Emulsion polymerization of styrene using irreversible addition–fragmentation chain transfer agents: effect on the course of the polymerization and molecular weight

The emulsion polymerization of styrene with three different chain transfer agents (CTAs) based on irreversible addition–fragmentation chain transfer (AFCT) mechanism was first reported in this work. The influences of these irreversible AFCT agents on the rate of polymerization, particle size, and molecular weight were investigated. It was found that the intrinsic activity and desorption behaviors of the CTAs determined the efficiency for molecular weight control, rate of polymerization, and particle size in the emulsion polymerization. It has been demonstrated that the rate of polymerization and particle size decreased dramatically in the presence of the irreversible AFCT agents with high chain transfer constant (ethyl α-p-toluenesulfonyl-methacrylate), meanwhile, the molecular weight of the polystyrene could not be controlled well, whereas the irreversible AFCT agents with low chain transfer constant (butyl(2-phenylallyl)sulfane and 2,3-dichloropropene) had a slight effect on the polymerization rate, particle size, and were fairly well for molecular weight control over the whole conversion range in the emulsion polymerization of styrene. The average number of radicals per particle and the number-average molecular weight were calculated by classical radical emulsion polymerization theory, and the experimental results were in good agreement with the results of model calculations, when the irreversible AFCT agents were used as CTAs. The effect of chain transfer agents on the kinetics and nucleation in the emulsion polymerization of styrene can be attributed to desorption of chain-transferred radicals from the polymer particles. The results of this work show that butyl(2-phenylallyl)sulfane as CTA in emulsion polymerization of styrene provides the best balance between the rate of polymerization and the efficiency for molecular weight control conflicting tendencies.     

High Molecular Weight Polystyrene Obtained by Cationic Emulsion Polymerization Catalyzed by Imidazolium‐Based Ionic Liquid

The ionic liquid 1‐n‐butyl‐3‐methylimidazolium heptachlorodiferrate (BMI.Fe₂Cl₇) is efficiently used as catalyst in the cationic emulsion polymerization of styrene. The effect of different reaction temperatures, surfactant, and ionic liquid concentrations on polymer properties as molecular weight distribution and particle size is evaluated. High weight average molecular weights, above 1000 kDa, are achieved at 70% of conversion in 100 nm polystyrene particles formed mainly by micellar nucleation. Particle sizes and molecular weights increase with the decrease of the amount of surfactant. Even at low concentrations, BMI.Fe₂Cl₇/styrene molar ratio equal to 1/1000, the ionic liquid proves to be efficient for the emulsion polymerization of styrene, and lower ionic liquid concentrations lead to the formation of longer polymer chains.     

Free-radical distributions in emulsion polymerization which employs oil-soluble radical generators

The use of oil-soluble radical generators for emulsion polymerization is considered. When radicals are formed in pairs within particles of a seed latex, the occurrence of radical desorption leads to complex kinetics. Use of radical balances and realistic simplifications produce a method for a relatively simple calculation of radical populations in the particles. Examples are restricted, for illustration purposes, to cases where the average number of radicals per particle, n , is less than one. Very low rates of radical desorption cause a substantial increase in n . As the desorption rate increases, the value of n decreases. n increases slowly with radical generation rate. Large decreases in the chain termination rate coefficient (which may accompany a gel effect) can have a negligible effect on the value of n . Radical distributions obtained from oil-soluble initiators can be slightly broader than those expected from the use of water-soluble initiators. The kinetics of emulsion polymerization will be similar for the two types of radical generator when radicals from oil-soluble generators can desorb from the polymer particles.     

