Seeded semicontinuous emulsion copolymerization of methyl methacrylate,butyl acrylate,and phosphonated methacrylates: Kinetics and morphology

A series of methyl methacrylate, butyl acrylate, and phosphonated methacrylate (MAPHOS) copolymers were prepared by seeded semicontinuous emulsion polymerization under monomer‐starved conditions by varying the amount and nature of phosphonated methacrylates (diester, monoacid, and diacid). The effects on the kinetics, molecular weight distribution, and particle size distribution were investigated. The molecular weights and particle growth were affected by the amount of acidic MAPHOS in the recipe. Secondary nucleation occurred above a critical concentration of acidic MAPHOS (5 wt %). Characterization of the latices by elemental analysis provided information on the phosphonic acid location and showed that phosphonic oligomers were formed in the aqueous phase. Particle size data and electrophoretic behavior of the latex afforded a discussion on the particle surface morphology. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 2469–2480, 2003     

Molecular weight distribution in composition controlled emulsion copolymerization

The effect of different strategies for copolymer composition control on the molecular weight distribution (MWD) and gel fraction in the emulsion copolymerization of methyl methacrylate and butyl acrylate was investigated. Starved and semistarved processes for copolymer composition control were both considered. For gel‐forming systems it was found that the starved process gave more gel and lower molecular weights than the semistarved process. The feasibility of simultaneous control of the copolymer composition and the MWD was assessed. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 1100–1109, 2000     

Emulsion terpolymerization of butyl acrylate/methyl methacrylate/vinyl acetate: Experimental results

A systematic study of the terpolymerization of butyl acrylate/methyl methacrylate/vinyl acetate (BA/MMA/VAc) was conducted. In this stage of the study, batch emulsion terpolymerizations were performed in a 5 L stainless steel pilot plant reactor. The experiments were designed using a Bayesian (optimal) technique. The polymers produced were characterized for conversion, composition, molecular weight, and particle size. Conversion, terpolymer composition, number- and weight-average molecular weight, and average particle size results are discussed in light of the influence of seven factors and the interaction of these factors. The factors studied include monomer feed composition, initiator concentration, chain transfer agent concentration, impurity concentration, initiator type, emulsifier concentration, and temperature. A “two-stage rate” phenomenon, similar to that occurring in bulk co- and terpolymerization and emulsion copolymerization of acrylic/vinyl acetate systems was observed in the conversion, composition and molecular weight data. Furthermore, an interesting yet often ignored effect of impurities on emulsion polymerization kinetics was explained. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35 : 1659–1672, 1997     

Butyl acrylate/methyl methacrylate latexes: adhesive properties

In this study, butyl acrylate/methyl methacrylate (BA/MMA) latexes of bimodal molecular weight and particle size distribution were prepared in a multi-step process by seeded conventional emulsion and seeded miniemulsion polymerization. For the conventional emulsion case, a BA/MMA batch copolymerization was conducted as a first step (seed generation) and was followed by a monomer addition step to ensure particle growth. In a third step, a BA/MMA pre-emulsified mixture was added to generate a second particle population. For the miniemulsion case, a BA/MMA copolymerization was carried out as a first step (seed generation) and was followed by a monomer addition step. The addition of a BA/MMA miniemulsion served to generate a bimodal particle size and molecular weight distribution. The final latexes were coated onto a polyethylene terephthalate carrier, dried and their performance as pressure-sensitive adhesives was evaluated using tack, peel and shear adhesion measurements. Structure-property relationships between the adhesive properties and the weight-average molecular weight and average particle size were examined. Even though the polymers obtained by miniemulsion showed better shear resistance, their shear resistance was low. There was no statistically significant difference in peel resistance of the polymers obtained by the two reactions. While a significant difference in tackiness between the two emulsion procedures was found when the adhesives were tested using the less sensitive, rolling ball test, no differences were found when they were tested using a loop tack test.     

Synthesis of Poly(n‐butyl acrylate/methyl methacrylate)/CNC Latex Nanocomposites via In Situ Emulsion Polymerization

Cellulose nanocrystals (CNCs) are renewable, nontoxic and naturally available organic nanoparticles derived from cellulosic resources such as cotton and wood pulp. Poly(n‐butyl acrylate‐co‐methyl methacrylate)/CNC latexes are successfully synthesized via in situ emulsion polymerization. The effect of CNC loading on overall conversion, polymer particle size, glass transition temperature (T_g), gel content, latex viscosity, and storage and loss moduli of dried latex are studied. While the effect of CNC content on overall conversion, polymer particle size, and T_g of the resulting latexes is negligible, significant increase in gel content, latex viscosity, and storage and loss moduli are observed.

