Addition polymers polymerization processes

Polymerization processes yielding polymers, whose mers are constitutionally identical to the reacting monomers are now classified as addition polymerizations. Thus styrene can be converted, by addition polymerization, to polystyrene ... 

The majority of polymer flow processes are characterized as low Reynolds number Stokes (i.e. creeping) flow regimes. Therefore in the formulation of finite element models for polymeric flow systems the inertia terms in the equation of motion are usually neglected. In addition, highly viscous polymer flow systems are, in general, dominated by stress and pressure variations and in comparison the body forces acting upon them are small and can be safely ignored. 

The initiators which are used in addition polymerizations are sometimes called catalysts, although strictly speaking this is a misnomer. A true catalyst is recoverable at the end of the reaction, chemically unchanged. Tliis is not true of the initiator molecules in addition polymerizations. Monomer and polymer are the initial and final states of the polymerization process, and these govern the thermodynamics of the reaction the nature and concentration of the intermediates in the process, on the other hand, determine the rate. This makes initiator and catalyst synonyms for the same material The former term stresses the effect of the reagent on the intermediate, and the latter its effect on the rate. The term catalyst is particularly common in the language of ionic polymerizations, but this terminology should not obscure the importance of the initiation step in the overall polymerization mechanism. 

An example of a commercial semibatch polymerization process is the early Union Carbide process for Dynel, one of the first flame-retardant modacryhc fibers (23,24). Dynel, a staple fiber that was wet spun from acetone, was introduced in 1951. The polymer is made up of 40% acrylonitrile and 60% vinyl chloride. The reactivity ratios for this monomer pair are 3.7 and 0.074 for acrylonitrile and vinyl chloride in solution at 60°C. Thus acrylonitrile is much more reactive than vinyl chloride in this copolymerization. In addition, vinyl chloride is a strong chain-transfer agent. To make the Dynel composition of 60% vinyl chloride, the monomer composition must be maintained at 82% vinyl chloride. Since acrylonitrile is consumed much more rapidly than vinyl chloride, if no control is exercised over the monomer composition, the acrylonitrile content of the monomer decreases to approximately 1% after only 25% conversion. The low acrylonitrile content of the monomer required for this process introduces yet another problem. That is, with an acrylonitrile weight fraction of only 0.18 in the unreacted monomer mixture, the low concentration of acrylonitrile becomes a rate-limiting reaction step. Therefore, the overall rate of chain growth is low and under normal conditions, with chain transfer and radical recombination, the molecular weight of the polymer is very low. 

An alternative polymerization process utilizes a slurry of calcium chloride in NMP as the polymerization medium. The solubiHty of calcium chloride is only 6% at 20°C however, the salt continues to dissolve as conversion of monomers to polymer proceeds and calcium chloride/polyamide complexes are formed. Polymer molecular weight is further increased by the addition of /V, /V- dim ethyl a n i1 in e as an acid acceptor. This solvent system produces fiber-forming polymer of molecular weights comparable to that formed in HMPA/NMP. 

The neat resin preparation for PPS is quite compHcated, despite the fact that the overall polymerization reaction appears to be simple. Several commercial PPS polymerization processes that feature some steps in common have been described (1,2). At least three different mechanisms have been pubUshed in an attempt to describe the basic reaction of a sodium sulfide equivalent and -dichlorobenzene these are S Ar (13,16,19), radical cation (20,21), and Buimett s (22) Sj l radical anion (23—25) mechanisms. The benzyne mechanism was ruled out (16) based on the observation that the para-substitution pattern of the monomer, -dichlorobenzene, is retained in the repeating unit of the polymer. Demonstration that the step-growth polymerization of sodium sulfide and /)-dichlorohenzene proceeds via the S Ar mechanism is fairly recent (1991) (26). Eurther complexity in the polymerization is the incorporation of comonomers that alter the polymer stmcture, thereby modifying the properties of the polymer. Additionally, post-polymerization treatments can be utilized, which modify the properties of the polymer. Preparation of the neat resin is an area of significant latitude and extreme importance for the end user. 

Because plastics are almost invariably modified with one or more additives, there are three components of chemical analysis the high molecular weight portion, ie, the polymer the additives, ie, plasticizer and mold-release agent and the residuals remaining from the polymerization process. The high... 

The living polymerization process offers enormous flexibiUty in the design of polymers (40). It is possible to control terminal functional groups, pendant groups, monomer sequencing along the main chain (including the order of addition and blockiness), steric stmcture, and spatial shape. 

The ionic liquid process has a number of advantages over traditional cationic polymerization processes such as the Cosden process, which employs a liquid-phase aluminium(III) chloride catalyst to polymerize butene feedstocks [30]. The separation and removal of the product from the ionic liquid phase as the reaction proceeds allows the polymer to be obtained simply and in a highly pure state. Indeed, the polymer contains so little of the ionic liquid that an aqueous wash step can be dispensed with. This separation also means that further reaction (e.g., isomerization) of the polymer s unsaturated ot-terminus is minimized. In addition to the ease of isolation of the desired product, the ionic liquid is not destroyed by any aqueous washing procedure and so can be reused in subsequent polymerization reactions, resulting in a reduction of operating costs. The ionic liquid technology does not require massive capital investment and is reported to be easily retrofitted to existing Cosden process plants. 

