic material. The morphology of the hybrid miniemulsion droplets, the seed and the final latex was analyzed by TEM. The morphologies achieved could be explained by theoretical equilibrium morphology maps based on the interfacial tensions of the monomeric, polymeric, inorganic and aqueous phases. © 2014 Wiley Periodicals, Inc. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 792–799