Emulsion polymerization. VI. Concentration of monomers in latex particles

Nonpolymerizing latex particles surrounded by an aqueous phase saturated with monomer absorb only a finite amount of monomer, even if the monomer is a good solvent for the polymer, because the surface energy of each particle increases on swelling. At equilibrium the change in surface energy and the free energy of mixing exactly balance. Equations based on this thermodynamic principle predict with good accuracy the saturation swelling of crosslinked and uncrosslinked latex particles and the partitioning of monomer between the aqueous phase and latex particles at partial saturation. The available experimental data on swelling of latex polymers with monomers are reviewed. Earlier papers assumed that during emulsion polymerization the monomer concentration in the latex particles is independent of conversion as long as monomer droplets are present. This assumption is shown to be a justifiable approximation. The thermodynamics of the swelling of latex particles with a blend of two monomers is presented. The calculations indicate that copolymerization in emulsion should define reactivity ratios differing from those of homogeneous copolymerization by not more than 40% if the solubility of the comonomers in water is low. The reactivity ratio scheme is strictly applicable to emulsion copolymerization if the solvent properties of the two comonomers are identical.     

Prediction of polymer composition in batch emulsion copolymerization

Monomer partitioning in emulsion copolymerization plays a key role in determining composition drift and polymerization rates. The combination of recently developed thermodynamically based monomer partitioning relationships with mass balance equations, makes predictions of monomer partitioning in emulsion copolymerizations possible in terms of monomer mole fractions and monomer concentrations in the particle and aqueous phases. Using this approach, the effects of monomer to water ratios and polymer volumes on the monomer mole fraction within the polymer particle phase in a nonpolymerizing system at thermodynamic equilibrium can be determined. Comparison of these monomer partitioning predictions with experiments for the monomer system methyl acrylate—vinyl acetate shows good agreement. Furthermore, composition drift occurring in a polymerizing system as a function of conversion can be predicted if the assumption is made that equilibrium is maintained during reaction. Comparison of predictions with experimental results for emulsion copolymerizations of the monomer systems methyl acrylate—vinyl acetate and methyl acrylate—indene shows good agreement. © 1994 John Wiley & Sons, Inc.     

A molecular theory for particle nucleation: primary particle formation in emulsion polymerization

Homogeneous nucleation is fundamentally important in emulsion polymerization. A molecular theory is proposed to quantify primary particle formation in the process. The proposed model divides a polymerization system into three portions: the domains formed by growing radicals, their surrounding aqueous solution, and dispersed monomer droplets. In general, the total free energy of the domains is contributed from the mixing among the molecules including monomer and water, the elasticity of oligomeric radical chains, and the transferable free energy of electrolytes; while that of the outer solution is from the mixing of monomer and water molecules and the transferable energy of electrolytes. Application of this theory to vinyl acetate emulsion polymerization has shown that the critical degree of polymerization (j(cri)) predicted is in a good agreement with the value derived from experimental data reported in literature. Furthermore, this model can also estimate the concentrations of VAc and water in the domain at the degrees of polymerization around j(cri).     

Evidence for and against concentration gradients in polymerizing latex particles

A single-charge emulsion polymerization involving a monomer which is a good solvent for its polymer is considered. It is shown to be unlikely that within the polymerizing latex particles there are concentration gradients large enough measurably to affect the kinetics of the reaction. The average displacement of monomers due to Brownian motion within the latex particles and in the absence of concentration gradients is calculated. This diffusive mean free path, corresponding to an interval involving less than 1% change in conversion, is shown to be much longer than the radius of the latex particle. Consequently, loci where monomer concentration is perturbed by conversion to polymer are immediately swamped by unreacted monomer. Also, direct experimental evidence exists showing that the monomer concentration in latex particles is about the same when nonpolymerizing latex particles are saturated or during polymerization in the presence of monomer excess. The thermodynamics of saturation swelling preclude the possibility of the existence of large concentration gradients. The arguments that have been advocated in the literature for core–skin separation within polymerizing latex particles were based on conversion data which were thought to be linear with time, while a reexamination indicates that they were not. The observed core–skin separation obtained when butadiene or tritiated styrene were copolymerized with styrene in the presence of a polystyrene homopolymer seed latex has questionable relevance to single-charge homopolymerization. There are reasons to doubt that the distribution of co-monomers within latex particles can be frozen by their conversion to polymers in a two-stage emulsion polymerization.     

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     

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.     

