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

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

Maximum Achievable Particle Size in Emulsion Polymerization: Modeling of Large Particle Sizes

A simplified model for particle formation in emulsion polymerization (comprising aqueous‐phase propagation to degrees of polymerization which may enter a pre‐existing particle and/or form new particles by homogeneous or micellar nucleation, coupled with the aqueous‐phase and intra‐particle kinetics of oligomeric radicals) is formulated to provide a model suitable for the simulation of systems containing large‐sized particles. The model is particularly useful to explore conditions for growth of large particles while avoiding secondary particle formation. Applied to the Interval II emulsion polymerization of styrene with persulfate initiator at 50°C, it is found that there is an effective maximum particle size that can be achieved if the formation of new particles is to be avoided. The parameter space of initiator concentration, particle number concentration and particle radius is mapped to show a “catastrophe” surface at the onset of new nucleation. Advanced visualization techniques are used to interpret the large number of simulations in the series, showing a maximum achievable particle diameter of around 5 μm.     

Model filled polymers. VIII. Synthesis of crosslinked polymeric beads by seed polymerization

Monodisperse crosslinked polystyrene (PS) and polymethacrylate (PMA) beads of sizes greater than 1 μm in diameter are prepared by particle nucleation onto pre-existing polymer seeds in a multistage emulsion polymerization, in the absence of emulsifier. An adequate seed number concentration, which decreases with increasing seed size, is necessary to achieve monodisperse beads. Monodisperse multicomposition beads are prepared by polymerizing styrene onto PMA seeds, but not by polymerizing methyl methacrylate onto PS seeds. Phase separation in growing seed particles or surface polymerization following free radical capture may lead to the formation of asymmetric shaped particles.     

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     

Analysis of particle formation under monomer-starved conditions in emulsion polymerization reactors

An important characteristic of monomer-starved nucleation in semibatch reactors is that the rate of growth of particles is controlled by the rate of monomer addition. The reduced rate of growth of particles prolongs the nucleation interval by slowing down the rate of emulsifier micelle depletion and forms a larger number of particles (N_p). Model calculations show how N_p varies with the formulation parameters as the monomer-flooded nucleation shifts into monomer-starved one. Particle formation in the intermediate conversion of interval III of the styrene batch emulsion polymerization also showed an enhancement because of a low rate of growth of newly formed particles. However, at a higher conversion, the rate of particle formation decreased significantly. Modeling results show that the reduction in the rate of particle formation at high conversions could not be simply explained by existing theories which rely on the decrease in monomer concentration in the aqueous phase as a means to explain the decrease in the rate of radical capture.     

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 Nucleation and Growth in the Emulsion Polymerization of Styrene: Effect of Monomer/Water Ratio and Electrolyte Concentration

This work is an extension of previous research results reported by our team (Colloid and Polymer Science 2013, 291: 2385-2398), where large scale and high solid content latexes of poly(n-butyl acrylate) were obtained with the particle coagulation method induced by the electrolyte. However, how to prepare controlled particle size distribution polymer latex has not been studied. Thus, in this study, the effect of the monomer/water ratios and electrolyte concentrations on particle formation and growth methods were studied by following the tracks of the evolutions of particle size, number and distribution as a function of reaction time or conversion. Experimental results showed that the length of time that particle nucleation occurred increased with increasing monomer charged for the systems without electrolyte. A point worthy of attention here is that homogeneous nucleation may occur at high monomer concentrations (30/70, 40/60). However, electrolyte added could be made the nucleation mechanism shift from micellar/homogeneous nucleation to micelle /coagulation nucleation. As a result, the final particle size distribution can be controlled by adding an appropriate electrolyte to regulate the nucleation mechanism. Spherical and uniformly sized particles could be obtained when electrolyte concentration is between 0.2 wt% and 0.4 wt% for water at the high monomer/water ratio (40/60). The effects of electrolyte concentration on nucleation mechanism mainly were expressed by decreasing the solubility of the monomer and interparticle potential, and then preventing homogeneous nucleation and enhancing particle coagulation.     

Particle formation mechanism and kinetic model of ultrasonically initiated emulsion polymerization

A general kinetic model of particle formation in an ultrasonically initiated emulsion polymerization system is presented. This model takes into account homogeneous, micelle entry, and monomer droplet nucleation mechanism. The effects of the ultrasound in producing free radical, degrading free radical and influencing the fashion of the nucleation are also considered. Moreover, chain transfer to monomer and termination in the aqueous phase, capture of oligomer radicals by particles, and coagulation of particles are also considered. An analytical solution is obtained for the initial particle stage consideration. This model predicts that, if the desorption of radical from particles can be neglected, the concentration of the total radical in the aqueous phase is directly proportional to the cavitation concentration. Model predictions are in good agreement with experimental data obtained from the literature.     

