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     

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

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

The free radical distribution in emulsion polymerization using oil-soluble initiators

A new approach is presented to calculate both the distribution of particles with iradicals and the average number of radicals per particle in emulsion polymerizations carried out using oil-soluble initiators. The convergence and accuracy of the approach were examined. It was found that, in agreement with previously published experimental results, the present approach predicts a kinetic behavior similar to that found for water-soluble initiators. This effect is primarily due to the desorption of initiator radicals from the polymer particles rather than the contribution of the fraction of oil-soluble initiator dissolved in the aqueous phase.     

Radical desorption in the emulsion polymerisation of vinyl monomers

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

The role of chain transfer agents in the emulsion polymerization of styrene

The effect of chain transfer agents on the nucleation and growth of polymer particles in the emulsion polymerization of styrene were examined extensively. The chain transfer agents used are carbon tetrachloride, carbon tetrabromide, and four primary mercaptans (C₂, n-C₄, n-C₇, and n-C₁₂). It is shown that with an increase in the amount of chain transfer agents charged the rate of polymerization per particle decreases progressively. The number of polymer particles formed, on the other hand, increases initially then decreases. These effects can be enhanced by using a chain transfer agent with higher values of chain transfer constant and solubility in water. It is also demonstrated that with increasing radical desorption from the particles, aided by chain transfer agents, the emulsifier dependence exponent for the number of polymer particles formed increases from 0.6 to 1.0 and the initiator dependence exponent decreases from 0.4 to 0. The effect of chain transfer agents on the nucleation and growth of polymer particles in the emulsion polymerization of styrene can be explained in terms of desorption of chain-transfered radicals from the polymer particles.     

Particle nucleation in emulsion polymerization. III. Nucleation in systems with anionic emulsifier investigated by seeded and unseeded polymerization

Studies of seeded and unseeded polymerization of styrene using sodium dodecylsulfate as emulsifier have been carried out in order to investigate the mechanism of particle nucleation in such systems and to test the theory presented in Part I of this series. The rate of capture of water-soluble oligomeric radicals was considered to be governed by absorption of oligomers with chain length one less than the critical chain length. It was concluded that the micelles became the dominating loci for particle nucleation above CMC for the emulsifier. A complete nonsteady-state model for particle initiation above CMC which takes into account radical desorption and reabsorption has been developed. It was indicated that, even for styrene, desorption of radicals may play a role in controlling the radical and particle number of interval I under certain conditions. The model also showed that the efficiencies of particles in absorbing radicals could be calculated from physical parameters, such as diffusion constants and surface charge densities, which are available for the system.     

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

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

PARTICLE SIZE DISTRIBUTION OF POLYMER POWDERS BY ANALYSIS OF SORPTION KINETICS

A method has been proposed for determination of particle size distributions of polymer powders via analysis of the Fickian sorption and desorption kinetics of organic vapors. The basis for this method is a model describing the kinetics of sorption in homogeneous spherical particles having diameters distributed a-mong a finite set of diameters. A computation procedure has been developed for determining the weight fractions of each particle diameter which optimize the fit between the model and experimental sorption data. This procedure has been applied to gravimetric sorption data for several organic vapors in PVC powders ranging in diameter from 0.2 to 80 μm. For samples whose particle structure meets the assumptions of the model, the procedure yields histographic distributions closely approximating the particle size distributions determined by conventional microscopic and sedimentation methods. For porous or agglomerated particles, the method yields an “equivalent spherical size distribution” which adequately describes the sorption kinetics, but may differ significantly from size distributions measured by other methods.     

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.     

Molecular weight distribution in emulsion polymerizations

A mathematical formulation is given which describes the evolution of the number distribution of the molecular weight (MWD) of linear polymer chains that grow in emulsion polymerization systems. The resulting set of coupled ordinary differential equations takes into account the microscopic events of free radical entry, exit, chain annihilation, bimolecular termination (by combination and disproportionation), and chain transfer in a mono- or polydisperse system. Simple analytic solutions are presented for systems in which the number of particles, as well as the average number of free radicals per particle, is constant and in which the rate coefficients are size independent. These solutions indicate that compartmentalization of the free radicals in the latex particles results in a significant increase in the polydispersity of the polymer produced by emulsion polymerization, compared with that in bulk systems. The theory shows that significant mechanistic information may be obtained from experimental MWDs and that, in principle, experimental conditions may be prescribed to grow a desired MWD. The MWDs are presented in a novel manner that facilitates the comparison of theory with experiment.     

