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     

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

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

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     

Heterogeneous polymerization with polyaspartate macromonomer having vinyl pendant groups. II. Control of particle diameter and diameter distribution in dispersion copolymerization

To control particle diameter and particle diameter distribution in dispersion copolymerization of styrene and sodium polyaspartate macromonomer containing vinylbenzyl pendant groups, effects of some polymerization parameters, water contents, initiator concentration, styrene monomer concentration, reaction temperature, and type of initiator on the particle diameter and the diameter distribution were investigated. Variation of the water contents from 20 to 80 vol % controls the resultant particle diameter from 0.066 to 0.47 μm. The diameter increased with increasing initiator concentration. This tendency is similar to dispersion polymerization system using a nonpolymerizable stabilizer. Particle diameter distribution broadened with increasing styrene monomer concentration. This trend was attributed to the increase of a period of particle formation. This result indicated that the period of particle formation affected the resultant particle diameter distribution. Particle diameter distribution was successfully improved (CV = 9.1 from 23.6%) by shortening of decomposition time of initiator. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 2281–2288, 2009     

Polymeric and colloidal features of latex particles with surface amino groups obtained by semicontinuous seeded cationic emulsion polymerization*

Monodisperse latex particles with different amounts of surface amino and amidine groups were synthesized by means of a semicontinuous seeded cationic emulsion polymerization of styrene and a cationic monomer. High partial overall conversions for styrene and limited ones for the cationic monomer were achieved. A reliable method for the quantification of surface amidine and amino groups was developed. It was found that the amount of surface amidine groups provided by the cationic initiator was higher when the amount of cationic monomer added increased. The value for the partition coefficient of the cationic monomer indicated that this polymerizes with the same probability in the water phase as in the particle. The colloidal stability, in terms of critical coagulation concentration, shows that the latexes would be useful as polymeric supports in immunoassays. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 3878–3886, 2005     

Influence of n‐dodecyl mercaptan as chain transfer agent in dispersion polymerization of styrene

Dispersion polymerization of styrene with n‐dodecyl mercaptans (DDM) as the chain transfer agent was investigated. PS particles with various molecular weight, molecular weight distribution (MWD), and particle diameter were prepared by varying the concentration of DDM and also the addition time of DDM before and after the particle nucleation. The average particle diameter was increased, whereas polymerization rate, molecular weight, and MWD were decreased with increasing DDM concentrations from 0 to 10 wt %. The effect of addition of DDM before and after particle nucleation was studied at 0.4, 0.8, and 1.0 wt % DDM. The addition of DDM before particle nucleation produced PS particles of relatively large particle diameter and low molecular weight when compared with the addition of DDM after particle nucleation. This study shows that particle nucleation occurs in about 5–6 min, which corresponds to the 15–16% conversion, 372–378 nm in D_n , and provides a facile way to control the particle size and interesting information about the particle formation using the delayed addition of DDM. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 6612–6620, 2008     

The production of high polymer to surfactant microlatexes

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

Kinetics of the styrene emulsion polymerization using n‐dodecyl mercaptan as chain‐transfer agent

The kinetics of the styrene emulsion polymerization using n‐dodecyl mercaptan as chain‐transfer agent was studied. It was found that the chain‐transfer agent (CTA) had no effect on polymerization rate but substantially affected the molecular weight distribution (MWD). The efficiency of the CTA in reducing the MWD was lowered by the mass‐transfer limitations. The process variables affecting CTA mass transfer were investigated. A mathematical model for the process was developed. The outputs of the model include monomer conversion, particle diameter, number of polymer particles, and number‐average and weight‐average molecular weights. The model was validated by fitting the experimental data. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 4490–4505, 2000     

Reversible‐addition fragmentation chain transfer radical emulsion polymerization by a nanoprecipitation process

Polymerizations of styrene under emulsion reversible‐addition fragmentation chain transfer polymerization conditions are reported. Using a recently developed nanoprecipitaiton process, emulsion particles were formed by the precipitation of an acetone solution of a macroRAFT agent into an aqueous solution of poly(vinyl alcohol). The particles were then swollen with monomer and subsequently polymerized. Emulsion polymerizations were performed at 65 and 75 °C in which either KPS, BPO, or a combination of both was used as an initiating source. Reactions were also performed at temperatures over 100 °C in which the thermal initiation of styrene was used as an initiating source. In all cases, the polymerizations proceeded in a living manner, yielding polymers that showed an incremental increase in molecular weight with time and had narrow molecular weight distributions. Plots of number‐ average molecular weight versus conversion were linear, indicating a controlled polymerization. The resulting latices were colloidally stable and gave particle size distributions with a typical average particle diameter in the 150 nm range. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 5708–5718, 2006     

