Chain transfer agents/reactions

Chain transfer is the reaction of a propagating radical with a non-radical substrate (X-Y, Scheme 6.1) to produce a dead polymer chain and a new radical (Y ) capable of initiating a polymer chain. The transfer agent (X-Y) may be a deliberate additive (e.g. a thiol) or it may be the initiator, monomer, polymer, solvent or an adventitious impurity. 

The ends of polymer chains are often not representative of the overall chain composition. This arises because the initiator and transfer agent-derived radicals can show a high degree of selectivity for reaction with a particular monomer type (Section 3.4). Similarly, there is specificity in chain tennination. Transfer agents show a marked preference for particular propagating species (Section 6.2.2 and 6.2.3). The kinetics of copolymerization are such that the probability for termination of a given chain by radical-radical reaction also has a marked dependence on the nature of the last added units (Section 7.4.3). 

In production, anhydrous formaldehyde is continuously fed to a reactor containing well-agitated inert solvent, especially a hydrocarbon, in which monomer is sparingly soluble. Initiator, especially amine, and chain-transfer agent are also fed to the reactor (5,16,17). The reaction is quite exothermic and polymerisation temperature is maintained below 75°C (typically near 40°C) by evaporation of the solvent. Polymer is not soluble in the solvent and precipitates early in the reaction. 

If a linear mbber is used as a feedstock for the mass process (85), the mbber becomes insoluble in the mixture of monomers and SAN polymer which is formed in the reactors, and discrete mbber particles are formed. This is referred to as phase inversion since the continuous phase shifts from mbber to SAN. Grafting of some of the SAN onto the mbber particles occurs as in the emulsion process. Typically, the mass-produced mbber particles are larger (0.5 to 5 llm) than those of emulsion-based ABS (0.1 to 1 llm) and contain much larger internal occlusions of SAN polymer. The reaction recipe can include polymerization initiators, chain-transfer agents, and other additives. Diluents are sometimes used to reduce the viscosity of the monomer and polymer mixture to faciUtate processing at high conversion. The product from the reactor system is devolatilized to remove the unreacted monomers and is then pelletized. Equipment used for devolatilization includes single- and twin-screw extmders, and flash and thin film evaporators. Unreacted monomers are recovered for recycle to the reactors to improve the process yield. 

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. 

Tetiafluoioethylene—peifluoiopiopyl vinyl ethei copolymeis [26655-00-5] aie made in aqueous (1,2) oi nonaqueous media (3). In aqueous copolymerizations water-soluble initiators and a perfluorinated emulsifying agent are used. Molecular weight and molecular weight distribution are controlled by a chain-transfer agent. Sometimes a second phase is added to the reaction medium to improve the distribution of the vinyl ether in the poljmier (11) a buffer is also added. 

Suspension polymerization of VDE in water are batch processes in autoclaves designed to limit scale formation (91). Most systems operate from 30 to 100°C and are initiated with monomer-soluble organic free-radical initiators such as diisopropyl peroxydicarbonate (92—96), tert-huty peroxypivalate (97), or / fZ-amyl peroxypivalate (98). Usually water-soluble polymers, eg, cellulose derivatives or poly(vinyl alcohol), are used as suspending agents to reduce coalescence of polymer particles. Organic solvents that may act as a reaction accelerator or chain-transfer agent are often employed. The reactor product is a slurry of suspended polymer particles, usually spheres of 30—100 pm in diameter they are separated from the water phase thoroughly washed and dried. Size and internal stmcture of beads, ie, porosity, and dispersant residues affect how the resin performs in appHcations. 

The newly formed short-chain radical A then quickly reacts with a monomer molecule to create a primary radical. If subsequent initiation is not fast, AX is considered an inhibitor. Many have studied the influence of chain-transfer reactions on emulsion polymerisation because of the interesting complexities arising from enhanced radical desorption rates from the growing polymer particles (64,65). Chain-transfer reactions are not limited to chain-transfer agents. Chain-transfer to monomer is ia many cases the main chain termination event ia emulsion polymerisation. Chain transfer to polymer leads to branching which can greatiy impact final product properties (66). 

Molecular Weight. PE mol wt (melt index) is usually controlled by reaction temperature or chain-transfer agents. Reaction temperature is the principal control method in polymerization processes with Phillips catalysts. On the other hand, special chemical agents for chain transfer are requited for... 

Both propylene and isobutylene ate comonomers that are incorporated along the chain, resulting in additional short-chain branching. One important factor in controlling polymer crystallinity is the choice of chain-transfer agent. Ethane and methane, for example, are inefficient agents whose presence in the monomer feed stream must be considered in reaction control. 