羟基硅油乳液合成中“漂油”现象的探索

研究了以DBSA为乳化剂与催化剂的阴离子乳液聚合D4过程中的乳液粒子形成及粒径的变化。分析实验现象发现,该体系中羟基硅油乳胶粒是通过胶束和单体珠滴两种方式形成的,由单体珠滴生成的体积较大的羟基硅油乳胶粒是形成羟基硅油乳液“漂油”的主要原因。     

Kinetics and mechanism of emulsifier-free emulsion polymerization: Styrene/surface active ionic comonomer system

The emulsifier-free emulsion polymerizations of styrene in the presence of the surface active comonomer, undecylenic isethionate sodium salt (at concentration below its critical micelle concentration), and of the initiator, potassium persulfate, indicate that the number of polymer particles and the rate of polymerization at steady state is dependent on 1-power of the comonomer concentration and 1/2-power of the initiator concentration. This result suggests a homogeneous nucleation mechanism by which particles are formed from coiled-up oligomeric radical chains originally dissolved in the aqueous phase. Size distribution of the particles is rather narrow and has a uniformity very close to one (ca. 1.02) after 30% conversion. Addition of salt such as sodium sulfate to increase the ionic strength in the aqueous phase results in a formation of micelles (which can grow to become polymer particles) in addition to the formation of polymer particles through the homogeneous nucleation mechanism. Variation of the ionic strength leads to a variation in the number of polymer particles due to a competition between these two nucleation mechanisms and gives a minimum of the number of polymer particles and a maximum of the average particle diameter.     

STUDY ON THE FORMATION MECHANISM OF MONODISPERSE PARTICLES IN THE EMULSIFIER-FREE EMULSION POLYMEAIZATION OF METHYL METHACRYLATE AND BUTYL ACRYLATE

The formation mechanism of monodisperse polymer latex particles in the emulsifier-free emulsion polymerizationof methyl methacrylate and butyl acrylate with potassium persulfate as initiator was investigated. A multi-step formationmechanism for the monodisperse polymer particles was proposed. The nucleation mechanism is considered to be thecoagulation of the precursor particles by homogeneous nucleation when the primary particles reach a critical size with highsurface charge density and sufficient stability. It had been proved by a special experiment that the early latex particles formedby the coagulation were stable. The primary particles grow by absorbing monomers and radicals in the polymerization systemand then become colloidally unstable again due to the understandable decrease of particle surface charge density, which leadsto the aggregation of the growing particles and the formation of larger latex pedicles therefrom. Aner the nucleation period,the preferential aggregation of the smaller particles in the propagation process leads to the change of the particles towards auniform size and narrower particle size distribution. The coexistence and competition of homogeneous nucleation,coagulation, propagation and aggregation result in the increase of the polydispersity index (U = D_(43)/D_(10)) in the first Stage,then its decrease in the later stage because of the competition of propagation and aggregation, and the gradual formation ofthe monodisperse particles.     

MMA/BA/聚乙二醇马来酸单酯钠盐无皂乳液聚合的成粒机理

研究了在少量聚乙二醇马来酸单酯钠盐存在下,MMA/BA无皂乳液聚合成粒过程,发现聚合初期产生的初级粒子消失后,两次周期性地产生小粒子。经分析,是新的成核作用产生的,表明在聚合的中晚期,成核过程并未真正结束,而是处于成核-聚并的动态平衡之中。     

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     

Grafting of dodecyl methacrylate onto hydroxylated polybutadiene by miniemulsion polymerization

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

On the kinetics of styrene emulsion polymerization above CMC. I. A mathematical model

A detailed mathematical model of the kinetics of styrene emulsion polymerization has been proposed. Its main features/assumptions are compartmentalization, micellar and homogeneous nucleation, particle formation by both initiator‐derived and desorbed radicals, dependence on the particle size of the rate coefficients, thermodynamic considerations, and aqueous phase kinetics. The model predicts that micellar nucleation dominates over homogeneous nucleation and that the evolution of the nucleation rate reaches a maximum, where desorbed radicals have an important contribution. Initiator‐derived radicals with only one monomeric unit have also a significant contribution on the rate of capture in particles. The results suggest that the correctness of the instantaneous termination approach depends not only on the size of the particle, but also on the type of entering radical (initiator‐derived or monomeric). © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 2201–2218, 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     

Particle formation in interval III of the emulsion polymerization of styrene with aerosol‐MA as an emulsifier

