Bulk polymerizations

Bulk Polymerization. The bulk polymerization of acryUc monomers is characterized by a rapid acceleration in the rate and the formation of a cross-linked insoluble network polymer at low conversion (90,91). Such network polymers are thought to form by a chain-transfer mechanism involving abstraction of the hydrogen alpha to the ester carbonyl in a polymer chain followed by growth of a branch radical. Ultimately, two of these branch radicals combine (91). Commercially, the bulk polymerization of acryUc monomers is of limited importance. 

Bulk Polymerization. The bulk polymerization of acrylonitrile is complex. Even after many investigations into the kinetics of the polymerization, it is stiU not completely understood. The complexity arises because the polymer precipitates from the reaction mixture barely swollen by its monomer. The heterogeneity has led to kinetics that deviate from the normal and which can be interpreted in several ways. 

Bulk polymerization has been studied at relatively low temperatures and in toluene and carbon tetrachloride solutions carried to low conversions (12). The effects of temperature and different organic peroxide initiators have been observed. The molecular weight of soluble polymer after 3% conversion is ca — 19,000 and is somewhat dependent on initiator concentration or temperature between 35 and 65 °C. With di-2-methylpentanoyl 

Bulk Polymerization. The spontaneous polymerisation of VDC, so often observed when the monomer is stored at room temperature, is caused by peroxides formed from the reaction of VDC with oxygen. Very pure monomer does not polymerize under these conditions. Irradiation by either uv or y-rays (26,28) also induces polymerization of VDC. 

Bulk Polymerizations. In the bulk polymerization of vinyl acetate the viscosity increases significantly as the polymer forms making it difficult to remove heat from the process. Low molecular weight polymers have been made in this fashion. Continuous processes are known to be used for bulk polymerizations (68). 

Three bulk polymerization processes are commercially important for the production of methacrylate polymers batch cell casting, continuous casting, and continuous bulk polymerization. Approximately half the worldwide production of bulk polymerized methacrylates is in the form of molding and extmsion compounds, a quarter is in the form of cell cast sheets, and a quarter is in the form of continuous cast sheets. 

Bulk and solution polymerizations are more or less self-explanatory, since they operate under the conditions we have assumed throughout most of this chapter. A bulk polymerization may be conducted with as few as two components monomer and initiator. Production polymerization reactions are carried out to high conversions which produces several consequences we have mentioned previously  

Fig. 1. Bulk polymerization of vinyHdene chloride at 45°C, with 0.5 wt % benzoyl peroxide as initiator (29).

Fig. 1. Bulk polymerization of diethylene glycol bis(aHylcarbonate) at 45°C with initial addition of 3.0% diisopropyl percarbonate. Rates of polymerization as measured by density and catalyst consumption decrease with time at a given temperature (14).

DADC HomopolymeriZation. Bulk polymerization of CR-39 monomer gives clear, colorless, abrasion-resistant polymer castings that offer advantages over glass and acryHc plastics in optical appHcations. Free-radical initiators are required for thermal or photochemical polymerization. 

The Hquid monomers are suitable for bulk polymerization processes. The reaction can be conducted in a mold (casting, reaction injection mol ding), continuously on a conveyor (block and panel foam production), or in an extmder (thermoplastic polyurethane elastomers and engineering thermoplastics). Also, spraying of the monomers onto the surface of suitable substrates provides insulation barriers or cross-linked coatings. 

Early efforts to produce synthetic mbber coupled bulk polymerization with subsequent emulsification (9). Problems controlling the heat generated during bulk polymerization led to the first attempts at emulsion polymerization. In emulsion polymerization hydrophobic monomers are added to water, emulsified by a surfactant into small particles, and polymerized using a water-soluble initiator. The result is a coUoidal suspension of fine particles, 

Elbert R, Laschewsky A and Ringsdorf H 1985 Hydrophilic spacer groups in polymerizable lipids— formation of biomembrane models from bulk polymerized lipids J. Am. Ohem. Soc. 107 4134-41 

Copolymerization is effected by suspension or emulsion techniques under such conditions that tetrafluoroethylene, but not ethylene, may homopolymerize. Bulk polymerization is not commercially feasible, because of heat-transfer limitations and explosion hazard of the comonomer mixture. Polymerizations typically take place below 100°C and 5 MPa (50 atm). Initiators include peroxides, redox systems (10), free-radical sources (11), and ionizing radiation (12). 

Acrylonitrile and its comonomers can be polymerized by any of the weU-known free-radical methods. Bulk polymerization is the most fundamental of these, but its commercial use is limited by its autocatalytic nature. Aqueous dispersion polymerization is the most common commercial method, whereas solution polymerization is used ia cases where the spinning dope can be prepared directly from the polymerization reaction product. Emulsion polymerization is used primarily for modacryhc compositions where a high level of a water-iasoluble monomer is used or where the monomer mixture is relatively slow reacting. 

Once the radicals diffuse out of the solvent cage, reaction with monomer is the most probable reaction in bulk polymerizations, since monomers are the species most likely to be encountered. Reaction with polymer radicals or initiator molecules cannot be ruled out, but these are less important because of the lower concentration of the latter species. In the presence of solvent, reactions between the initiator radical and the solvent may effectively compete with polymer initiation. This depends very much on the specific chemicals involved. For example, carbon tetrachloride is quite reactive toward radicals because of the resonance stabilization of the solvent radical produced [1]  

The assumption that k values are constant over the entire duration of the reaction breaks down for termination reactions in bulk polymerizations. Here, as in Sec. 5.2, we can consider the termination process—whether by combination or disproportionation to depend on the rates at which polymer molecules can diffuse into (characterized by kj) or out of (characterized by k ) the same solvent cage and the rate at which chemical reaction between them (characterized by kj.) occurs in that cage. In Chap. 5 we saw that two limiting cases of Eq. (5.8) could be readily identified  

Because the polymerization occurs totally within the monomer droplets without any substantial transfer of materials between individual droplets or between the droplets and the aqueous phase, the course of the polymerization is expected to be similar to bulk polymerization. Accounts of the quantitative aspects of the suspension polymerization of methyl methacrylate generally support this model (95,111,112). Developments in suspension polymerization, including acryUc suspension polymers, have been reviewed (113,114). 

The procedure of forming copolymers dates back to the early 1940s when only phenoHc resins were avaHable. Copolymers were produced by bulk polymerization of phenol [108-95-2] and formaldehyde [50-00-0]. Because the resulting soHd product had the shape of the vessel in which polymerization 

The first quantitative model, which appeared in 1971, also accounted for possible charge-transfer complex formation (45). Deviation from the terminal model for bulk polymerization was shown to be due to antepenultimate effects (46). Mote recent work with numerical computation and C-nmr spectroscopy data on SAN sequence distributions indicates that the penultimate model is the most appropriate for bulk SAN copolymerization (47,48). A kinetic model for azeotropic SAN copolymerization in toluene has been developed that successfully predicts conversion, rate, and average molecular weight for conversions up to 50% (49). 

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