Polymer chain transfer

COMBINATION) POLYMER + POLYMER -(CHAIN TRANSFER) POLYMER + RH — (CHAIN TRANSFER) POLYMER-00 + RH -(REACTION WITH OXYGEN) POLYMER + 0 ... 

Zinck, R, Valente, A., Mortreux, A., Visseaux, M. In situ generated half-lanthanidocene based catalysts for the controlled ohgomerisation of styrene Selectivity, block copolymerisation and chain transfer. Polymer, 48, 4609 614 (2007). 

Inhibitors slow or stop polymerization by reacting with the initiator or the growing polymer chain. The free radical formed from an inhibitor must be sufficiently unreactive that it does not function as a chain-transfer agent and begin another growing chain. Benzoquinone is a typical free-radical chain inhibitor. The resonance-stabilized free radical usually dimerizes or disproportionates to produce inert products and end the chain process. 

The molecules used in the study described in Fig. 2.15 were model compounds characterized by a high degree of uniformity. When branching is encountered, it is generally in a far less uniform way. As a matter of fact, traces of impurities or random chain transfer during polymer preparation may result in a small amount of unsuspected branching in samples of ostensibly linear molecules. Such adventitious branched molecules can have an effect on viscosity which far exceeds their numerical abundance. It is quite possible that anomalous experimental results may be due to such effects. 

Throughout this section we have used mostly p and u to describe the distribution of molecular weights. It should be remembered that these quantities are defined in terms of various concentrations and therefore change as the reactions proceed. Accordingly, the results presented here are most simply applied at the start of the polymerization reaction when the initial concentrations of monomer and initiator can be used to evaluate p or u. The termination constants are known to decrease with the extent of conversion of monomer to polymer, and this effect also complicates the picture at high conversions. Note, also, that chain transfer has been excluded from consideration in this section, as elsewhere in the chapter. We shall consider chain transfer reactions in the next section. 

The three-step mechanism for free-radical polymerization represented by reactions (6.A)-(6.C) does not tell the whole story. Another type of free-radical reaction, called chain transfer, may also occur. This is unfortunate in the sense that it complicates the neat picture presented until now. On the other hand, this additional reaction can be turned into an asset in actual polymer practice. One of the consequences of chain transfer reactions is a lowering of the kinetic chain length and hence the molecular weight of the polymer without necessarily affecting the rate of polymerization. 

It is apparent from these reactions how chain transfer lowers the molecular weight of a chain-growth polymer. The effect of chain transfer on the rate of polymerization depends on the rate at which the new radicals reinitiate polymerization ... 

If the rate constant kj is comparable to kp, the substitution of a polymer radical with a new radical has little or no effect on the rate of polymerization. If kj hp, the rate of polymerization will be decreased by chain transfer. 

The magnitude of the individual terms in the summation depends on both th( specific chain transfer constants and the concentrations of the reactants undei consideration. The former are characteristics of the system and hence quantitie over which we have little control the latter can often be adjusted to study particular effect. For example, chain transfer constants are generally obtainec under conditions of low conversion to polymer where the concentration o polymer is low enough to ignore the transfer to polymer. We shall return belov to the case of high conversions where this is not true. 

As noted above, chain transfer to polymer does not interfere with the determination of other transfer constants, since the latter are evaluated at low conversions. In polymer synthesis, however, high conversions are desirable and extensive chain transfer can have a dramatic effect on the properties of the product. This comes about since chain transfer to polymer introduces branching into the product ... 

A moment s reflection reveals that the effect on v of transfer to polymer is different from the effects discussed above inasmuch as the overall degree of polymerization is not decreased by such transfers. Although transfer to polymer is shown in one version of Eq. (6.84), the present discussion suggests that this particular transfer is not pertinent to the effect described. Investigation of chain transfer to polymer is best handled by examining the extent of branching in the product. We shall not pursue the matter of evaluating the transfer constants, but shall consider instead two specific examples of transfer to polymer. 