To accelerate the polymerization process, some water-soluble salts of heavy metals (Fe, Co, Ni, Pb) are added to the reaction system (0.01-1% with respect to the monomer mass). These additions facilitate the reaction heat removal and allow the reaction to be carried out at lower temperatures. To reduce the coagulate formation and deposits of polymers on the reactor walls, the additions of water-soluble salts (borates, phosphates, and silicates of alkali metals) are introduced into the reaction mixture. The residual monomer content in the emulsion can be decreased by hydrogenizing the double bond in the presence of catalysts (Raney Ni, and salts of Ru, Co, Fe, Pd, Pt, Ir, Ro, and Co on alumina). The same purpose can be achieved by adding amidase to the emulsion. 

Perhaps the most familiar addition polymer is polyethylene, a solid derived from the monomer ethylene. We might represent the polymerization process as... 

NMR methods can be applied to give quantitative determination of initiator-derived and other end groups and provide a wealth of information on the polymerization process. They provide a chemical probe of the detailed initiation mechanism and a greater understanding of polymer properties. The main advantage of NMR methods over alternative techniques for initiator residue detection is that NMR signals (in particular nC NMR) are extremely sensitive to the structural environment of the initiator residue. This means that functionality formed by tail addition, head addition, transfer to initiator or primary radical termination, and various initiator-derived byproducts can be distinguished. 

There are additional factors that may reduce functionality which are specific to the various polymerization processes and the particular chemistries used for end group transformation. These are mentioned in the following sections. This section also details methods for removing dormant chain ends from polymers formed by NMP, ATRP and RAFT. This is sometimes necessary since the dormant chain-end often constitutes a weak link that can lead to impaired thermal or photochemical stability (Sections 8.2.1 and 8.2.2). Block copolymers, which may be considered as a form of end-functional polymer, and the use of end-functional polymers in the synthesis of block copolymers are considered in Section 9.8. The use of end functional polymers in forming star and graft polymers is dealt with in Sections 9.9.2 and 9.10.3 respectively. 

Structurally, plastomers straddle the property range between elastomers and plastics. Plastomers inherently contain some level of crystallinity due to the predominant monomer in a crystalline sequence within the polymer chains. The most common type of this residual crystallinity is ethylene (for ethylene-predominant plastomers or E-plastomers) or isotactic propylene in meso (or m) sequences (for propylene-predominant plastomers or P-plastomers). Uninterrupted sequences of these monomers crystallize into periodic strucmres, which form crystalline lamellae. Plastomers contain in addition at least one monomer, which interrupts this sequencing of crystalline mers. This may be a monomer too large to fit into the crystal lattice. An example is the incorporation of 1-octene into a polyethylene chain. The residual hexyl side chain provides a site for the dislocation of the periodic structure required for crystals to be formed. Another example would be the incorporation of a stereo error in the insertion of propylene. Thus, a propylene insertion with an r dyad leads similarly to a dislocation in the periodic structure required for the formation of an iPP crystal. In uniformly back-mixed polymerization processes, with a single discrete polymerization catalyst, the incorporation of these intermptions is statistical and controlled by the kinetics of the polymerization process. These statistics are known as reactivity ratios. 

Since Carothers introduced the distinction between condensation and addition polymers based on the composition relationship between monomer and structural unit, a number of examples of polymerization processes have been found which formally resemble the condensation type but which proceed without evolution of a by-product. For example, a glycol and a diisocyanate react intermolecularly as follows ... 

The chemical and physical properties of the polymers obtained by these alternate methods are identical, except insofar as they are affected by differences in molecular weight. In order to avoid the confusion which would result if classification of the products were to be based on the method of synthesis actually employed in each case, it has been proposed that the substance be referred to as a condensation polymer in such instances, irrespective of whether a condensation or an addition polymerization process was used in its preparation. The cyclic compound is after all a condensation product of one or more bifunctional compounds, and in this sense the linear polymer obtained from the cyclic intermediate can be regarded as the polymeric derivative of the bifunctional monomer(s). Furthermore, each of the polymers listed in Table III may be degraded to bifunctional monomers differing in composition from the structural unit, although such degradation of polyethylene oxide and the polythioether may be difficult. Apart from the demands of any particular definition, it is clearly desirable to include all of these substances among the condensation... 

HPLC methods of determining the amounts of different additives in polymeric materials are preceded by an extraction process or dissolution of the polymer matrix. Although extraction-HPLC is often observed to be superior to the traditional spectroscopic techniques (UV and IR) in analysing additives, it is frequently difficult to obtain reproducible results in view of the variability of the extraction yield. On the other hand, it is equally difficult to obtain quantitative data in the dissolution/reprecipitation-HPLC method because of entrapment of analytes in the polymer precipitate and the potential for high absorption of the additives on the polymer surface. 

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