Methyl methacrylate emulsion polymerization at low monomer concentration: Kinetic modeling of nucleation,particle size distribution,and rate of polymerization

The results of a mathematical model developed in the authors' previous work are discussed and compared against final number (N) and size distribution of particles (PSD) and the rate of polymerization (RP) experimental data of methyl methacrylate (MMA) emulsion polymerization above the critical micelle concentration (cmc) of the surfactant. On the basis of the model results, the hypothesis that the observed bimodal PSD can be ascribed to secondary nucleation as proposed in the literature is questionable. It is discussed that this PSD can also be caused by differences in the growing rate of different‐size particles as predicted for styrene emulsion polymerization. Because of the small particle size obtained at low initial monomer concentration, the high rate of free‐radical desorption reduces the accumulation of these species; therefore, the autoacceleration effect is less pronounced for the conditions under study compared with the usual behavior of the RP during MMA emulsion polymerization above cmc. Similarities and differences between model predictions and experimental data are discussed. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2547–2556, 2001     

Semicontinuous seeded cationic emulsion polymerization of styrene: The effects of the concentration and type of cationic surfactant

The objective of this work was to analyze the effects of the concentration and type of cationic surfactant on the kinetic features (instantaneous and overall conversions) and colloidal characteristics [mean particle diameter, particle size distribution (PSD), and surface charge density] in the semicontinuous seeded cationic emulsion polymerization of styrene. 2,2′‐Azobis(N,N′‐dimethyleneisobutyramidine)dihydrochloride was used as an initiator. The surfactants were dodecyltrimethylammonium bromide (DTAB) and hexadecyltrimethylammonium bromide (HDTAB). So that the evolution of some polymeric and colloidal characteristics of the synthesized latices could be followed, the overall and instantaneous conversions were defined and determined gravimetrically. The PSDs and average particle diameters were determined by transmission electron microscopy and photon correlation spectroscopy. The surface charge density was determined by conductimetric titration. The evolution of the instantaneous conversions, the total number of particles, and the PSDs of the different reactions were related to the nucleation, growth, and coagulation processes taking place in the semicontinuous seeded emulsion polymerizations. The PSDs obtained from the reactions carried out with the emulsifier DTAB, at a concentration equal to its critical micelle concentration (cmc) and at a concentration twice its cmc, presented more and smaller particles than those obtained by the addition of HDTAB to the polymerization recipe. At lower emulsifier concentrations equal to half of the cmc, the system had lower colloidal stability with DTAB. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 2322–2334, 2003     

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     

Particle formation under monomer‐starved conditions in the semibatch emulsion polymerization of styrene. I. Experimental

Particle formation and particle growth compete in the course of an emulsion polymerization reaction. Any variation in the rate of particle growth, therefore, will result in an opposite effect on the rate of particle formation. The particle formation in a semibatch emulsion polymerization of styrene under monomer‐starved conditions was studied. The semibatch emulsion polymerization reactions were started by the monomer being fed at a low rate to a reaction vessel containing deionized water, an emulsifier, and an initiator. The number of polymer particles increased with a decreasing monomer feed rate. A much larger number of particles (within 1–2 orders of magnitude) than that generally expected from a conventional batch emulsion polymerization was obtained. The results showed a higher dependence of the number of polymer particles on the emulsifier and initiator concentrations compared with that for a batch emulsion polymerization. The size distribution of the particles was characterized by a positive skewness due to the declining rate of the growth of particles during the nucleation stage. A routine for monomer partitioning among the polymer phase, the aqueous phase, and micelles was developed. The results showed that particle formation most likely occurred under monomer‐starved conditions. A small average radical number was obtained because of the formation of a large number of polymer particles, so the kinetics of the system could be explained by a zero–one system. The particle size distribution of the latexes broadened with time as a result of stochastic broadening associated with zero–one systems. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3940–3952, 2001     

Kinetics and mechanism of the cationic polymerization of trioxane. II. Consideration of hydride transfer

The occurrence of hydride-transfer reactions during the cationic polymerization of trioxane was demonstrated, and rate constants were obtained. The donor of hydride ions in the transfer reactions was the monomer. The hydride-transfer reaction was a first-order reaction with respect to the concentration of the monomer, and it was governed, just as polymerization and depolymerization were (Shieh, Y. T.; Chen. S. A. J. Polym. Sci. Part A: Polym. Chem. 1999, 37, 483–492) by morphological changes. The hydride-transfer rate constants were 5 orders of magnitude smaller than those for polymerizations and depolymerizations. The rate constants for the reactions, including the polymerizations, depolymerizations, and hydride transfers, were smaller for the active centers on the solid surface than for those in solution, that is, k^′_p was less than k_p, k^′_d was less than k_d, and k^′_ht was less than k_ht. As a reaction medium, benzene had special effects on the kinetics of the cationic polymerization of trioxane. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4198–4204, 1999     

