Incorporation of nonionic emulsifiers inside particles in emulsion polymerization: mechanism and methods of suppression

Emulsion polymerizations of styrene were carried out using two kinds of polyoxyethylene lauryl ether nonionic emulsifiers having different hydrophilic-lipophilic balances (HLB): Emulgen 109P (HLB 13.6); and Emulgen 150 (HLB 18.3). In both cases, incorporation of emulsifier inside polystyrene (PS) particles was clearly observed, as previously reported for the emulsion polymerization of styrene and methacrylic acid using polyoxyethylene nonyl phenyl ether (Emulgen 911, HLB 13.7) nonionic emulsifier. The generality of the incorporation phenomenon of nonionic emulsifier inside polymer particles in emulsion polymerization was clarified. In the case of Emulgen 109P, which is more hydrophobic than Emulgen 150, about 30% of the total amount was incorporated inside the PS particles, higher than for Emulgen 150 (15%). The difference seemed to be ascribed to the difference in the affinities between the nonionic emulsifiers and styrene, which cause the incorporation of emulsifier. On the basis of this idea, suppression of the incorporation was achieved by decreasing the polymerization temperature and the monomer-feed rate. This strongly supports the proposed incorporation mechanism.     

Preparation of multihollow polystyrene particles by seeded emulsion polymerization using seed particles with incorporated nonionic emulsifier: effect of temperature

Seeded emulsion polymerizations of styrene using polystyrene (PS) seed particles with incorporated nonionic emulsifier were carried out at 40 and 70 °C to investigate the influence of temperature during the polymerization process including the swelling step of the seed particles with monomer on the formation of multihollow PS particles. An increase in the temperature during the polymerization process caused an increase in the rate of coalescence (i.e., the degree of coalescence at any given time) of the small water domains in the inside. After the coalescence proceeded excessively, the water domains were eventually discharged from the particles to the medium, resulting in nonhollow particles. The results show that it is important for the preparation of the multihollow PS particles to control the coalescence of a lot of small water domains inside the seed particles with the incorporated nonionic emulsifier, and strongly support the formation mechanism previously proposed. Part CCCXX of the series “Studies on Suspension and Emulsion”.     

The preparation of sterically stabilized polymer dispersions

The emulsion polymerizations of styrene (St) and butyl acrylate (BA) stabilized by nonionic polyoxyethylene type emulsifiers did not show the long stationary rate interval. This was discussed in terms of two opposing effects: 1) the decreased monomer concentration at the reaction loci due to the depletion of monomer droplets or depressed monomer droplet degradation and 2) the increased number of polymer particles with increasing conversion. The continuous particle nucleation is attributed to the continuous release of emulsifier from the emulsifier saturated monomer droplets and/or the presence of monomer swollen micelles (microdroplets). The limited particle flocculation operative at lower emulsifier concentrations increases the nonstationary-state polymerization. The particle agglomeration is accompanied by the increased reaction order x (N_p vs. [E]^x) above 0.6. The increased uniformity of monomer emulsion stabilized by Tween 20 by homogenization of monomer emulsion increased the final conversion and the polymerization rate as well. The polymerization rate vs. conversion curve of the homogenized emulsion characterized with broader stationary rate interval reminds the four rate intervals system typical for miniemulsion. The accumulation of polymer and nonionic emulsifier within the monomer phase preserves the monomer droplets up to high conversion. The decreased monomer droplet degradation rises the monomer-starved condition or the depressed transport of both monomer and emulsifier to the reaction loci.     