Effect of chain transfer agents on the kinetics and mechanism of particle nucleation in the emulsion polymerization of vinyl pivalate

We have studied the kinetics and mechanism of particle nucleation in the emulsion polymerization of vinyl pivalate (VPi) under a wide variety of conditions. Quantitative comparisons between the theoretical and experimental estimations of the average number of radicals per polymer particle, as a function of the amounts of surfactant were performed. The relationship between and the parameter α _w, the ratio of radical production in the aqueous phase to termination per particle, can be explained by assuming that chain-transferred monomer radicals escape from the particle. We studied the influence of the chain transfer agents (CTA), namely, n-dibutyl disulfide, t-dibutyl disulfide and l-cysteine in the emulsion polymerization. The addition of a CTA had a strong influence on the resulting degree of polymerization. The experimental results can be accounted on the basis of a kinetic analysis of the chain transfer reaction, assuming an increase of the rate of escape of chain-transferred radicals from the polymer particle.     

Miniemulsion polymerization of styrene with chain transfer agent as cosurfactant

Miniemulsion polymerization of styrene with the chain transfer agent n-dodecyl mercaptan (DDM) used as cosurfactant was studied. Droplet size and shelf life for unpolymerized miniemulsions were measured and compared with those of equivalent macroemulsions. The miniemulsion monomer droplets with dodecyl mercaptan as cosurfactant were very stable. Shelf lives were from 17 h to 3 months. The kinetics of miniemulsion polymerization were studied. Unlike other miniemulsion systems where the cosurfactant does not act as a chain transfer agent, the polymerization rate falls with cosurfactant level because the chain transfer agent enhances radical desorption from the particles. The polymerization rate in all the miniemulsions was lower than that of the corresponding macroemulsions. Polymerized particles were larger than in the corresponding macroemulsions, but molecular weights were lower. Results indicate that DDM can serve as an effective cosurfactant as well as a chain transfer agent. The fact that the molecular weights are lower in the miniemulsion reactions indicates predominant droplet nucleation. © 1997 John Wiley & Sons, Inc.     

Particle nucleation and monomer partitioning in styrene O/W microemulsion polymerization

Particle nucleation in the polymerization of styrene microemulsions was found to take place throughout the polymerization as indicated by measurements of the particle number as a function of conversion. A mechanism based on the nucleation in the microemulsion droplets was proposed to explain the experimental findings although homogeneous nucleation and coagulation during polymerization were not completely ruled out. A thermodynamic model was developed to simulate the partitioning of monomer in the different phases during polymerization. The model predicts that the oil cores of the microemulsion droplets were depleted early in the polymerization (4% conversion). Due to the high monomer/polymer swelling ratio of the polymer particles, most of the monomer resides in the polymer particles during polymerization. The termination of chain growth inside the polymer particles was attributed to the chain transfer reaction to monomer. The low n? (less than 0.5) of the microemulsion system was attributed to the fast exit of monomeric radicals.     

Radical desorption in the emulsion polymerisation of vinyl monomers

The dependence of emulsion polymerisation rates on a number of important parameters is considered. Attention is paid to the use of seeded emulsion systems for the evaluation of radical desorption coefficients (k _o). Experimental conditions are shown to be important. When the average number of radicals per particle is low, large changes in the rate coefficient for chain termination do not have a large effect on the kinetics. With styrene and methylmethacrylate, radical re-absorption by the polymer particles is shown to be important and radical capture efficiences can be high. Consistency is established between the results of a number of workers and values fork _o are shown to be lower than those calculated from chain transfer rates.     

Polymerization of styrene in alcohol/water mediated by a macro‐RAFT agent of poly(N‐isopropylacrylamide) trithiocarbonate: From homogeneous to heterogeneous RAFT polymerization