Condensative chain polymerization. II. Preferential esterification of propagating end group in Pd-catalyzed CO-insertion polycondensation of 4-bromophenol derivatives

For a development of condensative chain polymerization where polycondensation proceeds from an initiator in a chain polymerization manner to yield polymer with a defined molecular weight and a narrow molecular weight distribution, the Pd-catalyzed polycondensation of 4-bromophenol derivatives with CO is studied. Model reactions showed that monomer reacted the polymer terminal Br preferentially compared to the monomer Br, but that the ester exchange reaction of polymer backbone with monomer phenoxide occurred in some extent. In the polymerization of 4-bromo-2-n-octylphenol with CO using 4-bromo-2,6-dimethylphenyl benzoate as an initiator, the molecular weight of polymer increased in proportion to time up to 30 min. The GPC elution curves showed that oligomers were produced from the initiator. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2607–2618, 1999     

Polymers of carbonic acid. XXVII. Macrocyclic polymerization of trimethylene carbonate

2,2-Dibutyl-2-stanna-1,3-dioxepane (DSDOP) was used as cyclic initiator for the polymerization of trimethylene carbonate (TMC). The polymerizations were either conducted in concentrated chlorobenzene solution at 50 and 80°C or in bulk at 60 and 120°C. With monomer/initiator ratios ≤100 the conversion was complete within 2 h at 80°C and within 12 h at 50°C. Variation of the reaction time revealed that the rapid polymerization is followed by a relatively rapid (backbiting) degradation even at 80°C. The polymerizations in bulk at 60°C were somewhat slower than those at 80°C in solution, but the influence of degradation reactions was less pronounced. With optimized reaction time the number average molecular weight (M_n) roughly parallels the monomer/initiator ratio and M_n's up to 100,000 were obtained. In contrast to a classical living polymerization broader polydispersities (1.5–1.7) were found. In the case of 5,5-dimethyltrimethylene carbonate rapid degradation and chain transfer reactions prevented the formation of high molecular weight polymers. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2179–2189, 1999     

Ethylene polymerization reactions with Ziegler–Natta catalysts. III. Chain-end structures and polymerization mechanism

Ethylene polymerization reactions with many Ziegler–Natta catalysts exhibit a number of features that differentiate them from polymerization reactions of α olefins: (1) a relatively low ethylene reactivity, (2) markedly higher polymerization rates in the presence of α olefins, (3) a high reaction order with respect to ethylene concentration, and (4) a strong reversible rate depression in the presence of hydrogen. A detailed kinetic analysis of ethylene polymerization reactions¹ provided the basis for a new kinetic scheme that postulates the equilibrium formation of Ti C₂H₅ species with the H atom in the methyl group β-agostically coordinated to the Ti atom in an active center. This mechanism predicts several new features of ethylene polymerization reactions, one being that chain initiation via insertion of any α-olefin molecule into the Ti H bond should proceed with an increased probability compared to that via ethylene insertion into the same bond. As a result, a significant fraction of ethylene/α-olefin copolymer chains should contain α-olefin units as the starting units. This article provides experimental data supporting this prediction on the basis of both a detailed structural analysis of co-oligomers formed in ethylene/1-pentene and ethylene/4-methyl-1-pentene copolymerization reactions and a spectroscopic analysis of chain ends in the copolymers. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4281–4294, 1999     

The inverse emulsion polymerization of acrylamide using polystyrene-graft-polyoxyethylene as the stabilizer

Inverse emulsion polymerization of aqueous solution of acrylamide (AM) in toluene is carried out using polystyrene-graft-polyoxyethylene (PSt-g-PEO) as an emulsifier. The kinetics of polymerization, morphology of the particle, and particle size of the inverse emulsion have been investigated. The rates of polymerization are found to be proportional to the initiator concentration, the monomer concentration, and the emulsifier concentration. The morphology of the particle shows a spherical structure. The effects of amphipathic graft copolymer structure on the average molecular weight of polyacrylamide are studied. The mechanism of the inverse emulsion polymerization using amphipathic graft copolymer as emulsifier is proposed. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2719–2725, 1999     

