Contents Emulsion Polymerization

M ass Process. In the mass (or bulk) (83) ABS process the polymerization is conducted in a monomer medium rather than in water. This process usually consists of a series of two or more continuous reactors. The mbber used in this process is most commonly a solution-polymerized linear polybutadiene (or copolymer containing sytrene), although some mass processes utilize emulsion-polymerized ABS with a high mbber content for the mbber component (84). If a linear mbber is used, a solution of the mbber in the monomers is prepared for feeding to the reactor system. If emulsion ABS is used as the source of mbber, a dispersion of the ABS in the monomers is usually prepared after the water has been removed from the ABS latex. 

The incidence of these defects is best determined by high resolution F nmr (111,112) infrared (113) and laser mass spectrometry (114) are alternative methods. Typical commercial polymers show 3—6 mol % defect content. Polymerization methods have a particularly strong effect on the sequence of these defects. In contrast to suspension polymerized PVDF, emulsion polymerized PVDF forms a higher fraction of head-to-head defects that are not followed by tail-to-tail addition (115,116). Crystallinity and other properties of PVDF or copolymers of VDF are influenced by these defect stmctures (117). 

The quahty of the water used in emulsion polymerization has long been known to affect the manufacture of ESBR. Water hardness and other ionic content can direcdy affect the chemical and mechanical stabiUty of the polymer emulsion (latex). Poor latex stabiUty results in the formation of coagulum in the polymerization stage as well as other parts of the latex handling system. 

Random copolymers of vinyl chloride and other monomers are important commercially. Most of these materials are produced by suspension or emulsion polymerization using free-radical initiators. Important producers for vinyl chloride—vinyUdene chloride copolymers include Borden, Inc. and Dow. These copolymers are used in specialized coatings appHcations because of their enhanced solubiUty and as extender resins in plastisols where rapid fusion is required (72). Another important class of materials are the vinyl chloride—vinyl acetate copolymers. Principal producers include Borden Chemicals Plastics, B. F. Goodrich Chemical, and Union Carbide. The copolymerization of vinyl chloride with vinyl acetate yields a material with improved processabihty compared with vinyl chloride homopolymer. However, the physical and chemical properties of the copolymers are different from those of the homopolymer PVC. Generally, as the vinyl acetate content increases, the resin solubiUty in ketone and ester solvents and its susceptibiUty to chemical attack increase, the resin viscosity and heat distortion temperature decrease, and the tensile strength and flexibiUty increase slightly. 

At the same time, however, considerable research was being done, especially in Germany, on a novel process called emulsion polymerization, in which the monomer was polymerized as an emulsion in the presence of water and soap. This seemed advantageous since the product appeared as a latex, just like natural mbber, leading to low viscosity even at high soHds content, while the presence of the water assured better temperature control. The final result, based mainly on work at the LG. Farbenindustrie (IGF) (10), was the development of a butadiene—styrene copolymer prepared by emulsion polymerization, the foremnner of the present-day leading synthetic mbber, SBR. 

In emulsion polymerization, NBR with acrylonitrile content between 15 and 50% can be obtained. The increase in the acrylonitrile content in the NBR produces an increase in the polar nature and solubility parameter in the copolymer [12]. Furthermore, the increase in acrylonitrile content improves the resistance to oils and also increases the glass transition temperature of the copolymers from -60 to-lO C. 

Since the 1940s, alkanesulfonates have served as emulsifiers in the emulsion polymerization of vinylchloride. Nevertheless, the detailed mechanisms of this process are not yet completely known. An important advantage of using alkanesulfonates is that they produce latices with a high solid content, which can be effectively processed by spray drying [90]. 

Research on the modelling, optimization and control of emulsion polymerization (latex) reactors and processes has been expanding rapidly as the chemistry and physics of these systems become better understood, and as the demand for new and improved latex products increases. The objectives are usually to optimize production rates and/or to control product quality variables such as polymer particle size distribution (PSD), particle morphology, copolymer composition, molecular weights (MW s), long chain branching (LCB), crosslinking frequency and gel content. 