The reversible addition fragmentation chain transfer (RAFT) polymerization of styrene in alcohol/water mixture mediated with the poly(N‐isopropylacrylamide) trithiocarbonate macro‐RAFT agent (PNIPAM‐TTC) is studied and compared with the general RAFT dispersion polymerization in the presence of a small molecular RAFT agent. Both the homogeneous/quasi‐homogeneous polymerization before particle nucleation and the heterogeneous polymerization after particle nucleation are involved in the PNIPAM‐TTC‐mediated RAFT polymerization, and the two‐stage increase in the molecular weight (M_n) and nanoparticle size of the synthesized block copolymer is found. In the initial homogeneous/quasi‐homogeneous polymerization, the M_n and nanoparticle size slowly increase with monomer conversion, whereas the M_n and particle size quickly increase in the subsequent heterogeneous RAFT polymerization, which is much different from those in the general RAFT dispersion polymerization. Besides, the PNIPAM‐TTC‐mediated RAFT polymerization runs much faster than the general RAFT dispersion polymerization. This study is anticipated to be helpful to understand the polymer chain extension through RAFT polymerization under dispersion conditions. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

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     

Emulsion copolymerization of styrene and methyl methacrylate

Chain transfer constants to monomer have been measured by an emulsion copolymerization technique at 44°C. The monomer transfer constant (ratio of transfer to propagation rate constants) is 1.9 × 10^?5 for styrene polymerization and 0.4 × 10^?5 for the methyl methacrylate reaction. Cross-transfer reactions are important in this system; the sum of the cross-transfer constants is 5.8 × 10^?5. Reactivity ratios measured in emulsion were r₁ (styrene) = 0.44, r₂ = 0.46. Those in bulk polymerizations were r₁ = 0.45, r₂ = 0.48. These sets of values are not significantly different. Monomer feed compcsition in the polymerizing particles is the same as in the monomer droplets in emulsion copolymerization, despite the higher water solubility of methyl methacrylate. The equilibrium monomer concentration in the particles in interval-2 emulsion polymerization was constant and independent of monomer feed composition for feeds containing 0.25–1.0 mole fraction styrene. Radical concentration is estimated to go through a minimum with increasing methyl methacrylate content in the feed. Rates of copolymerization can be calculated a priori when the concentrations of monomers in the polymer particles are known.     

Kinetics and mechanism of emulsifier-free emulsion polymerization. III. Styrene/nonionic comonomer (2-hydroxyethyl methacrylate) system

The emulsifier-free emulsion polymerizations of styrene in the presence of about 0.33–2.7% (relative to styrene) of the water soluble comonomer, 2-hydroxyethyl methacrylate (HEMA), and of the initiator, potassium persulfate (KPS), were carried out. It was found that KPS plays a predominant role in the particle nucleation process, since the number density of polymer particles (N_p) was dependent on the 0.97-power of [KPS]. The nucleation ability of HEMA was weak, since N_p was dependent only on the 0.17-power of [HEMA]. The particle nucleation stage ceased quite early before 1% conversion, leading to nearly monodispersed polymer particles. The nucleation is suggested to be via the homogeneous nucleation mechanism. The particles grow via the core-shell structure mechanism (shell region polymerization), since the particle size is rather large—from 1500 to 6000 Å. The amount of HEMA can affect the shell thickness and physical properties of the shell, such as the monomer swelling capacity and monomer diffusion rate.     

Determination of Monomer Transfer Constants in Emulsion Polymerization

The monomer transfer constant, C_m can be determined from the chain length distribution (CLD) under conditions in which the monomer transfer reaction rate is much larger than the other chain termination processes. Such reaction conditions are feasible in emulsion polymerization where bimolecular termination reactions are relatively less important. We conducted theoretical investigations aimed at finding the necessary reaction conditions to apply the CLD method to emulsion polymerization. The number of polymer chains per polymer particle needs to be large enough in order to keep the effects of unknown chain lengths to a minimum, i.e., the unknown chains formed during the nucleation period and those which stop growing when the polymerization is stopped for sampling. In emulsion polymerization, the polymer concentration at the polymerization locus is higher than the corresponding bulk polymerization as long as monomer droplets exist, and the polymer transfer reaction may possess significant effects under conditions where monomer transfer reactions are important. The Monte Carlo (MC) simulation results have shown that although the CLD profile becomes broader due to the polymer transfer reactions, they do not significantly change the slope, from which C_m is determined. According to the present simulation results, the CLD method is considered applicable even when the polymer transfer reaction cannot be neglected. The MC simulation method can be used to find the experimental conditions where the CLD method is applicable.     