Kinetics and mechanisms of emulsion polymerization initiated by oil-soluble initiators. IV. Kinetic modeling of unseeded emulsion polymerization of styrene initiated by 2,2′-azobisisobutyronitrile

To explain the kinetic features of particle formation and growth in unseeded emulsion polymerization initiated by oil-soluble initiators, a mathematical kinetic model is proposed, based on the assumption that when initiator radicals or monomer radicals in the water phase enter monomer-solubilized emulsifier micelles, initiate polymerization, and propagate to a chain length which is long enough not to desorb from the micelles, the micelles are regarded to be transformed into polymer particles. It is demonstrated by comparing the experimental results obtained in the emulsion polymerization of styrene initiated by the oil-soluble initiator, 2,2'-azobisisobutyronitrile, with sodium lauryl sulfate as emulsifier that the proposed kinetic model satisfactorily explains the kinetic features such as the effects of initial emulsifier, initiator, and monomer concentrations on both the number of polymer particles produced and the monomer conversion versus time histories. © 1993 John Wiley & Sons, Inc.     

Influence of hydrophilic–lipophilic balance of nonionic emulsifiers on emulsion copolymerization of styrene and methacrylic acid

Emulsion copolymerizations of styrene and methacrylic acid (MAA) with various nonionic emulsifiers having a hydrophilic–lipophilic balance (HLB) range of 13.7–17.2 were performed to clarify the influence of emulsification state on polymerization. The emulsification state with a lower-HLB value emulsifier was worse than that with a higher one. In the lowest HLB value, MAA was predominantly polymerized over styrene in the early stage of the copolymerization, resulting in predominant (heterogeneous) distribution of MAA units in the inside of the final polymer particles. In the higher-HLB emulsifiers, styrene and MAA were simultaneously copolymerized, resulting in a homogeneous MAA distribution. The percentage of incorporation of the nonionic emulsifier inside the particles was the highest (49% based on the total amount of the emulsifier) in the lowest HLB, whereas it was 1% in the highest HLB. Part CCLXXXIV of the series “Studies on suspension and emulsion”.     

Nucleation in Emulsion Polymerization: Another Step towards Non-Micellar Nucleation Theory

Summary : Comprehensive experimental results of the nucleation stage of styrene emulsion polymerization in the absence as well as in the presence of emulsifier at different concentrations are presented. In addition, the influence of initiator type and presence of seed particles are studied. The nucleation mechanism is verified by means of on-line monitoring of the optical transmission and the conductivity of the aqueous phase. Results prove that micelles do not alter the nucleation mechanism which comprises the initiation of water soluble oligomers in the aqueous phase followed by their aggregation into colloidally stable latex particles. Surfactants assist with nucleation as they lower the activation free energy of particle formation. Contrary, in the presence of seed particles above a critical volume fraction the formation of new particles can be suppressed.     

The effect of pH on emulsion polymerization of styrene in the presence of an amphoteric emulsifier

An emulsion polymerization of styrene in the presence of an amphoteric emulsifier of the betaine type; N,N-dimethyl-n-laurylbetaine (LNB), has been studied at various pH values. The relationships between the physicochemical properties of LNB aqueous solutions, the emulsion polymerization process and the characteristics of the synthesized latex particles were studied under various pH conditions. The polymerization rate and the particle number concentration decreased with increasing pH of LNB aqueous solution and changed in shape at both ca. pH 4 and pH 8–10. The properties of LNB aqueous solution also changed with the pH and changed in shape at the same pH as that of the emulsion polymerization. These pH values were in good agreement with the pH at which the LNB molecule changed its ionic form. The number of synthesized latex particles was proportional to the number of LNB micelles in the solution, below pH 10. The particle size of the synthesized latex particles and the molecular weight of the latex polymers also changed with the properties of LNB aqueous solutions, accompanying the change of the ionic form of LNB molecules.     