Partition coefficient for small amounts of monomer,solvent, or plasticizer in a two-phased polymer blend or IPN

Theoretical calculations based on statistical thermodynamics are presented addressing the partitioning behavior of a monomer, solvent, or plasticizer in a two-phased polymer system. A phase-separated interpenetrating polymer network (IPN) consisting of a polyurethane (PU) and poly(methyl methacrylate) (PMMA) (50/50 by weight) is chosen as the model. Methyl methacrylate (MMA) is chosen as the partitioning small molecule, which is added at 20% by weight of the polymers. It is shown that the free energy of mixing this MMA is minimum only when the MMA is partitioned nearly uniformly between the two phases. It is also shown that such mixing of a small molecule in a polymer system is controlled by the entropic rather than enthalpic contributions to the free energy changes. © 1996 John Wiley & Sons, Inc.     

Emulsion polymerization of hydrophobia monomers

Emulsion polymerization is the most important industrial polymerization process for manufacturing water based polymers. The heterogeneous nature of the process requires the diffusion of monomers from the emulsified droplets, through the aqueous medium, into the polymer particles where the polymerization takes place. Adequate solubility of the monomer is necessary for the diffusion process to occur effectively. Consequently, very hydrophobic monomers cannot be readily incorporated by emulsion polymerization. The use of a catalytic level of cyclodextrin allows the use of very hydrophobic monomers in emulsion polymerization.^[1] The mechanism of the process is believed to involve a catalytic cycle in which cyclodextrin acts as a “Phase Transport Catalyst”, continuously complexing and solubilizing the hydrophobic monomers and releasing them to the polymer particles. The kinetics and thermodynamics are favorable for the reaction to proceed.     

Maltodextrin as stabilizer for emulsion polymerization: Adsorption and grafting behavior

Emulsion polymerization of the three-monomer system butyl acrylate–styrene–methacrylic acid was performed in batch using a commercial maltodextrin derived from starch degradation as stabilizer. Stable latexes with narrow particle size distributions were obtained in all examined cases. A method was developed to analyze and quantify the partitioning of the maltodextrin between the continuous phase (supernatant) and the particle phase. Significant differences between the polysaccharides adsorbed onto particles with or without emulsion polymerization reaction were observed. The possible reactions of maltodextrin in presence of a radical initiator were studied in aqueous phase, thus confirming maltodextrin degradation. The formation of copolymers involving the original monomers and the stabilizer according to two different reactive pathways was also confirmed. In terms of adsorbed maltodextrin, two different contributions were observed: maltodextrin physically adsorbed and maltodextrin chemically grafted and/or physically incorporated into the polymer.     

Preparation of highly monodisperse poly(methyl methacrylate) particles incorporating fluorescent rhodamine 6G for colloidal crystals

Soap-free emulsion polymerization was extended to preparation of monodisperse poly(methyl methacrylate) (PMMA) particles incorporating rhodamine 6G (R6G) fluorescent molecules. The polymerization was conducted in the presence of an anionic monomer, p-styrenesulfonate (NaSS), which improved dispersion stability of the polymer particles. NaSS concentrations was ranged up to 2 mol/m3 H2O in the polymerization at 0.5 kmol/m3 H2O methyl methacrylate (MMA) monomer and 5 mol/m3 H2O potassium persulfate (KPS) initiator for R6G concentrations from 0.1 to 10 mol/m3-polymer. At R6G concentrations lower than 1.0 mol/m3-polymer, PMMA particles were highly monodisperse and incorporated most R6G molecules. The average sizes of PMMA particles were in a rage of 160-300 nm, and decreased with the concentration of NaSS. The high monodispersity of the particles enabled the fabrication of colloidal crystals of the particles with a vertical deposition method.     

Facile fabrication of monodisperse polymer hollow spheres

This article reports the facile synthesis of monodisperse polymer hollow spheres by seeded emulsion polymerization without additional treatment. In this method, P(St-MMA-MAA) copolymer latex particles were first prepared by emulsifier-free emulsion polymerization and then used as seeds to carry out emulsion polymerization of methyl methacrylate (MMA), divinyl benzene (DVB), and 2-hydroxyethyl methacrylate (HEMA) with potassium persulfate (KPS) as initiator at 80 degrees C. The void of hollow spheres was readily adjusted by changing the monomer/seed weight ratio, and it could be enlarged while the diameters of hollow spheres changed little after etching by dimethyl formamide (DMF). The effects of synthetic parameters including the monomer composition and the properties of seeds on the morphology of hollow spheres were investigated in detail. On the basis of the experimental results, it seemed reasonable to conclude that the formation of hollow spheres was due to the "dissolution" of seeds in monomers and phase separation between the constituent polymers. As a thermodynamic factor, sodium dodecyl sulfate (SDS) would allow the preparation of solid particles depending on its level.     

