Emulsion polymerization chain transfer

Such a mechanism could also explain the apparent induction period found at the beginning of the polymerizations. With very small particles and large chain transfer, the polymerization could be acting as if it were in a homogeneous medium. This produces very low rates compared with a standard emulsion polymerization. As particle size increases, the rate rises because chain-transferred monomers would not diffuse into the aqueous phase. 

Reversible addition-fragmentation chain transfer (RAFT) polymerization has been one of the most promising recent advances in the controlled free radical poljmerization (CRP) technique for both the homogeneous and heterogeneous sys-tem.P The mechanism of the RAFT has been established by a dynamic equihbrium between the active and the dormant spedes.f Although RAFT polymerizations were well developed in the heterogeneous media via emulsion,minie-mulsion and ab initio emulsion polymerization, RAFT emulsion polymer-... 

Emulsion Process. The emulsion polymerization process utilizes water as a continuous phase with the reactants suspended as microscopic particles. This low viscosity system allows facile mixing and heat transfer for control purposes. An emulsifier is generally employed to stabilize the water insoluble monomers and other reactants, and to prevent reactor fouling. With SAN the system is composed of water, monomers, chain-transfer agents for molecular weight control, emulsifiers, and initiators. Both batch and semibatch processes are employed. Copolymerization is normally carried out at 60 to 100°C to conversions of - 97%. Lower temperature polymerization can be achieved with redox-initiator systems (51). 

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. 

Aqueous emulsion polymerization is carried out using a fluorinated emulsifier, a chain-transfer agent to control molecular weight, and dispersion stabilizers such as manganic acid salts and ammonium oxalate (13,14). 

Basic Components. The principal components in emulsion polymerization are deionized water, monomer, initiator, emulsifier, buffer, and chain-transfer agent. A typical formula consists of 20—60% monomer, 2—10 wt % emulsifier on monomer, 0.1—1.0 wt % initiator on monomer, 0.1—1.0 wt % chain-transfer agent on monomer, various small amounts of buffers and bacteria control agents, and the balance deionized water. 

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. 

Buffers are frequently added to emulsion recipes and serve two main purposes. The rate of hydrolysis of vinyl acetate and some comonomers is pH-sensitive. Hydrolysis of monomer produces acetic acid, which can affect the initiator, and acetaldehyde which as a chain-transfer agent may lower the molecular weight of the polymer undesirably. The rates of decomposition of some initiators are affected by pH and the buffer is added to stabilize those rates, since decomposition of the initiator frequently changes the pH in an unbuffered system. Vinyl acetate emulsion polymerization recipes are usually buffered to pH 4—5, eg, with phosphate or acetate, but buffering at neutral pH with bicarbonate also gives excellent results. The pH of most commercially available emulsions is 4—6. 

Often a chain-transfer agent is added to vinyl acetate polymerizations, whether emulsion, suspension, solution, or bulk, to control the polymer molecular weight. Aldehydes, thiols, carbon tetrachloride, etc, have been added. Some emulsion procedures call for the recipe to include a quantity of preformed PVAc emulsion and sometimes antifoamers must be added (see Foams). 

Mechanisms. Because of its considerable industrial importance as well as its intrinsic interest, emulsion polymerization of vinyl acetate in the presence of surfactants has been extensively studied (75—77). The Smith-Ewart theory, which describes emulsion polymerization of monomers such as styrene, does not apply to vinyl acetate. Reasons for this are the substantial water solubiUty of vinyl acetate monomer, and the different reactivities of the vinyl acetate and styrene radicals the chain transfer to monomer is much higher for vinyl acetate. The kinetics of the polymerization of vinyl acetate has been studied and mechanisms have been proposed (78—82). 

Emulsion polymerizations of vinyl acetate in the presence of ethylene oxide- or propylene oxide-based surfactants and protective coUoids also are characterized by the formation of graft copolymers of vinyl acetate on these materials. This was also observed in mixed systems of hydroxyethyl cellulose and nonylphenol ethoxylates. The oxyethylene chain groups supply the specific site of transfer (111). The concentration of insoluble (grafted) polymer decreases with increase in surfactant ratio, and (max) is observed at an ethoxylation degree of 8 (112). 

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. 

Many emulsion polymerizations can be described by so-called zero-one kinetics. These systems are characterized by particle sizes that are sufficiently small dial entry of a radical into a particle already containing a propagating radical always causes instantaneous termination. Thus, a particle may contain either zero or one propagating radical. The value of n will usually be less than 0.4. In these systems, radical-radical termination is by definition not rate determining. Rates of polymerization are determined by the rates or particle entry and exit rather than by rates of initiation and termination. The main mechanism for exit is thought to be chain transfer to monomer. It follows that radical-radical termination, when it occurs in the particle phase, will usually be between a short species (one that lias just entered) and a long species. 