     

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     

Stabilization and kinetics in the emulsion copolymerization of butyl acrylate and methyl methacrylate

We carried out emulsion homopolymerizations and copolymerizations of butyl acrylate (BuA) and methyl methacrylate (MMA) with different types and concentrations of surfactants to determine the influence of these parameters on the particle size and particle size distribution and to elucidate the mechanism of particle formation. As expected, the mechanisms of nucleation above and below the critical micelle concentration were very different; however, it was also found that the presence of partially soluble monomers such as MMA in the water phase had a significant influence on the critical micelle concentration of Triton X‐405 (>50%). In addition, the nucleation mechanism during copolymerization seemed to be dominated by BuA, with the number of particles per liter being very similar to the number nucleated during its homopolymerization. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2832–2846, 2001     

Determination of chain transfer constant to dodecanethiol in styrene/methyl methacrylate and butyl acrylate/methyl methacrylate copolymerization and effect of chain length on composition and stereochemical configuration of copolymers

Free radical copolymerization of styrene/methyl methacrylate (S/MMA) and butyl acrylate/methyl methacrylate (BA/MMA) in the presence of n-dodecanthiol (DDT) has been studied at 60°C in a 3 mol/L benzene solution using 2,2′-azobis(isobutyronitrile) (AIBN) as initiator. Overall chain transfer constant to DDT has been determined for both copolymerization systems, as a function of monomer feed composition using complete molecular weight distribution and the Mayo method. Overall transfer coefficients have values which are dependent on both monomer feed composition and individual comonomer transfer values. Composition, sequence distribution, and stereoregularity of copolymers obtained are, in our experimental conditions, independent of copolymer molecular weight. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 2913–2925, 1998     

Cross‐linking emulsion copolymerization of butyl acrylate with diallyl maleate

The emulsion copolymerization of butyl acrylate (BA) with a trifunctional cross‐linker, diallyl maleate (DAM), was investigated. The effect of the monomer feeding time and the amount of cross‐linker on the microstructural properties (branching, cross‐linking, gel formation, and sol MWD) of the seeded semicontinuous emulsion copolymerization of BA with DAM was investigated. It was found that the gel content was not significantly affected by increasing feeding time, but the level of quaternary carbons (an indication of the branching density) increased. On the other hand, increasing the amount of DAM in the feed composition caused gel content, level of quaternary carbons, and the cross‐linking density to increase. Interestingly, the level of quaternary carbons and the cross‐linking density sharply increased during the cooking period. The molecular weight of the sol decreased as DAM increased in the feed. In addition, the effect of process type, batch versus semibatch, was also considered and important differences in the level of quaternary carbons, cross‐linking, and gel content were found. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 4684–4694, 2005     

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     

Dispersion copolymerization of methyl methacrylate and n-butyl acrylate

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

Ultrasonically initiated emulsion polymerization of methyl methacrylate

The ultrasonically initiated emulsion polymerization of methyl methacrylate (MMA) was investigated. Experimental results show that sodium dodecyl sulfonate (SDS) surfactant plays a very important role in obtaining a high polymer yield, because in the absence of SDS, monomer conversion is near zero. Thus, the surfactant serves as an initiator and as interfacial modifier in this system (MMA/H₂O), and the monomer conversion increases significantly with increasing SDS concentration. An increase in the reactor temperature also leads to an increase in the monomer conversion. An appropriate increase in the N₂ purging rate also leads to higher conversion. The conversion of MMA decreases with increasing monomer concentration because of the higher viscosity of the system. With the experimental results, optimized reaction conditions were obtained. Accordingly, a high monomer conversion of about 67% and a high molecular weight of several millions can be obtained in a period of about 30 min. Furthermore, transmission electron micrographs show that the latex particles prepared are nanosized, indicating a promising technique for preparing nanoscale latex particles with a small amount of surfactant. In conclusion, a promising technique for ultrasonically initiated emulsion polymerization has been successfully performed. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3356–3364, 2001     

A systematic approach to the study of multicomponent polymerization kinetics: The butyl acrylate/methyl methacrylate/vinyl acetate example. IV. Optimal Bayesian design of emulsion terpolymerization experiments in a pilot plant reactor

A systematic study of the terpolymerization of butyl acrylate/methyl methacrylate/vinyl acetate (BA/MMA/VAc) is being conducted. In this stage of the study, emulsion terpolymerizations were performed in a 5 L stainless steel pilot plant reactor. The experimental trials were of the two-level factorial type and were designed optimally using a Bayesian method. The design procedure allowed us to improve our knowledge about the process using our prior knowledge and our subjective judgement. The polymers produced were characterized for conversion, composition, molecular weight, and particle size. The Bayesian design of experiments is shown to have several advantages over conventional factorial designs. © 1996 John Wiley & Sons, Inc.     