The emulsion polymerization of vinyl acetate. Factors controlling particle surface area and rate of polymerization

An emulsion polymerization system with uniform continuous addition of vinyl acetate monomer, Pluronic F68 surfactant, and persulfate initiator has been examined with variation of the surfactant concentration over a tenfold range. The particle surface area per unit weight of emulsion was found to vary directly as the surfactant/monomer ratio, as also did the emulsion viscosity. At constant polymer/emulsion weight the number of particles per unit emulsion weight varied directly as the cube of the surfactant concentration. It is shown that these relationships apply also to other monomers, such as styrene and methacrylate esters. The solubility of vinyl acetate in a range of Pluronic F68 aqueous solutions was determined, and it was shown that the rate of polymerization is dependent on the solubility of the monomer in the surfactant solution. It is concluded that when a water-soluble initiator is used, polymerization proceeds in the aqueous phase. The principal factors controlling the rate of polymerization in the emulsion polymerization of vinyl acetate are, consequently, the initiating system and the concentration of monomer in the aqueous phase. Solubilization characteristics indicate that the surfactant concentration will have a much greater effect on the less water-soluble monomers, such as styrene, than on the more soluble ones, such as vinyl acetate.     

The Growth of Polystyrene Latex Particles

Our understanding of the factors controlling the growth of polystyrene latex particles has recently undergone extensive revision. For this compatible monomer-polymer system, it was generally presumed that monomer and polymer were uniformly distributed throughout the particles, whereas we have found quite the contrary. Under a wide range of conditions, growing latex particles actually exhibit a distributed structure in which a monomer-rich shell encapsulates a polymer-rich core. First elucidated in kinetic studies of styrene emulsion polymerization, this behavior has also been observed in particles which reside in a state of equilibrium saturation with monomer. The encapsulation phenomenon is governed by the microscopic thermodynamic environment of the latex particles which has, in turn, a profound effect upon the conformational behavior of the long-chain polymer molecules as they interact with the particle-water interface. The control of latex particle properties by the staged addition of several monomers (overcoating) has been part of the industrial lore for many years. The successful execution of this technique has been attributed to either a slow monomer addition technique or to the inherent incompatibilities of the successive generations of polymer. In situations involving the addition of a monomer which is compatible with the seed polymer, the encapsulation phenomenon is probably the controlling factor in the overcoating process.     

Uniform nonspherical latex particles as model interpenetrating polymer networks

Polystyrene/polystyrene latex interpenetrating polymer networks (IPNs) were prepared by seeded emulsion polymerization of styrene–divinylbenzene mixtures in crosslinked monodisperse polystyrene particles. The resulting latexes comprised uniform nonspherical particles, e.g., ellipsodal and egg-like singlets, symmetry and asymmetric doublets, and ice cream cone-like and popcorn-like multiplets. The nonspherical particles, which were formed by separation of the second-stage monomer from the crosslinked seed network during swelling and polymerization, are excellent models for studying phase separation in IPN's. The degree of phase separation increased with increasing degree of crosslinking of the seed particles, monomer/polymer swelling ratio, polymerization temperature, and seed particle size, and with decreasing divinylbenzene concentration in the swelling monomer. The results were consistent with a thermodynamic analysis based on the elastic-retractile force of the polymer network, the monomer/polymer mixing force, and interfacial tension force.     

SCATTERING FUNCTION OF POLYMER BLENDS

For a system of flexible polymer molecules, the concepts of two concentrations, namely the segmental and the molecular concentrations, have been proposed in this paper. The former is equivalent to the volume fraction. The latter can be defined as the number of the gravity centers of macromolecules in a unit volume. The two concentrations should be correlated with each other by the conformational function of the polymer chain and should be discussed in different thermodynamic equations. On the basis of these concepts it has been proved that the Flory-Huggins entropy of mixing should be the result of the mixing “ideal gases of the gravity centers of macromolecules“. The general correlation between the free energy of mixing and the scattering function (structural factor) of polymer blends has been studied based on the general fluctuation theory. When the Flory-Huggins free energy of mixing is adopted, the de Gennes scattering function of a polymer blend can be derived.     

Polymer particle formation in soapless emulsion polymerization

Polymer particle formation in soapless emulsion polymerization for monomers that are soluble in diluent is studied theoretically and experimentally. A kinetic model is proposed assuming that polymer particles are formed by homogeneous nucleation of both growing radicals and dead polymer molecules above the critical size in solution. Based on this model, the dependence of the number of polymer particles on the concentration of initiator and monomer in solution is discussed for the polymerization system of methyl methacrylate–potassium persulfate–water. Experimental results of the number of polymer particles in this system can reasonably be interpreted by this model.     