Comparative study of classical surfactants and polymerizable surfactants (surfmers) in the reversible addition–fragmentation chain transfer mediated miniemulsion polymerization of styrene and methyl methacrylate

Cationic and anionic amphiphilic monomers (surfmers) were synthesized and used to stabilize particles in miniemulsion polymerization. A comparative study of classical cationic and anionic surfactants and the two surfmers was conducted with respect to the reaction rates and molecular weight distributions of the formed polymers. The reversible addition–fragmentation chain transfer process was used in the miniemulsion polymerization reactions to control the molecular weight distribution. The reaction rates of the surfmer‐stabilized miniemulsion polymerization of styrene and methyl methacrylate were similar (in most cases) to those of the classical‐surfactant‐stabilized miniemulsion polymerizations. The final particle sizes were also similar for polystyrene latexes stabilized by the surfmers and classical surfactants. However, poly(methyl methacrylate) latexes stabilized by the surfmers had larger particle sizes than latexes stabilized by classical surfactants. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 427–442, 2006     

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     

Formation of highly monodispersed emulsifier-free cationic poly(methylstyrene) latex particles

Highly monodispersed emulsifier-free poly(methylstyrene) (PMS) latex particles were prepared via an emulsifier-free emulsion polymerization in the presence of 2,2′-azobis-(2-amidineopropane) dihydrochloride (V-50) as an initiator. A combination of kinetics and molecular weight distribution studies revealed that the polymerization followed the micellization nucleation mechanism. Results showed that an appropriate initiator concentration was necessary to obtain monodisperse and stable latex particles. Conversion of methylstyrene was found to increase significantly with increasing initiator concentrations. However, the size of PMS latex particles decreased with both the increase of initiator concentration and the reaction temperature at a constant ionic strength. The particle size was increased as the ionic strength of the aqueous phase increased, yet the variation of ionic strength had little effect on the particle size distribution. SEM micrographs showed that an agitation rate of 350 rpm or higher was required in order to produce highly monodispersed poly(methylstyrene) latex particles. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2069–2074, 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     

The effect of feed conditions in the emulsion catalytic chain transfer polymerization of alkyl methacrylates

([bis[μ-[(2,3-butanedione dioximato)(2-)-O:O′]] tetrafluorodiborato(2-)-N,N′,N″,N‴] cobalt), CoBF, has been used for the effective catalytic chain transfer of alkyl methacrylate homo- and copolymers under emulsion polymerization conditions. The catalytic chain transfer process reduces the rate of polymerization such that when the monomer is fed over 60 min the instantaneous conversion is low enough for the particle to be swollen with monomer, allowing diffusion of the catalysts between the aqueous and monomer phases. When the amount of the catalyst is reduced, the rate is increased, eventually leading to viscous, glassy particles that prevent catalyst mobility, which is observed as a breakdown in the polymerization mechanism. This can be circumvented by the addition of a 20% shot of monomer at the start of the reaction. The effective chain transfer coefficient decreases on increasing the length of the ester group of the methacrylate. The analysis of the polymers made by the technique described shows that the T_g of the polymers observe a broad transition due to the effect of chain length being pronounced at low molecular mass. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 3549–3557, 1999     

Reversible addition–fragmentation chain transfer polymerization of methyl methacrylate in emulsion

Theoretical simulations showed that for controlled/living radical polymerization in an emulsion system, some of the earliest born particles could be superswollen to a size close to 1 μm. We hypothesized that the superswelling of these particles would lead to colloidal instability. Under the guidance of the simulation results, reversible addition–fragmentation chain transfer (RAFT) emulsion polymerization of methyl methacrylate (MMA) was carried out. Experimental results showed that increasing the initiation rate, surfactant level, and targeted molecular weight could improve the colloidal stability of the RAFT polymerization of MMA in an emulsion. The experimental results were in full accord with the theoretical predictions. The poor control of the molecular weight and polydispersity index was found to have a close relationship with the colloidal instability. For the first time, we demonstrated that RAFT polymerization could successfully be implemented with little coagulum, good control of the molecular weight, and a low polydispersity index with the same process used for traditional emulsion polymerization but with higher surfactant levels and initiation rates. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44:2837–2847, 2006     

Modeling molecular weight distribution in emulsion polymerization reactions with transfer to polymer