Chain transfer in anionic polymerization. Determination of chain-transfer constants by using carbon-14-labeled chain transfer agents

A method is described in which ¹⁴C-labeled chain-transfer agents are employed to measure chain-transfer constants in anionic polymerization as low as 10^?6. Each chain-transfer step incorporates one molecule of the chain-transfer agent into the polymer so that measurement of the activity and conversion allows evaluation of the chain-transfer constant. This method is independent of the initiator concentration and efficiency, making the technique especially useful when problems with the initiator are encountered. The experimental procedure is described in detail for the case of chain transfer to toluene in the n-butyllithium-initiated polymerization of styrene, where C_RH was found to be 5 × 10^?6. A mathematical treatment is given showing the relationship between the degree of polymerization (DP _n) and chain transfer.     

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     

Emulsion polymerization of vinyl acetate using iodine‐transfer and RAFT radical polymerizations

This study deals with control of the molecular weight and molecular weight distribution of poly(vinyl acetate) by iodine‐transfer radical polymerization and reversible addition‐fragmentation transfer (RAFT) emulsion polymerizations as the first example. Emulsion polymerization using ethyl iodoacetate as the chain transfer agent more closely approximated the theoretical molecular weights than did the free radical polymerization. Although ¹H NMR spectra indicated that the peaks of α‐ and ω‐terminal groups were observed, the molecular weight distributions show a relatively broad range (M_w/M_n = 2.2–4.0). On the other hand, RAFT polymerizations revealed that the dithiocarbamate 7 is an excellent candidate to control the polymer molecular weight (M_n = 9.1 × 10³, M_w/M_n = 1.48), more so than xanthate 1 (M_n = 10.0 × 10³, M_w/M_n = 1.89) under same condition, with accompanied stable emulsions produced. In the M_n versus conversion plot, M_n increased linearly as a function of conversion. We also performed seed‐emulsion polymerization using poly(nonamethylene L ‐tartrate) as the chiral polyester seed to fabricate emulsions with core‐shell structures. The control of polymer molecular weight and emulsion stability, as well as stereoregularity, is also discussed. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

Synthesis of anionic amphiphilic diblock copolymers of poly(styrene) and poly(acrylic acid) by reverse iodine transfer polymerization (RITP) in solution and emulsion

Reverse iodine transfer polymerization (RITP), offering the appealing potential of the in situ generation of transfer agents out of molecular iodine I₂, is employed in the synthesis of anionic amphiphilic diblock copolymers of poly(styrene) and poly(acrylic acid). Starting with well‐characterized poly(styrene) as macro‐transfer agents synthesized by RITP, diblock copolymers poly(styrene)‐b‐poly(tert‐butyl acrylate) of various lengths are successfully yielded in solution with a good architectural control. These blocks are then subjected to acid deprotection and subsequent pH control to give rise to anionic amphiphilic poly(styrene)‐b‐poly(acrylic acid). Besides, homopolymers of tert‐butyl acrylate are produced by RITP both in solution and in emulsion. Furthermore, a fruitful trial of the synthesis of diblock copolymers poly(tert‐butyl acrylate)‐b‐poly(styrene) is carried out through chain extension of the poly(tert‐butyl acrylate) latex as a macro‐transfer agent in seeded emulsion polymerization of styrene. Finally, the prepared block copolymer is deprotected to bring about its amphiphilic nature and a pH control caters for its anionic character. © 2013 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2013, 51, 4389–4398     

Efficiency of mercaptan chain transfer agents in emulsion copolymerizations. I. Influence on kinetics and microstructure. Modeling of radical desorption

