Control of particle size in dispersion polymerization of methyl methacrylate

Poly(methyl methacrylate) (PMMA) particles ranging in diameter from 2 to 10 μm were prepared by dispersion polymerization. The effects of various polymerization parameters on the size and monodispersity were systematically investigated. The particle size was found to increase with increasing polymerization temperature, concentration and decomposition rate of the initiator, and solvency of the dispersion medium. It also increased with increasing concentration and molecular weight of the polymeric stabilizer, poly(vinyl pyrrolidone) (PVP). As the monomer concentration was increased from 5 to 20 wt %, a minimum was found in the particle size at a monomer concentration of 10 wt %. A costabilizer was found to be necessary for preparing monodisperse particles at stabilizer concentrations below 2 wt %. A recycling experiment showed that the consumption of PVP was quite small in each cycle and the residual materials in this system could be reused readily. © 1993 John Wiley & Sons, Inc.     

Dispersion polymerization in polar solvents

The effect of the nitrogen purge, monomer purification, type of agitation, and presence of costabilizer on the particle size distribution (PSD) was investigated in the dispersion po-lymerization of styrene in ethanol and in the dispersion copolymerization of styrene and butyl acrylate in a water–ethanol mixture. Purging with nitrogen and, to a lesser extent, monomer purification, were of paramount importance to achieve monodispersity. The type of agitation had a week effect on the PSD, whereas the presence of costabilizer had no effect on the PSD. © 1995 John Wiley & Sons, Inc.     

Effect of reaction parameters on the particle size in the dispersion polymerization of 2-hydroxyethyl methacrylate

Poly(2-hydroxyethyl methacrylate) particles in the micron size range were obtained by the dispersion polymerization. Cellulose acetate butyrate and dibenzoyl peroxide were used as steric stabilizer and initiator, respectively. The ultimate particle size could be adjusted by the selection of a suitable polymerization medium consisting of an alcohol added to toluene and by varying their relative amounts. The particle size increased with increasing solubility parameter of the mixture, i.e., by decreasing the toluene/2-methylpropan-1-ol, toluene/butan-2-ol, and toluene/3-methylbutan-1-ol ratio. The particle size decreased with increasing concentration of the stabilizer and/or initiator. At the same time, the particle size distribution became narrower. Particles prepared from polymerization mixtures purged with nitrogen before the start of polymerization were smaller, and of narrower distribution, than those prepared from nitrogen-non-purged mixtures. Equilibrium swelling of particles in toluene decreased with the decreasing content of toluene in the polymerization mixture. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 3785–3792, 1999     

Preparation of micron-size monodisperse poly(2-hydroxyethyl methacrylate) particles by dispersion polymerization

Dispersion polymerization of 2-hydroxyethyl methacrylate using four categories of polymeric stabilizers in a mixture of good and poor solvents was performed to produce polymeric particles. The stabilizers employed were methyl methacrylate and styrene homopolymers, methacryloyl-terminated poly(methyl methacrylate) and polystyrene macromonomers, an amphiphilic poly(methyl methacrylate-co-methacrylic acid-graft-styrene), and polybutadiene derivatives containing reactive vinyl groups. Dispersion copolymerization with a small amount of the macromonomer gave micron-size particles with relatively narrow size distribution. The amphiphilic graft copolymer and the polybutadiene derivatives also afforded monodisperse particles. The mixed ratio between good and poor solvents greatly affected the particle size and size distribution. © 1996 John Wiley & Sons, Inc.     

Semibatch emulsion polymerization of methyl methacrylate using different polyurethane particles