A mathematical model was developed for the computation of the dynamic evolution of molecular weight distributions (MWDs) during nonlinear emulsion polymerization reactions. To allow the direct computation of the whole MWD, an adaptive orthogonal collocation technique was applied. The model was validated with experimental methyl methacrylate/butylacrylate (BuA) semicontinuous and vinyl acrylate (VA)/Veova10 continuous emulsion polymerization results. Both systems considered introduce significant chain‐transfer reactions to polymer chains as a result of the presence of BuA and VA, respectively. The model developed was able to represent quite properly the kinetics and MWD of polymer samples during emulsion polymerizations. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3513–3528, 2001     

Linking reactions of living polymers with bromomethylbenzene derivatives: Synthesis and characterization of star homopolymers and graft copolymers with polyelectrolyte branches

Anionic polymerization techniques utilizing 1,2,4,5-tetra(bromomethyl)- benzene as the linking agent were employed for the synthesis of four-arm star polymers with poly(tert-butyl methacrylate) (PtBuMA), poly(methyl methacrylate), poly(tert-butylacrylate) (PtBuA), or poly(2-vinylpyridine) (P2VP) branches. This work was extended through the “grafting onto” method, in combination with anionic polymerization techniques, to synthesize graft copolymers consisting of polystyrene backbones and PtBuA, PtBuMA, or P2VP branches. Postpolymerization reactions were performed to produce graft copolymers with polyelectrolyte branches. Crosslinking reactions were observed in some of the graft materials several months after their preparation. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4337–4350, 1999     

Effects of monomer structures on the evolution of liquid–crystal texture and crystallization during thin-film polymerization

We investigated in situ the effects of monomer structures on the formation and evolution of liquid–crystal texture and crystallization during thin-film polymerization of a series of liquid–crystalline and crystalline polymers. The monomers used in this study consisted of 2,6-acetoxynaphthoic acid (ANA), p-acetoxybenzoic acid (ABA), acetoxy acetanilide (AAA), and isophthalic acid (IA). The polycondensation reactions were conducted on the heating stage of a polarizing microscope. The formation of liquid crystallinity was found to be strongly dependent on the straight-monomer structures of ANA and ABA and their percentages as well as the reaction temperature. For the ANA/AAA/IA and ABA/AAA/IA reaction systems, the critical straight-monomer content (ANA or ABA) existed to form the liquid–crystalline (LC) state. Interestingly, the critical content to form liquid crystallinity decreased with an increase in the reaction temperature. Above the critical content, the appearance of a defective LC phase and the annihilation of disclinations were observed during the polycondensation reactions. The number of defects decreased with increasing reaction time through annihilation. The annihilation rate increased whereas the defect density decreased with increasing straight-monomer content. For the same molar ratio, the reaction system containing ANA had a faster annihilation rate than that containing ABA. Below the critical content, crystalline polymers were formed. Nucleation and crystal growth were observed during the reactions, and the rate of crystal growth decreased with increasing ANA or ABA content. For the systems having the same molar ratio of ANA or ABA, the ANA/AAA/IA system had a higher tendency to yield the LC phase than the ABA/AAA/IA system because ANA has a longer mesogenic unit. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 3084–3096, 1999     

Effect of dose rate on emulsion and microemulsion polymerization of styrene

Emulsion and microemulsion polymerization of styrene were initiated with a gamma ray to study the effect of dose rate on polymerization. In both systems, there is an apparent plateau of polymerization rate in the curve of reaction rate vs. conversion. It was shown that emulsion polymerization conformed to the Smith–Ewart theory very well. Changing the dose rate in interval 2 had no great influence on polymerization rate, but it changed the average lifetime of radicals in polymer particles and affected the molecular weight of polymer produced. For microemulsion polymerization it was assumed that in the plateau it is the number of growing polymer particles being kept constant, not the number of polymer particles. When the dose rate was changed while the polymerization came into the constant period, the polymerization rate and the molecular weight of the polymer varied with the dose rate. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 257–262, 1998     

Automated batch emulsion copolymerization of styrene and butyl acrylate

This article describes a method for carrying out emulsion copolymerization using an automated synthesizer. For this purpose, batch emulsion copolymerizations of styrene and butyl acrylate were investigated. The optimization of the polymerization system required tuning the liquid transfer method, sufficient oxygen removal from the reaction medium and setting a proper sampling procedure. The monomer conversion‐time plots obtained with gas chromatography revealed a good reproducibility of the automated reaction kinetics. Furthermore, the particle size distributions and the properties of the final products were found to be highly reproducible. The performance of the automated reactions was subsequently compared with the conventional ones: similar reproducibility of either synthetic method was observed. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2011