1,3-Dioxolane cationic copolymerization

Another stable polyacetal (POM Celcon) is produced by the cationic copolymerization of a mixture of trioxane and dioxolane (structure 5.23). 

Cationic Copolymerization of 1,3>5-Trioxane with 1,3-Dioxolane (Ring-Opening Copolymerization)... 

During the initial polymerization of trioxane with (C4H9)2OBF3 in melt or solution, no solid polymer is formed, and the reaction medium remains clear. Using a high resolution NMR spectroscope, C. S. H. Chen and A. Di Edwardo observed the appearance of soluble linear polyoxy-methylene chains. In the cationic copolymerization of trioxane with 1,3-dioxolane, V. Jaacks found also that a soluble copolymer forms first and turns later into a crystalline copolymer of different composition. Crystallization and polymerization proceed simultaneously in the solid phase. 

Rakova and Korotkov compared the rates of homopolymerization and copolymerization of styrene and butadiene [226], Styrene polymerizes very rapidly and butadiene slowly. Their copolymerization is slow at first, with preferential consumption of butadiene. When most of the butadiene is consumed, the reaction gradually accelerates yielding a product with a high styrene content. In the authors opinion, this is caused by selective solvation of the active centres by butadiene only after butadiene has polymerized, does styrene gain access to the centres [227], A similar behaviour was observed by Medvedev and his co-workes [228] and by many others. In our laboratory we observed this kind of behaviour in the cationic polymerization of trioxane with dioxolane. Although trioxane is polymerized much more rapidly than dioxolane, their copolymerization starts slowly, and is accelerated with progressing depletion of dioxolane from the monomer mixture [229],... 

Several papers57"59 were devoted to investigating a complex process such as the cationic copolymerization of monomeric formaldehyde with dioxolane in the gas, liquid, and gas-liquid phases. It is known that polyacetal resins are industrially produced by copolymerizing cyclic acetals (trioxane, 1,3,5,7-tetraoxane), or by anionic homopolymerization of monomeric formaldehyde with subsequent modification of end groups. 

Fig. 9. Kinetic curves of the reagents conversion in liquid-phase cationic copolymerization of formaldehyde with 1,3-dioxolane. 1) 1,3 dioxolane consumption 2) 1,3,5-trioxepane yield 3) yield of ethylene oxide units in copolymer 4) yield of soluble polymer...

The extruder can be used for a variety of polymerizations even if no preformed polymer is present.89 These include the continuous anionic polymerization of caprolactam to produce nylon 6,90 anionic polymerization of capro-lactone 91 anionic polymerization of styrene 92 cationic copolymerization of 1,3-dioxolane and methylal 93 free radical polymerization of methyl methacrylate 94 addition of ammonia to maleic anhydride to form poly(succin-imide) 95 and preparation of an acrylated polyurethane from polycaprolactone, 4,4 -methylenebis(phenyl isocyanate), and 2-hydroxyethyl acrylate.96 The technique of reaction injection molding to prepare molded parts is slightly different. Polyurethanes can be made this way by... 

Polymerization of 1,3,5-trioxane (TXN) gives linear polyoxymethylene (POM), a homopolymer of formaldehyde 39). This is the only polyacetal made on the technical scale. Two methods are used for the industrial production of stable, high-molecular-weight POMs. This is either the anionic polymerization of formaldehyde or the cationic copolymerization of the cyclic trimer of formaldehyde TXN with ethylene oxide or 1,3-dioxolane (DXL) ... 

Many papers relate to the cationic polymerization of acrolein but the unambiguous estimation of this has not been made. Copolymerization of acrolein with styrene initiated by BFjOEt at - 78 °C produces a copolymer, which by n.m.r. analysis contains a large proportion of acrolein incorporated into the copolymer through aldehyde addition (92%). Kinetic equations have been proposed to describe the cationic copolymerization of 1,3-dioxolane with formaldehyde. ... 

The cationic copolymerization of trioxane with ethylene oxide, 1,3-dioxolane, and suchlike is initiated either with strong protonic acids or Lewis acids, for example BF3. Molecular weight is controlled by the catalyst concentration and monomer purity, and also by chain transfer agents such as methylal [248], which may lead to more stable end groups. Most processes are run below the melting temperature of the polymer (164-167°C) in precipitating agents or in bulk, and are carried out in kneaders or double-screw reactors [249, 250], but there are also some descriptions of melt processes [251]. 

In the domain of the cationic ring-opening polymerization in dispersion, until now only one system has been investigated. In 1968, Penczek et al published results of the studies of the cationic copolymerization of 1,3-dioxolane and 1,3,5-trioxane initiated with BF3 and carried out in cyclohexane in the presence or the absence of poly(ethylene oxide). Hie initial concentration of 1,3-dioxolane in these studies was 20 times lower than the initial concentration of 1,3,5-trioxane. The former monomer was used with the purpose of protecting poly (1,3,5-trioxane) from depolymerization. It was found that depolymerization stops when 1,3-dioxolane monomeric unit is the terminal one. 

Polyoxymethylene, also referred to as acetal resin or POM, is obtained either by anionic polymerization of formaldehyde or cationic ring-opening copolymerization of trioxane with a small amount of a cyclic ether or acetal (e.g., ethylene oxide or 1,3-dioxolane) [Cherdron et al., 1988 Dolce and Grates, 1985 Yamasaki et al., 2001]. The properties and uses of POM have been discussed in Sec. 5-6d. 