Aqueous acrylic‐polyurethane (AC–PU) hybrid emulsions were prepared by semibatch emulsion polymerization of methyl methacrylate (MMA) in the presence of four polyurethane (PU) dispersions. The PU dispersions were synthesized with isophorone diisocyanate (IPDI), 1000 and 2000 molecular weight (MW) poly(neopentyl) adipate, 1000 MW polytetramethyleneetherglycol, butanediol (BD), and dimethylol propionic acid (DMPA). MMA was added in the monomer emulsion feed. We studied the effect of the use of different PU seed particles on the rate of polymerization, the particle size and distribution, the number of particles, and the average number of radicals per particle. The PU rigidity was controlled by varying the polyol chemical structure, the polyol MW (M_n), and by adding BD. The monomer feed rate was varied to study its influence on the process. It was observed that the PU particles that had been prepared with a higher MW polyol swelled better with MMA before the monomer‐starved conditions occurred. There seemed to be no significant discrepancies between the series with different PU seeds in the monomer‐starved conditions. The overall conversion depended on the monomer addition rate, and the polymerization rate acquired a constant value that was comparable to the value of the monomer addition rate. The instantaneous conversion increased slightly. The average particle size increased, and the total particle number in the reactor was constant and similar to the number of PU particles in the initial charge. The average number of radicals per particle increased. The differences between the system with a constant particle number and average number of radicals per particle and the system with a fixed radical concentration are discussed. The semibatch emulsion polymerization of MMA in the presence of PU particles studied was better compared to the system with a fixed radical concentration. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 844–858, 2005     

Preparation of methyl methacrylate and glycidyl methacrylate copolymerized nonporous particles

Particles of methyl methacrylate (MMA) and glycidyl methacrylate (GMA) copolymer having narrow size distributions were prepared by the method of dispersion polymerization. Results from the analysis of particle porosity and the correlation of specific surface area with the reciprocal of particle diameter suggest that the prepared particles were nonporous. The particle size was found to decrease from 4.2 to 2.1 μm with increasing the mass ratio of GMA/MMA from 0.1 to 0.75. Polymer particles having an average diameter falling in this range are suitable for being employed as the stationary phase in protein chromatography. The decrease in particle size when GMA was present could be due to the increase in adsorption rate of poly(vinyl pyrrolidone). The oligomer chains that were rich in GMA were more active for adsorbing and grafting PVP, compared with the moiety of MMA. An increase in the GMA/MMA ratio also leaded to a decrease in epoxy‐group density on the particle surface, since the reactivity of GMA was greater than that of MMA. Results of this work suggest that the influence of GMA/MMA mass ratio on the particle size and surface functionality of the nonporous particles was very significant. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 1457–1463, 1999     

Effects of surface charge density on emulsion kinetics and secondary particle formation in emulsifier-free seeded emulsion polymerization of methyl methacrylate

 Experiments were carried out to investigate the effects of surface charge density on emulsion kinetics and secondary particle formation in emulsifier-free seeded emulsion polymerization. Three monodisperse seed latices with different surface charge densities were prepared from styrene/NaSS comonomers using the two-stage shot-growth process. After purification of the seed latices, they were used in seeded emulsion polymerization of methyl methacrylate. The initial rate of poly-merization and the average number of radicals per particle for the high-charged seed latex system were lower than that of the low-charged case. The low rate of polymerization resulted from the low rate of radical adsorption in the beginning of the reaction due to the electrical repulsion between seeds and oligomeric radicals. In this case, because of the secondary particles, particle size distribution became bimodal. The low rate of radical adsorption and the formation of secondary particles reduced the average number of radicals per particle. The rate of polymerization (R _p) increased, but the rate of polymerization per particle (R _p/N _p) decreased. Received: 9 December 1996 Accepted: 7 March 1997     

Dispersion copolymerization of styrene and butyl acrylate in polar solvents

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

Ultrasonically initiated emulsion polymerization of methyl methacrylate

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

Dispersion copolymerization of methyl methacrylate and n-butyl acrylate

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

Photoinitiated dispersion polymerization of methyl methacrylate: A quick approach to prepare polymer microspheres with narrow size distribution

Photoinitiated dispersion polymerization of methyl methacrylate was carried out in a mixture of ethanol and water as dispersion medium in the presence of poly(N‐vinylpyrrolidone) (PVP) as the steric stabilizer and Darocur 1173 as photoinitiator. 93.7% of conversion was achieved within 30 min of UV irradiation at room temperature, and microspheres with 0.94 μm number–average diameter and 1.04 polydispersity index (PDI) were obtained. X‐ray photoelectron spectroscope (XPS) analysis revealed that only parts of surface of the microspheres were covered by PVP. The particle size decreased from 2.34 to 0.98 μm as the concentration of PVP stabilizer increased from 2 to 15%. Extra stabilizer (higher than 15%) has no effect on the particle size and distribution. Increasing medium polarity or decreasing monomer and photoinitiator concentration resulted in a decrease in the particle size. Solvency of reaction medium toward stabilizer, which affects the adsorption of stabilizer on the particle surface, was shown to be crucial for controlling particle size and uniformity because of the high reaction rate in photoinitiated dispersion polymerization. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 1329–1338, 2008     