Fluorescent polymer particles incorporating pyrene derivatives

Fluorescent polymer particles incorporating pyrene and alkynylpyrenes were prepared by miniemulsion polymerization of styrene. The pyrenes were simply dissolved in styrene monomer and then added to the reaction mixture in a vessel, followed by ultrasonication and the polymerization. The pyrenes were incorporated in the polystyrene particles and gave monomer fluorescence emission. The fluorescent particles incorporating the alkynylpyrenes, which have high fluorescence quantum yield and short fluorescence lifetime, showed the same fluorescence emission intensity under air and nitrogen. The fluorescence of the alkynylpyrenes in the polymer particles will not be quenched by molecular dioxygen in contrast to that in organic solvents. Incorporation of fluorophore into polymer particles will protect the fluorophore from its undesirable interaction with oxygen, affording the particles highly fluorescent even under air. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 1470–1475, 2008     

Acetal-functionalized polymer particles useful for immunoassays

The synthesis of core-shell type polystyrene monodisperse particles with surface acetal groups was carried out by a two-step emulsion polymerization process. In a first step, the core was synthesized by batch emulsion polymerization of styrene (St), and in the second step, the shell was polymerized by batch emulsion terpolymerization of styrene, methacrylic acid (MAA), and methacrylamidoacetaldehyde dimethyl acetal (MAAMA), using the seed obtained previously. With the aim of analyzing the effect of the thickness of the shell, the pH of the reaction medium and the weight ratio of the termonomers to prepare the shell, on the amount of the functionalized groups, several core-shell type latex particles were synthesized by two-step emulsion polymerization in a batch reactor. The latexes were characterized by TEM and conductimetric titration to obtain the particle size distribution and the amount of carboxyl and acetal groups on the surface, respectively. Looking for the applicability of the synthesized latexes in immunoassays, IgG a-CRP rabbit antibody was covalently bonded to the surface of the particles synthesized in neutral medium. The complex latex-protein was immunologically active against the CRP antigen. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35 : 1605–1610, 1997     

Preparation of highly sulfonated polystyrene model colloids

Previous attempts to prepare monodisperse styrene/sodium styrene sulfonate copolymer latexes by batch, seeded, and semicontinuous emulsion polymerization were unsuccessful at high concentrations of the functional comonomer. Broad, and sometimes bimodal, size distributions, and large amounts of water soluble homopolymer were obtained. After removal of free monomer, solute and adsorbed homopolymer and copolymer, the overall incorporation of the functional comonomer was found to be low. To overcome these problems, a two stage “shot-growth” or in situ seeding technique was developed. A first stage copolymerization was carried out with a low concentration of sodium styrene sulfonate: the purpose of the functional comonomer was to enhance the stability and regulate the size of the seed particles. When this reaction had reached high conversion (> 90%), a second stage monomer mixture was added. The ratio of styrene to sodium styrene sulfonate in this mixture determined the final surface charge density. The mechanism by which the NaSS is incorporated in the polymer particles is considered to be by solution copolymerization with solute styrene monomer to form surface active oligoradicals. These radicals adsorb on the particle surface, initiate polymerization and become inextricably bound, preventing their transfer back to the aqueous phase. By this means, it was possible to vary independently the particle size and surface charge density. High concentrations of functional comonomer could be polymerized without undue wastage (incorporations were only slightly less than 100%) or loss of monodispersity. In extreme cases, the area per functional group fell below the theoretical minimum, indicating considerable hydration of the surface layers.     

Semibatch emulsion polymerization of methyl methacrylate using different polyurethane particles