Microemulsion and miniemulsion polymerization processes differ from emulsion polymerization in that the particle sizes are smaller (10-30 and 30-100 nm respectively vs 50-300 ran)77 and there is no discrete monomer droplet phase. All monomer is in solution or in the particle phase. Initiation usually takes place by the same process as conventional emulsion polymerization. As particle sizes reduce, the probability of particle entry is lowered and so is the probability of radical-radical termination. This knowledge has been used to advantage in designing living polymerizations based on reversible chain transfer (e.g. RAFT, Section 9.5.2)." 2... 

Heterogeneous polymerization processes (emulsion, miniemulsion, non-aqueous dispersion) offer another possibility for reducing the rate of termination through what are known as compartmcntalization effects. In emulsion polymerization, it is believed that the mechanism for chain stoppage within the particles is not radical-radical termination but transfer to monomer (Section 5.2.1.5). These possibilities have provided impetus for the development ofliving heterogeneous polymerization (Sections 9.3.6.6, 9.4.3.2, 9.5.3.6). 

Transfer constants of the macromonomers arc typically low (-0.5, Section 6.2.3.4) and it is necessary to use starved feed conditions to achieve low dispersities and to make block copolymers. Best results have been achieved using emulsion polymerization380 395 where rates of termination are lowered by compartmentalization effects. A one-pot process where macromonomers were made by catalytic chain transfer was developed.380" 95 Molecular weights up to 28000 that increase linearly with conversion as predicted by eq. 16, dispersities that decrease with conversion down to MJM< 1.3 and block purities >90% can be achieved.311 1 395 Surfactant-frcc emulsion polymerizations were made possible by use of a MAA macromonomer as the initial RAFT agent to create self-stabilizing lattices . 

We begin the discussion of EPM by elaborating on this physical picture. Figure 1 shows a typical emulsion CSTR reactor and polymerization recipe. The magnified portion of the latex shows the various phases and the major species involved. The latex consists of monomers, water, surfactant, initiator, chain transfer agent, and added electrolyte. We used the mechanism for particle formation as described in Feeney et al. (8-9) and Hansen and Ugelstad (2). We have not found it necessary to invoke the micellar entry theory 2, 2/ 6./ 11/ 12/ 14. 

Morton and Salatiello have deduced the ratio kpp/kp for radical polymerization of butadiene by applying the above described procedure, appropriately modified for the emulsion system they used. The primary molecular weight was controlled by a mercaptan acting as chain transfer agent, as in the experiments of Bardwell and Winkler cited above. Measurement of the mercaptan concentration over the course of the reaction provided the necessary information for calculating % at any stage of the process, and in particular at the critical conversion 6c for the initial appearance of gel. The velocity constant ratios which they obtained from their results through the use of Eq. 

Polymers may be made by four different experimental techniques bulk, solution, suspension, and emulsion processes. They are somewhat self-explanatory. In bulk polymerization only the monomers and a small amount of catalyst is present. No separation processes are necessary and the only impurity in the final product is monomer. But heat transfer is a problem as the polymer becomes viscous. In solution polymerization the solvent dissipates the heat better, but it must be removed later and care must be used in choosing the proper solvent so it does not act as a chain transfer agent. In suspension polymerization the monomer and catalyst are suspended as droplets in a continuous phase such as water by continuous agitation. Finally, emulsion polymerization uses an emulsifying agent such as soap, which forms micelles where the polymerization takes place. 

Monomer and initiator must be soluble in the liquid and the solvent must have the desired chain-transfer characteristics, boiling point (above the temperature necessary to carry out the polymerization and low enough to allow for ready removal if the polymer is recovered by solvent evaporation). The presence of the solvent assists in heat removal and control (as it also does for suspension and emulsion polymerization systems). Polymer yield per reaction volume is lower than for bulk reactions. Also, solvent recovery and removal (from the polymer) is necessary. Many free radical and ionic polymerizations are carried out utilizing solution polymerization including water-soluble polymers prepared in aqueous solution (namely poly(acrylic acid), polyacrylamide, and poly(A-vinylpyrrolidinone). Polystyrene, poly(methyl methacrylate), poly(vinyl chloride), and polybutadiene are prepared from organic solution polymerizations. 

Anomolous results have been observed in some emulsion polymerizations—inverse dependencies of N, Rp, and Xn on surfactant concentration. Some surfactants act as inhibitors or retarders of polymerization, especially of the more highly reactive radicals from vinyl acetate and vinyl chloride [Okamura and Motoyama, 1962 Stryker et al., 1967]. This is most apparent with surfactants possessing unsaturation (e.g., certain fatty acid soaps). Degradative chain transfer through allyl hydrogens is probably quite extensive. 

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