Inhibitors are characterized by inhibition constants which are defined as the ratio of the rate constant for transfer to inhibitor to the propagation constant for the monomer in analogy with Eq. (6.87) for chain transfer constants. For styrene at 50°C the inhibition constant of p-benzoquinone is 518, and that for O2 is 1.5 X 10. The Polymer Handbook (Ref. 3) is an excellent source for these and most other rate constants discussed in this chapter. 

In ionic polymerizations termination by combination does not occur, since all of the polymer ions have the same charge. In addition, there are solvents such as dioxane and tetrahydrofuran in which chain transfer reactions are unimportant for anionic polymers. Therefore it is possible for these reactions to continue without transfer or termination until all monomer has reacted. Evidence for this comes from the fact that the polymerization can be reactivated if a second batch of monomer is added after the initial reaction has gone to completion. In this case the molecular weight of the polymer increases, since no new growth centers are initiated. Because of this absence of termination, such polymers are called living polymers. 

Chain transfer is far more important than in the anionic case, so we do not encounter living polymers in cationic systems. 

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. 

The enthalpy of the copolymerization of trioxane is such that bulk polymerization is feasible. For production, molten trioxane, initiator, and comonomer are fed to the reactor a chain-transfer agent is in eluded if desired. Polymerization proceeds in bulk with precipitation of polymer and the reactor must supply enough shearing to continually break up the polymer bed, reduce particle size, and provide good heat transfer. The mixing requirements for the bulk polymerization of trioxane have been reviewed (22). Raw copolymer is obtained as fine emmb or flake containing imbibed formaldehyde and trioxane which are substantially removed in subsequent treatments which may be combined with removal of unstable end groups. 

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. 

The molecular weight of a polymer can be controlled through the use of a chain-transfer agent, as well as by initiator concentration and type, monomer concentration, and solvent type and temperature. Chlorinated aUphatic compounds and thiols are particularly effective chain-transfer agents used for regulating the molecular weight of acryUc polymers (94). Chain-transfer constants (C at 60°C) for some typical agents for poly(methyl acrylate) are as follows (87) ... 

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. 

Chain transfer is an important consideration in solution polymerizations. Chain transfer to solvent may reduce the rate of polymerization as well as the molecular weight of the polymer. Other chain-transfer reactions may iatroduce dye sites, branching, chromophoric groups, and stmctural defects which reduce thermal stabiUty. Many of the solvents used for acrylonitrile polymerization are very active in chain transfer. DMAC and DME have chain-transfer constants of 4.95-5.1 x lO " and 2.7-2.8 x lO " respectively, very high when compared to a value of only 0.05 x lO " for acrylonitrile itself DMSO (0.1-0.8 X lO " ) and aqueous zinc chloride (0.006 x lO " ), in contrast, have relatively low transfer constants hence, the relative desirabiUty of these two solvents over the former. DME, however, is used by several acryhc fiber producers as a solvent for solution polymerization. 

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. 

Suitable catalysts are /-butylphenylmethyl peracetate and phenylacetjdperoxide or redox catalyst systems consisting of an organic hydroperoxide and an oxidizable sulfoxy compound. One such redox initiator is cumene—hydroperoxide, sulfur dioxide, and a nucleophilic compound, such as water. Sulfoxy compounds are preferred because they incorporate dyeable end groups in the polymer by a chain-transfer mechanism. Common thermally activated initiators, such as BPO and AIBN, are too slow for use in this process. 

The monomer can also be copolymerized with acrylamide. Because of the high chain-transfer rate of aUyflc radicals, the molecular weights tend to be lower than for acryflc polymers. These polymers are sold either as a viscous solution or a dry powder made by suspension polymeriza tion (see Allyl monomers AND POLYPffiRS). 

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. 

Butyl mbber, a copolymer of isobutjiene with 0.5—2.5% isoprene to make vulcanization possible, is the most important commercial polymer made by cationic polymerization (see Elastomers, synthetic-butyl rubber). The polymerization is initiated by water in conjunction with AlCl and carried out at low temperature (—90 to —100° C) to prevent chain transfer that limits the molecular weight (1). Another important commercial appHcation of cationic polymerization is the manufacture of polybutenes, low molecular weight copolymers of isobutylene and a smaller amount of other butenes (1) used in adhesives, sealants, lubricants, viscosity improvers, etc. 

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