Emulsion polymerization of methyl methacrylate under pulsed microwave irradiation

Emulsion polymerization of methyl methacrylate (MMA) under pulsed microwave irradiation (PMI) with higher peak pulse power was studied. The effects of various parameters of PMI on the polymerization were analyzed and compared with that under conventional heating (CH) process. The results were summarized, as compared with that under CH, as follows. The amount of initiator used to reach constant conversion reduced by 50% at the same polymerization time; at the same initiator concentration 0.15 and 0.2 wt.%, the polymerization rate increased by 131% and 163%, respectively. The molecular weight of polymer obtained was 1.1-2.0 times larger than that under CH; at the same irradiation energy, the conversion achieved using a lower pulse power was greater than that using a higher pulse power. There seemed to be a factor of the irradiation energy efficiency; in other words, for the monomer conversion, the irradiation energy of low pulse power had a higher efficiency. The conversion achieved using a 3.5 μs pulse width was almost the same as that using a 1.5 μs pulse width. The results indicated that PMI had a significant non-thermal effect on the emulsion polymerization of MMA so as to effectively enhance the polymerization rate. The glass transition temperature (T_g), the polydispersity index (PDI) and the regularity of the polymer obtained using two processes were similar, indicating that the physical properties and microstructure of the polymer were not modified by the use of microwaves.     

Mechanism of the anionic polymerization of methyl methacrylate initiated by tetramethylammonium–triphenylmethide in tetrahydrofuran

A tetramethylammonium (TMA)–triphenylmethide (TPM) initiator generated in situ by the reaction of trimethyltriphenylmethylsilane with tetramethylammonium fluoride in tetrahydrofuran was found to have greater stability than the corresponding tetrabutylammonium or tetrahexylammonium derivatives. The predominant mode of degradation of TMA–TPM was found to be the TMA‐mediated methylation of TPM anions. The initiation of methyl methacrylate by TMA–TPM in tetrahydrofuran at ?78 °C was demonstrated to produce quantitative yields of poly(methyl methacrylate) with polydispersities of less than 1.1. Although the initiator efficiencies were low (9–40%) because of relatively slow initiation on the polymerization timescale, the initiation appeared to be rapid enough to give relatively narrow molecular weight distributions. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 237–244, 2004     

Studies on bulk polymerization of methyl methacrylate. I. Thermal polymerization

The thermal bulk polymerization of methyl methacrylate (MMA) in a wide range of temperatures has been studied using a dilatometric reactor. It is shown that, irrespective of the care taken to purify the MMA, the evolution of the time-conversion curve can be explained only if we account for the presence of an impurity associated with the monomer acting as a free radical initiator. The activation energy for the decomposition of this impurity has been estimated as 98 kJ/mol. Having accounted for this impurity, the activation energy for the real thermal polymerization of the MMA has been estimated to be 75 kJ/mol. © 1993 John Wiley & Sons, Inc.     

Connection of poly(methyl methacrylate) microgel particles dispersed in poly(vinyl alcohol) matrix by seed polymerization

Poly(methyl methacrylate) microgels covered with poly(hydroxyethyl methacrylate) thin layer was dispersed in poly(vinyl alcohol) matrix. Homogeneous and regular arrangement of the microgel particles was suggested by Bragg diffraction for the films prepared by varying the PVA/microgel ratio (from 6/4 to 3/7 (w/w)). It was proved that the regular arrangement and connection of the microgels by seeded polymerization in poly(vinyl alcohol) were possible. © 1996 John Wiley & Sons, Inc.     