The effect of chain transfer agents (CTA) on the emulsion copolymerization of styrene and butyl acrylate was studied in a bench scale 7 L reactor. On-line estimates of conversion were obtained through the joint use of calorimetric measurements and fast gravimetric data. Off-line measurements of partial conversions, molecular weight distribution (MWD), glass transition temperature (T_g), and particle diameter were also performed in order to investigate the effect of two mercaptans (tert-butanethiol and n-dodecanethiol) on both the kinetics of the polymerization process and the microstructure-dependent properties of the copolymer. The obtained experimental results were interpreted in terms of radical desorption and diffusive limitations of the CTA between the oil droplets and the particles. A model has been derived to compute the kinetic constants, the number of radicals per particle, and both the GPC/SEC diagrams and DSC thermograms related to MWD and T_g measurements, respectively. Several batch and semibatch examples are proposed to show that these important variables are satisfactorily fit by the model. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 157–168, 1998     

Modeling and Experimentation of RAFT Solution Copolymerization of Styrene and Butyl Acrylate,Effect of Chain Transfer Reactions on Polymer Molecular Weight Distribution

Chain transfer reactions widely exist in the free radical polymerization and controlled radical polymerization, which can significantly influence polymer molecular weight and molecular weight distribution. In this work, the chain transfer reactions in modeling the reversible addition–fragmentation transfer (RAFT) solution copolymerization are included and the effects of chain transfer rate constant, monomer concentration, and comonomer ratio on the polymerization kinetics and polymer molecular weight development are investigated. The model is verified with the experimental RAFT solution copolymerization of styrene and butyl acrylate, with good agreements achieved. This work has demonstrated that the chain transfer reactions to monomer and solvent can have significant impacts on the number‐average molecular weight (M_n) and dispersity (Ð).     

Synthesis of Structurally Well‐Defined Telechelic Polymers by Organostibine‐Mediated Living Radical Polymerization: In Situ Generation of Functionalized Chain‐Transfer Agents and Selective ω‐End‐Group Transformations

Several organostibine chain‐transfer agents possessing polar functional groups have been prepared by the reactions of azo initiators and tetramethyldistibine ( 1 ). Carbon‐centered radicals thermally generated from the azo initiators were trapped by 1 to yield the corresponding organostibine chain‐transfer agents. The high yields observed in the synthesis of the chain‐transfer agents strongly suggest that distibines have excellent radicophilic reactivity. As the reactions proceeded under neutral conditions, functional groups that are incompatible with ionic conditions were incorporated into the chain‐transfer agents. The chain‐transfer agents were used in living radical polymerization to synthesize the corresponding α‐functionalized polymers. As the functional groups in the chain‐transfer agents did not interfere with the polymerization reaction, well‐controlled polymers possessing number‐average molecular weights (M_ns) predetermined by the monomer/transfer agent ratios were synthesized with low polydispersity indices (PDIs). The organostibanyl ω‐polymer ends were transformed into a number of different functional groups by radical‐coupling, radical‐addition, and oxidation reactions. Therefore, it was possible to synthesize well‐controlled telechelic polymers with the same and also with different functional groups at their α‐ and ω‐polymer ends. Distibine 1 was also found to increase PDI control in the living radical polymerization of styrene and methyl methacrylate (MMA) using a purified organostibine chain‐transfer agent. Well‐controlled poly(methyl methacrylate)s with M_n values ranging from 10 000 to 120 000 with low PDIs (1.05–1.15) were synthesized by the addition of a catalytic amount of 1 . The results have been attributed to the high reactivity of distibine 1 towards polymer‐end radicals, which are spontaneously deactivated to yield organostibine dormant species.     

Model for Kinetics of Vinyl Chloride Polymerization

This paper gives a critical review of recent models for the polymerization of vinyl chloride. In solution and bulk polymerization the effect of eventual degradative chain transfer to monomer, addition of chain transfer agents, and precipitation of polymer is discussed. A model for emulsion polymerization is described which includes particle formation and kinetics of polymerization where especially desorption and reabsorption of radicals in the particles are included.