Particle nucleation in the seeded emulsion polymerization of styrene in the presence of Aerosol‐MA emulsifier micelles and in the absence of monomer droplets (interval III) was investigated. The seed particles were swollen with different amounts of the styrene monomer before the experiments. A larger number of polymer particles formed in interval III than in the corresponding seeded batch operation in the presence of monomer droplets. The increase in the number of particles could be attributed to the reduced rate of growth of new particles, which retarded the depletion of emulsifier micelles. The number of secondary particles initially increased with the initial polymer weight ratio in the seed particles (w_p0) but decreased at a higher range of w_p0, after reaching a maximum at w_p0 = 0.60, and eventually was reduced to zero. At high values of w_p0 (>0.75), polymerization occurred in the seed particles, whereas few or no new particles were formed despite the presence of micelles. The cessation of particle formation at high conversions was ascertained with a semibatch process in which the neat monomer feed was added to the reaction vessel containing the seed particles and emulsifier micelles. For w_p0 > 0.85, the emulsifier micelles were disintegrated to stabilize the seed particles with no secondary particle formation. The possible reasons for the cessation of particle formation at high w_p0 were examined. The size distribution of secondary particles showed a positive skewness in terms of volume because of the declining rate of growth for particles, together with a low rate of growth for small particles. The distribution breadth of new particles sharpened with increasing w_p0. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1652–1663, 2002     

Compartmentalized polymerization with oil-soluble initiators. Kinetic effect of single radical formation

The stationary state distribution of radicals in compartmentalized systems initiated by oil-soluble initiators have been calculated for various cases of single radical formation as well as a simultaneous generation of single radicals and pairs of radicals in the particles. The effect of a contribution from radicals produced by initiator dissolved in the aqueous phase has been considered. Desorption and reabsorption of radicals, aqueous phase termination, total rate of radical formation and the water-solubility of the initiator are quantified in terms of dimensionless parameters. The calculations predict that single radicals generated in the particles are kinetically indistinguishable from radicals produced in the aqueous phase over a wide range of variation of the parameters. It is shown that if the rate of generation of single radicals constitutes only about 10 per cent of the overall rate of radical formation in the particles, the former radicals account for the major part of the rate of polymerization. The mechanisms previously proposed to account for the similar kinetic behaviour observed with water-soluble and oil-soluble initiators are discussed. It is concluded that the present calculations support the view that this similarity is mainly due to radicals produced by the water-soluble fraction of the initiator. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35 : 2347–2354, 1997     

MMA/BA无皂乳液聚合机理研究--三阶段成粒机理

用Coulter LS230激光粒径分析仪研究MMA/BA无皂乳液共聚合中单分散粒子的成粒机理.根据理论和实验数据分析,其成核过程为均相成核机理.根据粒径分布和粒子数变化情况,把无皂乳液聚合过程分为3个阶段:第一阶段为成核-凝聚阶段,体系粒子数密度迅速增加,而粒径变化较小;第二阶段为成核-凝聚、增长-聚并共存阶段,当粒子数密度开始快速减少时,标志着第一阶段结束,第二阶段开始,当初级粒子开始消失时,标志着第二阶段结束;第三阶段为增长-聚并阶段.成核过程结束后,粒子迅速增长,较小粒子在增长过程中的优先聚并,导致粒径逐渐趋向均一,最终生成单分散性乳液.     

Control of surfactant level in starve-fed emulsion polymerization. I. Sulfate-containing oligomers: Preparation and application as surfactant in emulsion polymerization

It is well known that the amount of surfactant must be carefully controlled during starve-fed emulsion polymerization processes. Too little surfactant leads to emulsion instability and coagulation, while too much surfactant leads to secondary particle formation. Although these relationships are qualitatively understood in the art, there is little quantitative basis to guide the synthetic chemist, especially in multistep starve-fed emulsion polymerization processes to make larger supermicron particles. We have developed a method, which will be described in a companion article, to control the surfactant level by monitoring the surface tension during polymerization. In order to quantitatively predict how much surfactant to add at any given time, one needs to know in advance the adsorption characteristics of the soap. Further complicating the matter is the formation of “in situ” or oligomeric surfactant during polymerization with aqueous initiators such as ammonium persulfate. This work demonstrates how to prepare surface-active oligomers and how to make latex particles using them as surfactant. First, we established the mass balance for the initiator-derived sulfate groups in seed latexes by conductometric, potentiometric, and iodometric titrations. Based on the characterization of seed latexes, a method for determining the effective sulfate concentration has been developed. When surface-active oligomers were used as the only surfactant, we obtained a series of monodisperse, supermicron copolymer latex particles with diameters up to 3.22 μm. This is a similar result to that obtained with a commercially made anionic surfactant. © 1995 John Wiley & Sons, Inc.