Kinetics and mechanisms of emulsion polymerization of vinylidene chloride. I. Effects of operating variables on the rate of polymerization and the number of polymer particles produced

Emulsion polymerization of vinylidene chloride was carried out at 50°C using sodium lauryl sulfate as emulsifier and potassium persulfate as initiator, respectively. Contrary to the results so far reported, the stirring rate did not affect the progress of the polymerization and such an abnormal kinetic behavior as the rate of polymerization suddenly drops in the course of polymerization was not observed. The number of polymer particles produced was proportional to the 0.7 power of the concentration of emulsifier forming micelles and to the 0.3 power of the initial initiator concentration, respectively, and was independent of the initial monomer concentration. The rate of polymerization was in proportion to the 0.3 power of the concentration of emulsifier forming micelles, to the 0.5 power of the initial initiator concentration, to the 0.2 power of the initial monomer concentration, and to the 0.45 power of the number of polymer particles, respectively. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 1919–1928, 1998     

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     

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     

Role of emulsifier on the particle size and polymer particle size distribution using multiwavelength spectroscopy measurements

Latex emulsions depend strongly on the polymer composition, and particle size distribution, which in turn, is a function of the preparation of the latex and on the formulation and composition variables. This study reports measurements of particle size and particle size distribution of latex emulsions as function of the reaction time and the type and concentration of emulsifier by using the multiwavelength spectroscopy technique. Results show changes in the particle size of latex emulsions with the reaction time, obtaining larger particles and broader distributions with increasing of Tween 80 ratio. The steric stabilization provides the sole nonionic emulsifier is not enough to protect the polymer particle, causing the flocculation among the interactive particles, resulting in unstable latex. However, latex emulsions prepared with Tween 80 ratio <70 wt.% can stabilize efficiently the nucleated particles, probably due to the effects provided by both, the electrostatic and steric stabilization mechanisms. The same effect is shown in the curves of conversion (%) as a function of reaction time, resulting in slower polymerization rate for Tween 80 ratio >70 wt.%. On the other hand, smaller polymer particles, in all range of emulsifier mixture, have been obtained to higher emulsifier concentration.     

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     

苯乙烯微乳液种子聚合

通过观测苯乙烯微乳液种子聚合前后体系内聚合物粒子大小及其分布的变化发现,无论是γ射线还是KPS引发,聚合过程中都没有新的聚合物粒子生成。尽管聚合前体系中存在单体溶胀的胶束,但在聚合过程中这些胶束主要充当单体仓库,自己成核聚合的几率很低。由于微乳液种子聚合体系内,单体量相对较低,聚合物粒子数目很大,其聚合动力学明显不同于常规乳液种子聚合。     

Incorporation of nonionic emulsifier inside methacrylic polymer particles in emulsion polymerization

The incorporations of polyoxyethylene lauryl ether (Emulgen 109P) and polyoxyethylene nonylphenyl ether (Emulgen 911) nonionic emulsifiers inside poly(methyl methacrylate) (PMMA), poly(ethyl methacrylate) (PEMA), and poly(iso-butyl methacrylate) (Pi-BMA) particles prepared by emulsifier-present emulsion polymerizations were examined. To measure the amounts of the incorporated nonionic emulsifiers, optimum compositions of 2-propanol aqueous solutions to remove the nonionic emulsifier from the particle surfaces without removal from the insides were determined. The amount of the incorporation measured by gel permeation chromatography was increased in the order of PMMA > PEMA > Pi-BMA, which accorded with the order of miscibility between each polymer and the emulsifier.     

Surface functionalization of polystyrene latex particles with a liposaccharide monomer

Emulsifier-free latexes with immobilized carbohydrate residues have been prepared by batch or seed (co)polymerization of styrene in the presence of 11-(N-p-vinylbenzyl)amido undecanoyl maltobionamide (LIMA). The critical micelle concentration and the molecular surface area of LIMA were determined by surface tension and fluorescence measurements. Batch polymerization of LIMA with styrene was first performed using potassium persulfate, proving the efficiency of LIMA as emulsifier. Seed copolymerization was then investigated using polystyrene seed particles with varying experimental conditions (especially the LIMA surface coverage). Material balance of LIMA between aqueous phase and particles was obtained by separating both phases by ultracentrifugation and it was found that the surfaceactive monomer is preferentially on or in the particle (nearly 100% in batch and at most 70% in seed copolymerization). The presence of the carbohydrate residues at the particle surface was directly evidenced by ¹H-nuclear magnetic resonance, electron spectroscopy for chemical analysis and electrophoretic mobility.     

