Polymerization copolymerization

Copolymerization, Polymerization of two or more dissimilar monomers such as the creation of SBR, rubber from styrene and butadiene. 

In 1937 Robert McKee Thomas (1908-1986) and William Joseph Sparks (1904-1976) at the Standard Oil Development Company (now Exxon) synthesized butyl rubber via the copolymerization (polymerization of a mixture of monomers) of isobutylene (2-methylpropene (CHj)2C=CH2) with a small amount of isoprene. 

Yamashita, Y, Iwaya, Y, and Ito, K. (1975) Block copolymerization. Polymerization of NCA of methyl D-glutamate by telechelic polystyrene having glycyl groups as active chain ends. Makromolekulare Chemie, 176,1207-1216. 

The implementation of the comprehensive studies of the kinetics of polymerization or copolymerization (polymerization of two different monomers) is a difficult task. According to the earlier provided information the kinetics of polymerization consists of initiation rates, growth, completion and a series of side reactions. It requires often an additional research using other methods. 

Schildknecht, C. E. and I. Skeist (eds.), Polymerization Processes , Wiley-Interscience, New York, 1970. Presents the advances of the last 20 years in the fields of graft and block copolymerizations, polymerizations with Ziegler-type catalysts, by oxidative coupling, and the use of radiation (High Polym., vol. 29). 

Kel-F Trade name for a polymeric chlorotri-fluoroethene, often copolymerized. May be a liquid or solid. Inert to chemical attack and a thermoplastic (Teflon cannot be moulded). 

We have tacitly assumed that the rate constants depend only on the last unit of the chain. In such a situation, the copolymerization is called a Markov copolymerization of first order. The special case (i), r r- = 1, is a Markov copolymerization of order zero. If reactivity also depends on the penultimate unit of the chain, the polymerization is a Markov copolymerization of second order. 

Copolymerization to form polyketones proceeds by the carbonylation of some alkenes in the absence of nucleophiles. Copolymerization of CO and norbornadiene takes place to give the polyketone 28(28]. Reaction of ethylene and other alkenes with CO affords the polyketones 29. The use of cationic Pd catalysts and bipyridyl or 1,10-phenanthroline is important for the polymerization [29-31]. 

Copolymerization. Copolymerization occurs when a mixture of two or more monomer types polymerizes so that each kind of monomer enters the polymer chain. The fundamental structure resulting from copolymerization depends on the nature of the monomers and the relative rates of monomer reactions with the growing polymer chain. A tendency toward alternation of monomer units is common. 

We saw in the last chapter that the stationary-state approximation is apphc-able to free-radical homopolymerizations, and the same is true of copolymerizations. Of course, it takes a brief time for the stationary-state radical concentration to be reached, but this period is insignificant compared to the total duration of a polymerization reaction. If the total concentration of radicals is constant, this means that the rate of crossover between the different types of terminal units is also equal, or that R... 

In some instances, the resist polymer can be prepared in a single step by direct polymerization of the protected monomer(s) (37,88), entirely avoiding the intermediate PHOST. HOST-containing resist polymers have also been prepared by free-radical copolymerization of a latent HOST and a stable, acid-labile monomer, eg, the copolymerization of acetoxystyrene with tert-huty acrylate, followed by selective removal of the acetoxy group (89) (Fig. 30). 

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. 

Acrylamide copolymerizes with many vinyl comonomers readily. The copolymerization parameters ia the Alfrey-Price scheme are Q = 0.23 and e = 0.54 (74). The effect of temperature on reactivity ratios is small (75). Solvents can produce apparent reactivity ratio differences ia copolymerizations of acrylamide with polar monomers (76). Copolymers obtained from acrylamide and weak acids such as acryUc acid have compositions that are sensitive to polymerization pH. Reactivity ratios for acrylamide and many comonomers can be found ia reference 77. Reactivity ratios of acrylamide with commercially important cationic monomers are given ia Table 3. 

Acrylate polymerizations are markedly inhibited by oxygen therefore, considerable care is taken to exclude air during the polymerization stages of manufacturing. This inhibitory effect has been shown to be caused by copolymerization of oxygen with monomer, forming an alternating copolymer (81,82). 

In general, acryUc ester monomers copolymerize readily with each other or with most other types of vinyl monomers by free-radical processes. The relative ease of copolymerization for 1 1 mixtures of acrylate monomers with other common monomers is presented in Table 7. Values above 25 indicate that good copolymerization is expected. Low values can often be offset by a suitable adjustment in the proportion of comonomers or in the method of their introduction into the polymerization reaction (86). 

Despite numerous efforts, there is no generally accepted theory explaining the causes of stereoregulation in acryflc and methacryflc anionic polymerizations. Complex formation with the cation of the initiator (146) and enoflzation of the active chain end are among the more popular hypotheses (147). Unlike free-radical polymerizations, copolymerizations between acrylates and methacrylates are not observed in anionic polymerizations however, good copolymerizations within each class are reported (148). 

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). 

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). 

A schematic of a continuous bulk SAN polymerization process is shown in Figure 4 (90). The monomers are continuously fed into a screw reactor where copolymerization is carried out at 150°C to 73% conversion in 55 min. Heat of polymerization is removed through cooling of both the screw and the barrel walls. The polymeric melt is removed and fed to the devolatilizer to remove unreacted monomers under reduced pressure (4 kPa or 30 mm Hg) and high temperature (220°C). The final product is claimed to contain less than 0.7% volatiles. Two devolatilizers in series are found to yield a better quaUty product as well as better operational control (91,92). 

In all manufacturing processes, grafting is achieved by the free-radical copolymerization of styrene and acrylonitrile monomers in the presence of an elastomer. Ungrafted styrene—acrylonitrile copolymer is formed during graft polymerization and/or added afterward. 

Copolymer composition can be predicted for copolymerizations with two or more components, such as those employing acrylonitrile plus a neutral monomer and an ionic dye receptor. These equations are derived by assuming that the component reactions involve only the terminal monomer unit of the chain radical. The theory of multicomponent polymerization kinetics has been treated (35,36). 

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. 

There are two main advantages of acrylamide—acryUc-based flocculants which have allowed them to dominate the market for polymeric flocculants in many appHcation areas. The first is that these polymers can be made on a commercial scale with molecular weights up to 10—15 million which is much higher than any natural product. The second is that their electrical charge in solution and the charge density can be varied over a wide range by copolymerizing acrylamide with a variety of functional monomers or by chemical modification. 

Uses. Besides polymerizing TFE to various types of high PTEE homopolymer, TEE is copolymerized with hexafluoropropylene (29), ethylene (30), perfluorinated ether (31), isobutylene (32), propylene (33), and in some cases it is used as a termonomer (34). It is used to prepare low molecular weight polyfluorocarbons (35) and carbonyl fluoride (36), as well as to form PTEE m situ on metal surfaces (37). Hexafluoropropylene [116-15-4] (38,39), perfluorinated ethers, and other oligomers are prepared from TEE. 

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