Model for Kinetics of Vinyl Chloride Polymerization

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

Heat Effects in ZLC Experiments

The problem of nonisothermal desorption in a zero length column (ZLC) experiment is considered theoretically. Simple analytical expressions for the ZLC desorption curve are derived for certain limiting situations in which the governing equations reduce to a linear form. More general numerical solutions are calculated for a wide range of experimental conditions assuming both negligible mass transfer resistance and finite mass transfer resistance controlled by intraparticle diffusion. A simple criterion for negligible thermal effects is developed. It is shown that when the ZLC technique is applied to the measurement of diffusion in unaggregated zeolite crystals, as originally intended, heat effects are generally insignificant. However, when applied to the measurement of macropore diffusion in relatively large adsorbent particles heat effects can become important and may cause major modification of both the desorption rate and the shape of the desorption curve. A recent experimental ZLC study carried out with commercial adsorbent particles, under conditions of macropore diffusion control, showed an anomalous dependence of the desorption rate on both temperature and particle size. These effects can be qualitatively explained by the nonisothermal model. A more precise quantitative representation of these experiments will require a more refined model incorporating a nonlinear equilibrium isotherm as well as intraparticle diffusional resistance.     

Kinetics of the styrene emulsion polymerization using n‐dodecyl mercaptan as chain‐transfer agent

The kinetics of the styrene emulsion polymerization using n‐dodecyl mercaptan as chain‐transfer agent was studied. It was found that the chain‐transfer agent (CTA) had no effect on polymerization rate but substantially affected the molecular weight distribution (MWD). The efficiency of the CTA in reducing the MWD was lowered by the mass‐transfer limitations. The process variables affecting CTA mass transfer were investigated. A mathematical model for the process was developed. The outputs of the model include monomer conversion, particle diameter, number of polymer particles, and number‐average and weight‐average molecular weights. The model was validated by fitting the experimental data. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 4490–4505, 2000     

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.     

Mathematical modeling of seeded miniemulsion copolymerization for oil-soluble initiator

A mathematical model of seeded miniemulsion copolymerization of styrene-methyl methacrylate for oil-soluble initiator is presented. The mathematical model includes the mass transfer, from the miniemulsion droplets to the polymer particles, by both molecular diffusion and collision between miniemulsion droplets and the polymer particles. The mathematical model also includes the calculation of both the distribution of partices with i radicals and the average number of radicals per particle in the miniemulsion copolymerization using oil-soluble initator. Studies were carried out on the mass transfer coefficients of monomers across the interface between the miniemulsion droplet and the aqueous phase, hexadecane concentration in the miniemulsion droplets, the miniemulsion droplet sizes, and the collision between miniemulsion droplets. The results indicated that the copolymerization of styrene-methyl methacrylate was not a mass transfer controlled process. The mass transfer by collision between miniemulsion droplets and polymer particles plays an important role and was included in the model in order to predict the experimental data of seeded miniemulsion copolymerization.     

Adsorption and desorption of colloidal particles on glass in a parallel plate flow chamber—Influence of ionic strength and shear rate

The adsorption and desorption rates of 736 nm diameter polystyrene particles on glass were studiedin situ using a parallel plate flow chamber and automated image analysis. Adsorption and desorption rates were measured simultaneously during deposition, enabling the determination of initial deposition rates, blocked areas per particle, desorption rate coefficients, and the number of adhering particles in the stationary state. Deposition experiments were done from suspensions with different potassium nitrate concentrations (1, 10 and 50 mM) and at varying shear rates (15 to 200 s^–1). The initial deposition rate, the desorption rate, the blocked area per particle and the number of adhering particles in the stationary state showed major variations with the shear rate and the ionic strength of the suspension. At low ionic strength, the number of adhering particles showed an oscillatory behavior in time, presumably due to a varying interaction between particle and collector surface. Blocked areas, determined from deposition kinetics, ranged 705 to 2374 cross-sections at low ionic strength, and from 10 to 564 at high ionic strength and corresponded well with those estimated from local pair distribution functions which were obtained from an analysis of the spatial arrangement of the adhering particles.     