Bauer et al. describe the use of a noncontact probe coupled by fiber optics to an FT-Raman system to measure the percentage of dry extractibles and styrene monomer in a styrene/butadiene latex emulsion polymerization reaction using PLS models [201]. Elizalde et al. have examined the use of Raman spectroscopy to monitor the emulsion polymerization of n-butyl acrylate with methyl methacrylate under starved, or low monomer [202], and with high soUds-content [203] conditions. In both cases, models could be built to predict multiple properties, including solids content, residual monomer, and cumulative copolymer composition. Another study compared reaction calorimetry and Raman spectroscopy for monitoring n-butyl acrylate/methyl methacrylate and for vinyl acetate/butyl acrylate, under conditions of normal and instantaneous conversion [204], Both techniques performed well for normal conversion conditions and for overall conversion estimate, but Raman spectroscopy was better at estimating free monomer concentration and instantaneous conversion rate. However, the authors also point out that in certain situations, alternative techniques such as calorimetry can be cheaper, faster, and often easier to maintain accurate models for than Raman spectroscopy, hi a subsequent article, Elizalde et al. found that updating calibration models after... 

The size of the micelles is significantly increased by the addition of monomer up to a diameter of 4.5-5 nm. However, the size of the monomer droplets is stilt very much larger than that of the micelles (diameters up to 1 pm). In emulsion polymerization, one generally uses 0.5-5 wt% of emulsifier relative to monomer. With the usual oil-in-water emulsions, the water content varies from half to four times the amount of monomer. 

With emulsion polymerization it is possible to prepare very high-molecular-weight polymers at high rates of polymerization. The required reaction temperatures are low and can even be below 20 °C when redox systems are used for initiation (see Examples 3-11). Polymer emulsions with solid contents of 50% and higher can be very stable. In many cases, e.g., poly(vinyl acetate), they are directly used as paints (paint latices), coatings, or adhesives (see Sect. 2.5.4). 

Firestone and Shell started commercial production of cis-polyisoprene by the anionic process in the 1950 s but these plants are no longer in operation now. About the same time, Phillips started the manufacture of polybutadienes by the anionic route and ever since, there has been a steady growth in their use, particularly in the tire-tread as well as tire-carcass formulations. These solution polybutadienes, generally, have low vinyl contents but recently, Phillips has found some interesting applications for medium vinyl polybutadienes as well.14 Polybutadienes with 50-55 percent vinyl contents behave like emulsion polymerized SBR in tire tread formulations and exhibit very similar tread... 

MMBS has been used in blends for PVC already in the 1960s. It is prepared from a butadiene/styrene latex be emulsion polymerization (5). A high content of butadiene of more than 50% is desirable. 

In order to achieve the above objectives, three vinyl acrylic latexes of varying butyl acrylate content have been prepared and cleaned1 for use in the study. Several anionic and nonionic surfactants commonly usod in emulsion polymerization have been used to investigate the effects of surfactant structure and polymer composition on the solubilization process. Polarity of latex surface estimated from contact angle measurements have been used to study the effect of polymer polarity on surfactant adsorption. 

Emulsion Polymerization A typical recipe is give in Table I. Emulsion polymerization was carried out at 60°C under a nitrogen atmosphere using a batch process. Theoretical solids content in all the formulations was 25%, and generally the conversions were better than 98%. A polyvinyl acetate homopolymer and two poly (vinyl acetate-butyl acrylate) copolymers having VA/BA composition of 85/15 and 70/30 were prepared according to the above procedure. 

The first step in the manufacture of fine powder resins is to prepare an aqueous colloidal dispersion by polymerization with initiator and emulsifier present.21 Although the polymerization mechanism is not a typical emulsion type, some of the principles of emulsion polymerization apply here. Both the process and the ingredients have significant effects on the product.22 The solids contents of such disper-... 

---