Aqueous acrylic‐polyurethane (AC–PU) hybrid emulsions were prepared by semibatch emulsion polymerization of methyl methacrylate (MMA) in the presence of four polyurethane (PU) dispersions. The PU dispersions were synthesized with isophorone diisocyanate (IPDI), 1000 and 2000 molecular weight (MW) poly(neopentyl) adipate, 1000 MW polytetramethyleneetherglycol, butanediol (BD), and dimethylol propionic acid (DMPA). MMA was added in the monomer emulsion feed. We studied the effect of the use of different PU seed particles on the rate of polymerization, the particle size and distribution, the number of particles, and the average number of radicals per particle. The PU rigidity was controlled by varying the polyol chemical structure, the polyol MW (M_n), and by adding BD. The monomer feed rate was varied to study its influence on the process. It was observed that the PU particles that had been prepared with a higher MW polyol swelled better with MMA before the monomer‐starved conditions occurred. There seemed to be no significant discrepancies between the series with different PU seeds in the monomer‐starved conditions. The overall conversion depended on the monomer addition rate, and the polymerization rate acquired a constant value that was comparable to the value of the monomer addition rate. The instantaneous conversion increased slightly. The average particle size increased, and the total particle number in the reactor was constant and similar to the number of PU particles in the initial charge. The average number of radicals per particle increased. The differences between the system with a constant particle number and average number of radicals per particle and the system with a fixed radical concentration are discussed. The semibatch emulsion polymerization of MMA in the presence of PU particles studied was better compared to the system with a fixed radical concentration. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 844–858, 2005     

Sterically stabilized emulsion polymerization of styrene: Pseudo‐semicontinuous approach

The sterically stabilized emulsion polymerization of styrene initiated by a water‐soluble initiator at different temperatures has been investigated. The rate of polymerization (R_p) versus conversion curve shows the two non‐stationary‐rate intervals typical for the polymerization proceeding under non‐stationary‐state conditions. The shape of the R_p versus conversion curve results from two opposite effects—the increased number of particles and the decreased monomer concentration at reaction loci as the polymerization advances. At elevated temperatures the monomer emulsion equilibrates to a two‐phase or three‐phase system. The upper phase is transparent (monomer), and the lower one is blue colored, typical for microemulsion. After stirring such a multiphase system and initiation of polymerization, the initial coarse polymer emulsion was formed. The average size of monomer/polymer particles strongly decreased up to about 40% conversion and then leveled off. The initial large particles are assumed to be highly monomer‐swollen particles formed by the heteroagglomeration of unstable polymer particles and monomer droplets. The size of the “highly monomer” swollen particles continuously decreases with conversion, and they merge with the growing particles at about 40–50% conversion. The monomer droplets and/or large highly monomer‐swollen polymer particles also serve as a reservoir of monomer and emulsifier. The continuous release of nonionic (hydrophobic) emulsifier from the monomer phase increases the colloidal stability of primary particles and the number of polymer particles, that is, the particle nucleation is shifted to the higher conversion region. Variations of the square and cube of the mean droplet radius with aging time indicate that neither the coalescence nor the Ostwald ripening is the main driving force for the droplet instability. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 804–820, 2003     

Core–shell and gradient morphology polymer particles analyzed by X‐ray photoelectron spectroscopy: Effect of monomer feed order

The synthesis of composite latex particles possessing core–shell and gradient morphologies, respectively, using seeded starve‐fed semibatch emulsion polymerization of styrene (St) and methyl methacrylate (MMA) is presented. The focus is on the effect of the monomer feed order on the particle morphology development. The particle morphology is assessed using a novel approach which entails comparing the experimental surface composition as a function of polymerization time (particle growth) obtained by X‐ray photoelectron spectroscopy with the predicted surface composition using a mass balance mathematical model. Both types of composite latexes (core–shell and gradient) feature changes with polymerization time in the oxygen/carbon surface composition which enables one to track the morphology development. Differential scanning calorimetry is also implemented to analyze the extent of phase separation. The monomer feed order is shown to play a crucial role—under the present conditions, gradient and core–shell particles are obtained if the feed order is St/MMA (St fed first), but not if the feed order is reversed. These findings illustrate that thermodynamic factors are important, given that thermodynamically it is more favorable for MMA‐rich chains to occupy the oil–water interface to reduce the interfacial tension. Systems where St is the second stage monomer lead to mixed structures rather than the targeted core–shell or gradient morphology with St‐rich chains at the particle surface. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 2513–2526     

Nanoencapsulation of a hydrophobic compound by a miniemulsion polymerization process