Reactions involving the peroxodisulfate ion are usually slow at ca 20°C. The peroxodisulfate ion decomposes into free radicals, which are initiators for numerous chain reactions. These radicals act either thermally or by electron transfer with transition-metal ions or reducing agents (79). 

The compound R X is a chain-transfer agent, with X usually H or Cl. The net effect of chain transfer is to kill a growing chain and start a new one in its place, thus shortening the chains. Mercaptan chain-transfer agents ate often used to limit molecular weight, but under appropriate conditions, almost anything in the reaction mass (solvent, dead polymer, initiator) can act as a chain-transfer agent to a certain extent. 

The photopolymerization process taking place within a representative mixture of sensitizer, initiator, chain-transfer agent, and monomer, typical of positive Cromalin, has been studied in detail (41,42). The exact mechanism is still controversial, but a generalized reaction scheme can be postulated as follows, where L2 = biimidazole dimer, S = sensitizer, RH = chain-transfer agent, L2 = excited biimidazole dimer, L = biimidazole radical,... 

A typical recipe for batch emulsion polymerization is shown in Table 13. A reaction time of 7—8 h at 30°C is requited for 95—98% conversion. A latex is produced with an average particle diameter of 100—150 nm. Other modifying ingredients may be present, eg, other colloidal protective agents such as gelatin or carboxymethylcellulose, initiator activators such as redox types, chelates, plasticizers, stabilizers, and chain-transfer agents. 

Chain transfer to monomer and to other small molecules leads to lower molecular weight products, but when polymerisation occurs ia the relative absence of monomer and other transfer agents, such as solvents, chain transfer to polymer becomes more important. As a result, toward the end of batch-suspension or batch-emulsion polymerisation reactions, branched polymer chains tend to form. In suspension and emulsion processes where monomer is fed continuously, the products tend to be more branched than when polymerisations are carried out ia the presence of a plentiful supply of monomer. 

Telomerization Reactions. Butadiene can react readily with a number of chain-transfer agents to undergo telomerization reactions. The more often studied reagents are carbon dioxide (167—178), water (179—181), ammonia (182), alcohols (183—185), amines (186), acetic acid (187), water and CO2 (188), ammonia and CO2 (189), epoxide and CO2 (190), mercaptans (191), and other systems (171). These reactions have been widely studied and used in making unsaturated lactones, alcohols, amines, ethers, esters, and many other compounds. 

Acetals. Acetal resins (qv) are polymers of formaldehyde and are usually called polyoxymethylene [9002-81-7]. Acetal homopolymer was developed at Du Pont (8). The commercial development of acetal resins required a pure monomer. The monomer is rigorously purified to remove water, formic acid, metals, and methanol, which act as chain-transfer or reaction-terminating agents. The purified formaldehyde is polymerized to form the acetal homopolymer the polymer end groups are stabilized by reaction with acetic anhydride to form acetate end groups (9). 

The thiol ( -dodecyl mercaptan) used ia this recipe played a prominent role ia the quaUty control of the product. Such thiols are known as chain-transfer agents and help control the molecular weight of the SBR by means of the foUowiag reaction where M = monomer, eg, butadiene or styrene R(M) = growing free-radical chain k = propagation-rate constant = transfer-rate constant and k = initiation-rate constant. 

Other additives that may be incorporated include sodium hydrogen phosphates as buffering agents to stabilise that pH of the reaction medium, lauryl mercaptan or trichlorethylene as chain transfer agents to control molecular weight, a lubricant such as stearic acid and small amounts of an emulsifier such as sodium lauryl sulphate. 

The function of emulsifier in the emulsion polymerization process may be summarized as follows [45] (1) the insolubilized part of the monomer is dispersed and stabilized within the water phase in the form of fine droplets, (2) a part of monomer is taken into the micel structure by solubilization, (3) the forming latex particles are protected from the coagulation by the adsorption of monomer onto the surface of the particles, (4) the emulsifier makes it easier the solubilize the oligomeric chains within the micelles, (5) the emulsifier catalyzes the initiation reaction, and (6) it may act as a transfer agent or retarder leading to chemical binding of emulsifier molecules to the polymer. 

In termination, unsaturated and saturated ends are formed when the propagating species undergo disproportionation, head-to-head linkages when they combine, and other functional groups may be introduced by reactions with inhibitors or transfer agents (Scheme 1.2). In-chain defect structures (within the polymer molecule) can also arise by copolymerization of the unsaturated byproducts of initiation or termination. 

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