Effect of nonionic emulsifier on the production of multihollow polymer particles by the stepwise acid/alkali method

The effects of nonionic emulsifier on the formation of multihollow structures formed within sub-micron-sized polymer particles by the “acid/alkali method” proposed by the authors were examined. The original acid-swellable particles were produced by seeded emulsion terpolymerization of styrene, butyl acrylate, and dimethylaminoethyl methacrylate. The results indicate that the nonionic emulsifier had a great effect on the formation of multihollow particles.     

The Effect of pH on Emulsion Polymerization of Styrene in the Presence of an Amphoteric Emulsifier

The emulsion polymerization of styrene in the presence of an amphoteric emulsifier of the amino acid type, N-lauroyl-1-N, N-dimethyllysine (DMLL), has been studied at various pH values. The polymerization rate and the particle number concentration increased with increasing pH of the aqueous DMLL solution and these curves changed in slope at approximately pH 4 and pH 9. The physicochemical properties of the aqueous DMLL solution, such as CMC and the aggregation number, changed with the pH and similarly changed in slope at almost the same pH as the emulsion polymerization. These pH values were in good agreement with the pH at which the ionic form of the DMLL molecule changes. The number of latex particles formed changed in proportion to the number of DMLL micelles in the solution. The particle size and the molecular weight of the synthesized latex particles were also dependent on the physicochemical solution properties accompanying the change in the ionic forms of DMLL.     

Preparation of multihollow polymer particles by seeded emulsion polymerization using seed particles with incorporated nonionic emulsifier

Emulsion polymerizations of styrene using poly(oxyethylene) nonylphenyl ether nonionic emulsifier were carried out at different emulsifier and initiator (potassium persulfate, KPS) concentrations to prepare polystyrene (PS) seed particles with incorporated nonionic emulsifier. Seeded emulsion polymerizations of styrene using the PS seed particles with different amounts of incorporated emulsifier were carried out to develop a novel method for the preparation of multihollow particles. When seed particles with a small amount of incorporated emulsifier were used, non-hollow spherical particles were prepared. However, multihollow particles were obtained in the case of seed particles with a large amount of incorporated emulsifier. Moreover, the higher the initiator concentration in the preparation of seed particles, the more effectively were hollow particles prepared. On the basis of the above results, a mechanism for the formation of multihollow structure was suggested.     

On the emulsion polymerization of styrene in the presence of a nonionic emulsifier

The batch emulsion polymerization kinetics of styrene (St) initiated by a water-soluble peroxodisulfate in the presence of a nonionic emulsifier was investigated. The polymerization rate versus the conversion curves showed two nonstationary rate intervals, two rate maxima, and Smith–Ewart Interval 2 (nondistinct). The rate of polymerization and number of nucleated polymer particles were proportional to the 1.4th and 2.4th powers, respectively, of the emulsifier concentration. Deviation from the micellar nucleation model was attributed to the low water solubility of the emulsifier, the low level of the micellar emulsifier, and the mixed modes of particle nucleation. In emulsion polymerizations with a low emulsifier concentration, the number of radicals per particle and particle size increased with increasing conversion, and the increase was more pronounced at a low conversion. By contrast, in emulsion polymerizations with a high emulsifier concentration, the number of radicals per particle decreased with increasing conversion. This is discussed in terms of the mixed models of particle nucleation, the gel effect, and the pseudobulk kinetics. The formation of monodisperse latex particles was attributed to coagulative nucleation and droplet nucleation for the polymerizations with low and high emulsifier concentrations, respectively. The effects of the continuous release of the emulsifier from nonmicellar aggregates and monomer droplets, the close-packing structure of the droplet surface, and the hydrophobic nature of the emulsifier on the emulsion polymerization of St are discussed. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4422–4431, 1999     

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