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     

Kinetics of methyl methacrylate and n‐butyl acrylate copolymerization mediated by 2‐cyanoprop‐2‐yl dithiobenzoate as a RAFT agent

The RAFT (co)polymerization kinetics of methyl methacrylate (MMA) and n‐butyl acrylate (BA) mediated by 2‐cyanoprop‐2‐yl dithiobenzoate was studied with various RAFT concentrations and monomer compositions. The homopolymerization of MMA gave the highest rate. Increasing the BA fraction f_BA dramatically decreased the copolymerization rate. The rate reached the lowest point at f_MMA ～ 0.2. This observation is in sharp contrast to the conventional RAFT‐free copolymerization, where BA homopolymerization gave the highest rate and the copolymerization rate decreased monotonously with increasing f_MMA. This peculiar phenomenon can be explained by the RAFT retardation effect. The RAFT copolymerization rate can be described by 〈R_p〉/〈R_p〉₀ = (1 + 2(〈k_c〉/〈k_t〉)〈K〉)[RAFT]₀)^?0.5, where 〈R_p〉₀ is the RAFT‐free copolymerization rate and 〈K〉 is the apparent addition–fragmentation equilibrium coefficient. A theoretical expression of 〈K〉 based on a terminal model of addition and fragmentation reactions was derived and successfully applied to predict the RAFT copolymerization kinetics with the rate parameters obtained from the homopolymerization systems. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 3098–3111, 2007     

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.     

A mass spectrometric investigation of the water-soluble oligomers remaining after the emulsion polymerization of methyl methacrylate

A “surfactant-free” emulsion polymerization of methyl methacrylate was conducted at 80°C with ammonium persulfate initiator. The water-soluble MMA-based oligomers re-maining were isolated and analyzed both as-produced and after hydrolysis. NMR analysis revealed that the mole ratio of MMA repeat units to sulfate end groups in the former is 6.5. Matrix-assisted laser desorption/ionization time-of-flight mass spectrometry and gel permeation chromatography both showed that the mean number of MMA repeat units comprising the extracted material is 8–9. The hydrolysis procedure rids the oligomers of their terminal groups and converts some of the methyl ester groups to acid, greatly sim-plifying the mass spectrum. This appears to be the first direct measurement of “surfactants” produced in situ from monomer and persulfate initiator. © 1995 John Wiley & Sons, Inc.     

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.     

Dispersion copolymerization of styrene and butyl acrylate in polar solvents

Monodisperse copolymer particles from 1.1 to 2.6 μm in diameter were obtained by unseeded batch dispersion copolymerization of styrene and butyl acrylate in an ethanol–water medium. A two-level factorial design using bottle polymerizations was initially carried out including the following variables: stabilizer concentration, initiator concentration, polarity of the dispersion medium, initial monomer concentration, and temperature. Once the region of experimental conditions in which monodisperse latexes can be prepared was identified, further effort was devoted to analyze the effect of other variables. It was found that the temperature at which nucleation occurs and the evolution of the temperature after the onset of nucleation were critical to obtain monodisperse particles. The particle size increased with increasing initial monomer concentration and ethanol–water weight ratio, and decreasing stabilizer concentration. A minimum quantity of emulsifier was necessary to avoid coalescence of particles and to obtain monodisperse particles. © 1996 John Wiley & Sons, Inc.     

Seeded microemulsion polymerization of butyl acrylate

The seeded microemulsion polymerization of butyl acrylate was studied with γ-rays. The hydrodynamic diameter and its distribution of polymer particles in the seeded microemulsion before and after polymerization were determined with photon correlation spectroscopy (PCS). Though there were micelles in the microemulsion, it was found that new particle formation could be ignored during polymerization. The polymerization kinetics of the seeded microemulsion was investigated. The polymerization rate increases with the dose rate and added monomer content and decreases with the seed fraction. It was completely different from that for seeded emulsion polymerization. © 1998 John Wiley & Sons, Inc. J. Polym. Sci. A Polym. Chem. 36: 2631–2635, 1998