Polymerization of vinyl chloride at reduced monomer accessibility. III. Polymerization kinetics and molecular structure using PVC latex as seed

Vinyl chloride was polymerized at 53–97% of the saturation pressure in a water-suspended system at 55°C with an emulsion PVC latex as seed. A water-soluble initiator was used in various concentrations. The monomer was continuously charged as vapor from a storage vessel kept at lower temperature. Characterization included determination of molecular weight distribution and degree of long-chain branching by gel chromatography and viscometry and by thermal dehydrochlorination. To avoid diffusion control intense agitation was necessary. At a certain conversion, aggregation of primary particles resulted in restricted polymerization rate. Before aggregation, formation of new particles did not occur as the number of particles was high enough to ensure capture of all oligoradicals. The kinetic equation accepted for ordinary emulsion polymerization of vinyl chloride was qualitatively found to be valid after the pressure drop as well. Decreased termination rate may result in increased polymerization rate at reduced monomer concentration, i.e., a gel effect, especially at low particle numbers and high polymer contents. The molecular weight decreased with decreasing monomer concentration. This is in accordance with the new mechanism suggested for chain transfer to monomer starting with occasional head-to-head additions.     

Preparation and colloidal stability of monodisperse magnetic polymer particles

A previously proposed method was examined for producing monodisperse, submicrometer-sized magnetic polymer particles. The method applies soap-free emulsion polymerization during which Fe3O4 magnetic nanoparticles are heterocoagulated onto precipitated polymer nuclei. To chemically fix the magnetic particles to the polymer nuclei, vinyl groups were introduced on the Fe3O4 particles in a preliminary surface modification reaction with methacryloxypropyltrimethoxysilane, and methacryloxypropyldimethoxysilane (MPDMS) was added to reaction systems of the soap-free emulsion polymerization. The colloidal dispersion stability of magnetic polymer particles was improved by the addition of an ionic monomer, sodium p-styrenesulfonate (NaSS), during the polymerization. The polymerizations were carried out with styrene monomer and potassium persulfate initiator in ranges of NaSS concentrations (0-2.4 x 10(-3) M), NaSS addition times (60-80 min), and monomer concentrations (0.3-0.6 M) at fixed concentrations of 1.6 x 10(-2) M initiator and 1.3 x 10(-2) M MPDMS for pH 4.5 adjusted with a buffer system of [CH3COOH]/[NaOH]. The addition of NaSS during the polymerization could maintain the dispersion stability of magnetic polymer particles during the polymerization. Selection of the reaction conditions enabled the preparation of colloidally stable, submicrometer-sized magnetic polymer particles that had coefficients of variation of distribution smaller than the standard criterion for monodispersity, 10%.     

One‐stage synthesis of narrowly dispersed polymeric core‐shell microspheres

A method of one‐stage soap‐free emulsion polymerization to synthesize narrowly dispersed core‐shell microspheres is proposed. Following this method, core‐shell microspheres of poly(styrene‐co‐4‐vinylpyridine), poly(styrene‐co‐methyl acrylic acid), and poly[styrene‐co‐2‐(acetoacetoxy)ethyl methacrylate‐co‐methyl acrylic acid] are synthesized by one‐stage soap‐free emulsion polymerization of a mixture of one or two hydrophobic monomers and a suitable hydrophilic monomer in water. The effect of the molar ratio of the hydrophobic monomer to the hydrophilic one on the size, the core thickness, and the shell thickness of the core‐shell microspheres is discussed. The molar ratio of the hydrophobic and hydrophilic monomers and the hydrophilicity of the resultant oligomers of the hydrophilic monomer are optimized to synthesize narrowly dispersed core‐shell microspheres. A possible mechanism of one‐stage soap‐free emulsion polymerization to synthesize core‐shell microspheres is suggested and coagglutination of the oligomers of the hydrophilic monomers on the hydrophobic core is considered to be the key to form core‐shell microspheres. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 1192–1202, 2008     

茂型金属复合催化丙烯酸酯聚合物多孔材料的研究

以丙烯酸酯类单体、聚合物树脂粉料为主要原料,通过自制乳化剂的水乳液模板法和茂型金属-N,N-二甲基苯胺-过氧化物组成的复合氧化―还原引发体系,混合形成可室温快速聚合成型得到丙烯酸酯聚合物多孔材料的可浇注的悬浮乳液。研究了初始混合温度、搅拌速度和时间对操作工艺的影响和聚合固化过程中的热效应,讨论了聚合成孔机理、水和惰性树脂粉料对多孔材料孔隙和强度的影响、多孔材料的透气透水性能。结果表明,二茂铁比二茂钴、二茂镍、二茂钌等均具有更快的引发速率和单体转化率,在完全活性树脂粉料下成型的多孔材料可具有30 MPa以上抗压强度和40%以上的压缩形变,优异的透气透水性,开孔孔隙率达20%(V/V)以上;并且随着惰性树脂粉料的添加,多孔材料强度韧性和开孔孔隙率明显下降;而随着水用量的增加,开孔材料孔隙率增加,强度下降。