Production of micron-sized monodispersed polymer particles by seeded polymerization for the dispersion of highly monomer-swollen particles prepared with submicron-sized polymer seed particles utilizing the dynamic swelling method

For the purpose of extending the size range of polymer seed particles used in “dynamic swelling method” (DSM), first it was verified theoretically that the submicron-sized polymer particles produced by emulsion polymerization can also absorb a large amount of monomer by DSM in both equilibrium and kinetic control states. Next, on the basis of the theoretical results, experimentally about 2.6 μm-sized styrene-swollen polystyrene (PS) particles were prepared utilizing DSM in the presence of 0.64 μm-sized monodispersed PS seed particles produced by emulsifier-free emulsion polymerization. Moreover, 2.5 μm-sized monodispersed PS particles were produced by the addition of cupric chloride as a water-soluble inhibitor to depress the by-production of submicron-sized PS particles in the seeded polymerization at 30°C with 2,2′-azobis(4-methoxy-2,4-dimethylvaleronitrile) initiator. © 1998 John Wiley & Sons, Inc. J. Polym. Sci. A Polym. Chem. 36: 2513–2519, 1998     

Anionic polymerization of Lewis acid-activated methyl methacrylate by enamines

A novel ionic polymerization of methyl methacrylate (MMA) with a series of enamines (1) in the presence of methylaluminum bis(2,6-di-tert-butylphenoxide) (2) was examined. Both nucleophile (1) and electrophile (2) are indispensable for the present polymerization, in which (1) acts as initiator and (2) as activator. MMA polymerization proceeded smoothly in toluene at or below room temperature (r.t.) in the presence of 1 and 2 (1 ∼ 4 mol %, respectively), went to completion within 1 h, and afforded syndiotactic-rich PMMA with molecular weight distribution (M_w/M_n) in the 1.1 ∼ 1.4 range. The number-average molecular weight (M_n) of the polymer was significantly higher than that calculated from the feed ratio of 1 to the monomer, indicating low initiating efficiency. Kinetic studies coupled with isolation of an intermediate species proved that the real monomeric species involved in both initiation and propagation was a complex of MMA with 2. The effects of the concentrations of 1, 2, and MMA as well as the temperature of polymerization were also examined. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 3671–3679, 1999     

High polymerization of methyl methacrylate with organonickel/MMAO systems

A series of nickel complexes, including Ni(acac)₂, (C₅H₅)Ni(η³‐allyl), and [NiMe₄Li₂(THF)₂]₂, that were activated with modified methylaluminoxane (MMAO) exhibited high catalytic activity for the polymerization of methyl methacrylate (MMA) but showed no catalytic activity for the polymerization of ethylene and 1‐olefins. The resulting polymers exhibited rather broad molecular weight distributions and low syndiotacticities. In contrast to these initiators, the metallocene complexes (C₅H₅)₂Ni, (C₅Me₅)₂Ni, (Ind)₂Ni, and (Me₃SiC₅H₄)₂Ni provided narrower molecular weight distributions at 60 °C when these initiator were activated with MMAO. Half‐metallocene complexes such as (C₅H₅)NiCl(PPh₃), (C₅Me₅)NiCl(PPh₃), and (Ind)NiCl(PPh₃) produced poly(methyl methacrylate) (PMMA) with much narrower molecular weight distributions when the polymerization was carried out at 0 °C. Ni[1,3‐(CF₃)₂‐acac]₂ generated PMMA with high syndiotacticity. The NiR(acac)(PPh₃) complexes (R = Me or Et) revealed high selectivity in the polymerization of isoprene that produced 1,2‐/3,4‐polymer at 0 °C exclusively, whereas the polymerization at 60 °C resulted in the formation of cis‐1,4‐rich polymers. The polymerization of ethylene with Ni(1,3‐tBu₂‐acac)₂ and Ni[1,3‐(CF₃)₂‐acac]₂ generated oligo‐ethylene with moderate catalytic activity, whereas the reaction of ethylene with Ni(acac)₂/MMAO produced high molecular weight polyethylene. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 4764–4775, 2000     

Self-initiated atom transfer radical polymerization of methyl methacrylate in cyclohexanone

The self-initiated atom transfer radical polymerization (ATRP) of methyl methacrylate (MMA) in cyclohexanone (CHO) in the presence of CuCl₂/N,N,N′,N″,N″-pentamethyldiethylenetriamine (PMDETA) is reported. The linear semilogarithmic plot of ln([M]₀/[M]) vs time, the linear increase of number-average molecular weight (M_n) with conversion, and rather narrow molecular weight distributions (MWDs) have been observed, which are in agreement of the characteristics of living/controlled polymerization. The NMR spectrum revealed the existence of terminal chlorine. The chain extension further proved the living characteristic. The polymerization can only be successful using CHO as the solvent, and is well controlled at the temperature as low as 50 °C. The effects of ligand, solvent, temperature and monomer to catalyst ratio are all discussed.