Exploring the Limits of Emulsion Polymerization of Styrene for the Synthesis of Polymer Nanoparticles

Suspensions of polymer nanoparticles in water (latices) with average particle diameters between 20 and 80 nm were synthesized by batch emulsion polymerization of styrene using sodium dodecyl sulphate (SDS) as surfactant and potassium persulphate (KPS) as initiator. The influence of surfactant concentration, initiator concentration, monomer concentration, and reaction temperature on the final average particle diameters and size distributions of the latices were studied. The number of particles generated was proportional to the 0.56 power of the emulsifier concentration and to the 0.37 power of the initiator concentration in the whole concentration range which was observed. Furthermore, the final number of particles was dependant on the reaction temperature to the 2.06 power. With these correlations the average particle number as well as the average particle size could be estimated, and the results were in good agreement (±6%) with the experimental values. A reduction of the monomer/water ratio from 1:5 to 1:20 yielded smaller particle diameters, while leaving the particle number unaffected. The lower particle size limits for monomer ratios of 1:10 and 1:15 were estimated with diameters of about 18 and 16 nm.     

Styrene emulsion polymerization: Kinetics and particle size distributions in highly swollen latex systems

The results are reported of studies on the kinetics and the time evolution of the particle size distribution in seeded styrene emulsion polymerization systems wherein the seed latex particles were highly swollen with monomer as a result of prior swelling by dodecane. Conditions were such that no new latex particles were formed nor was a significant number of monomer droplets present (“Interval III”). The data were fitted to obtain values for the rate coefficients for entry and exit (desorption) of free radicals. It was found that, during the early part of the polymerization (when the polymer:monomer ratio in the latex particles is considerably less then in an equivalent emulsion polymerization system without dodecane), the entry rate coefficient was much smaller than that measured in systems without dodecane. This effect is consistent with an entry mechanism wherein entering free radicals must displace surfactant molecules from the latex particles.     

Exploring the Limits of Emulsion Polymerization of Styrene for the Synthesis of Polymer Nanoparticles

Summary. Suspensions of polymer nanoparticles in water (latices) with average particle diameters between 20 and 80 nm were synthesized by batch emulsion polymerization of styrene using sodium dodecyl sulphate (SDS) as surfactant and potassium persulphate (KPS) as initiator. The influence of surfactant concentration, initiator concentration, monomer concentration, and reaction temperature on the final average particle diameters and size distributions of the latices were studied. The number of particles generated was proportional to the 0.56 power of the emulsifier concentration and to the 0.37 power of the initiator concentration in the whole concentration range which was observed. Furthermore, the final number of particles was dependant on the reaction temperature to the 2.06 power. With these correlations the average particle number as well as the average particle size could be estimated, and the results were in good agreement (±6%) with the experimental values. A reduction of the monomer/water ratio from 1:5 to 1:20 yielded smaller particle diameters, while leaving the particle number unaffected. The lower particle size limits for monomer ratios of 1:10 and 1:15 were estimated with diameters of about 18 and 16 nm.     

Single-particle electrophoresis for studying the adsorption of cationic polymers onto anionic particles

Understanding the adsorption of polymers onto particles is crucial for many technological and biomedical applications. Even though polymer adsorption on particles is a dynamic process, most experimental techniques can only study the adsorption indirectly, in equilibrium and on the ensemble level. New analysis methods are required to overcome these limitations. We investigated the use of single-particle electrophoresis to study the adsorption kinetics of cationic polymers onto anionic particles and compared the resulting data to a theoretical model. In this approach, the electrophoretic mobility of single polystyrene (PS) particles, exposed to different concentrations of poly(2-guanidinoethyl methacrylate), was measured as a function of time. The polymer adsorption leads to an electrophoretic mobility change of the PS particle over time, from the initial negative value to a positive value at equilibrium. By fitting the kinetics data to the Langmuir model, the adsorption rate, desorption rate and equilibrium constant were determined. Finally, the adsorption kinetics of several other polymers was investigated. This showed that the presented technique enables direct analysis and comparison of the kinetics of polymer adsorption on the single-particle level.