The nanoencapsulation of hydrophobic compounds by miniemulsion polymerization, a convenient one‐step encapsulation technique for nanocapsules, was investigated in terms of the thermodynamics and kinetics. The encapsulation was achieved by polymerization inducing phase separation within minidroplets dispersed in an aqueous phase. Thermodynamic factors (the level and type of surfactant, the level of the hydrophilic comonomer, and the monomer/paraffin ratio), kinetic factors (the level of the crosslinking agent or chain‐transfer agent), and nucleation modes were all found to have a great influence on the latex morphology. Specifically, for a styrene/paraffin system, there were optimum levels of sodium dodecyl sulfate (1.0 wt %), the hydrophilic comonomer (1.0 wt % methyl acrylate acid), and the chain‐transfer agent (0.2 wt % n‐dodecanethiol) for obtaining well‐defined nanocapsules of paraffin with a styrene/paraffin ratio of 1:1. When the styrene/paraffin ratio was reduced, however, it was more difficult to achieve a fully encapsulated particle morphology. Homogeneous nucleation could compete with encapsulation, and this resulted in a pure polymer particle and a half‐moon morphology. Conditions were also found under which complete encapsulation could be observed with a water‐soluble initiator (potassium persulfate), contrary to certain reports. Replacing potassium persulfate with an oil‐soluble initiator (2,2‐azobisisobutyronitrile) had little influence on the morphology under those conditions. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 2145–2154, 2004     

The influence of surfactant coverage of the minidroplets on RAFT miniemulsion polymerization

The surfactant coverage of minidroplets was tuned by postaddition of more surfactants after preparation of the miniemulsion of styrene. The influence of surfactant coverage on reversible addition‐fragmentation chain transfer (RAFT) miniemulsion polymerization of styrene was investigated. When the surfactant (sodium dodecyl sulfate; SDS) coverage was as low as 40%, two kinds of particles, denoted as polymer and oligomer particles, were formed in the early stage of the polymerization. Polymer chains within two kinds of particles grew in a parallel way during the rest period of the polymerization. The oligomer particles contributed less than 10% to the final monomer conversion but consumed over one in third the original RAFT agent molecules. Oligomer particles were larger in size but much lower in molecular weight. Both the particle size and molecular weight distributions were bimodal. With increase of SDS coverage, the formation of oligomer particles was suppressed. As a result, the nucleation efficiency of the minidroplets was greatly enhanced and the molecular weight and particle size distributions were dramatically narrowed. The formation of the oligomer particles was ascribed to the superswelling occurring in the beginning stage of the polymerization. The experimental observations are in excellent accord to the superswelling theory. Postaddition of surfactant presents a novel method to narrow particle size and molecular weight distributions in RAFT miniemulsion polymerization. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 2293–2306, 2006     

Photoinitiated polymerization of methacrylic monomers in a poly(methyl methacrylate) matrix: A comparative study with other matrices (styrene–butadiene–styrene,polystyrene, and polybutadiene)

The kinetics and mechanism of the photoinitiated polymerization of 1,6‐hexanediol dimethacrylate (HDDMA) in a poly(methyl methacrylate) (PMMA) matrix were studied. The maximum double‐bond conversion, the maximum polymerization rate, the intrinsic reactivity, and the kinetic constants for propagation and termination were calculated. For this system, a reaction‐diffusion termination mechanism occurred from the start of the polymerization, and it was predominantly maintained until high monomer concentrations, probably because of the relatively high intermolecular attraction force between the PMMA matrix and HDDMA monomer. In addition, a comparative study of the photoinitiated polymerization of methacrylic monomers in four different polymeric matrices [styrene–butadiene–styrene (SBS), polystyrene (PS), polybutadiene (PB), and PMMA] was carried out. The aggregation state, vitreous or rubbery, of the monomer–matrix system and the intermolecular strength of attraction in the monomer–matrix system and growing macroradical and matrix systems were the principal factors influencing the kinetic and mechanistic behavior of these systems. When PB and SBS were used as matrices, crosslinked polymerized products were obtained as a result of the participation of double bonds of the matrix in the polymerization process (copolymerization). PS sequences in the SBS and PS matrices also took part in the polymerization process through the coupling of the benzylic radical to the growing macroradical. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 40: 120–127, 2002     

Synthesis of snowman‐like polymer‐silica asymmetric particles by combination of hydrolytic condensation process with γ‐ray radiation initiated seeded emulsion polymerization

We report on a facile route to synthesize snowman‐like asymmetric composite particles via γ‐ray initiated seeded emulsion polymerization after a hydrolytic condensation process on the surface of second monomer swollen poly(styrene‐divinylbenzene‐acrylic acid) seeds. Effects of the amounts and kinds of second monomer and inorganic precursor, different radiation polymerization conditions including dose rates and absorbed doses on the morphology of the obtained particles were investigated. The obtained asymmetric particles can serve as ideal solid surfactants to stabilize the water‐in‐oil emulsions, and soap‐free hierarchical materials were obtained by polymerization of monomers in water or oil phase. © 2013 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2014 , 52, 339–348     

Semicontinuous heterophase copolymerization of styrene and acrylonitrile

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