In the copolymerization of trioxane with dioxolane, reactivity ratios of dissolved copolymer cations are quite different from those of active centers in the crystalline phase. The former strongly prefer addition of dioxolane. The difference in reactivity ratios between dissolved and precipitated active centers is attributed to the fact that in the solid phase, polymerization and crystallization of the copolymer are simultaneous. The cationic chain ends are assumed to be directly on the crystal surface. Determination of the equilibrium concentrations of formaldehyde confirms this conclusion dissolved copolymer has a higher tendency to cleave formaldehyde than crystalline polyoxymethylene. In the latter stages of copolymerization the soluble copolymer is degraded gradually to the dioxolane monomer which is incorporated into the crystalline copolymer in an almost random distribution. 

In the copolymerization of trioxane with dioxolane, formaldehyde may also add to copolymer cations with terminal dioxolane unit (P2+) ... 

On the other hand copolymer with a trioxane unit at the cationic chain end (Pi+) may be converted intp P2+ by cleavage of several formaldehyde units. These side reactions change the nature of the active chain ends without participation of the actual monomers trioxane and dioxo-lane. Such reactions are not provided for in the kinetic scheme of Mayo and Lewis. In their conventional scheme, conversion of Pi+ to P2+ is assumed to take place exclusively by addition of monomer M2. Polymerization of trioxane with dioxolane actually is a ternary copolymerization after the induction period one of the three monomers—formaldehyde— is present in its equilibrium concentration. Being the most reactive monomer it still exerts a strong influence on the course of copolymerization (9). This makes it impossible to apply the conventional copolymerization equation and complicates the process considerably. 

In the homopolymerization of dioxolane below 30°C. tertiary oxonium ions exist exclusively (2, 5). Otherwise hydride transfer would occur (carbonium ions abstract hydride from monomeric cyclic formats) (II, 16). In trioxane polymerization, however, at least some of the active chain ends are carbonium ions they cause hydride transfer and elimination of formaldehyde (9, II, 13). Thus, in copolymerization we must expect two different kinds of structures for cationic chains with terminal trioxane unit. Oxonium ions (I) and carbonium ions (II) may have different reactivity ratios in the copolymerization, but hopefully this does not cause severe disturbance since I and II seem to be in a fast kinetic equilibrium with each other (3). Hence, we expect [I]/[II] to be constant under similar reaction conditions. 

Hence, dioxolane is slightly more reactive than trioxane toward crystalline polymer cations with terminal trioxane unit. The same result was obtained from similar copolymerization runs. 

The difference in formaldehyde equilibrium concentration between homogeneous and heterogeneous polymerization is large enough to indicate a difference in the physical state of cationic chain ends in the dissolved and in the crystalline polymer. Thus, Model B is ruled out. In the homopolymerization of trioxane and in the heterogeneous copolymerization with small amounts of dioxolane the active centers of chains which have precipitated from the solution predominantly are directly on the crystal surface (Model A). According to Wunderlich (20, 21), this is the first case in addition polymerization where Model A—simultaneous polymerization and crystallization—has been proved experimentally. 

One of the most prominent features in the heterogeneous copolymerization of trioxane is the occurrence of two different kinds of active centers—dissolved and crystalline copolymer cations. They have different copolymer reactivity ratios and different tendencies to depolymerize, i.e., different formaldehyde equilibrium concentrations. At first the formation of soluble copolymer with high dioxolane content did not raise much hope for obtaining a crystalline copolymer of good thermal stability from trioxane and dioxolane but the gradual depolymerization of the soluble copolymer proved to be a useful side reaction which greatly improved the situation. Eventually, the entire complicated process turned out to be quite favorable for the formation of a stable crystalline copolymer with the desired random distribution. 

The process based on cationic polymerization of 1,3,5-trioxane employs a different principle for stabilization of polymer. Trioxane is copolymerized with a few percent of 1,3-dioxolane (or ethylene oxide). The sequence of —OCH2— units is then separated from time to time by —OCH2CH2— units. The product of copolymerization is subsequently heated to eliminate the terminal units (unstable fraction). Depropagation proceeds until the stable —CH2CH2OH group is reached ... 

In many instances in cationic ring-opening polymerization, all the reaction steps, however, are reversible. The final composition of copolymer (in equilibrium) is governed then by thermodynamics. Thermodynamic approaches have been developed [305] and recently reviewed [306]. Such thermodynamic approach has been used to analyze the copolymerization of pairs of cyclic acetals (1,3-dioxolane with 1,3-dioxepane and... 

The copolymerization between trioxane and suitable comonomers (ethylene oxide, 1,3-dioxolane, diethylene glycol formal, 1,4-butane diol formal in amounts of 2-5% by weight) is performed using cationic initiators. The cationic initiators could be Lewis acids, such as BF3 or its etherate BF3Bu20 which was used, for example by Celanese (the mechanism of this reaction was studied in detail [163,164]) or protic acids such as perchloric acid, perfluoroalkane sulfonic acids and their esters and anhydrides. Heteropoly acids were used and also a series of carbenium, oxocarbenium salts, onium compounds, and metal chelates. To regulate the molecular weight chain-transfer agents, such as methylal and butylal, are added. 

Of the cationically-polymerizable cyclic acetals, 1-3-dioxolan has received the most attention. By means of an ion-trapping technique, quantitative measurements of the concentration of active centres have been made and correlated with initiator incorporation to confirm the living characteristics of the linear polymers under certain conditions. The oxycarbenium ion nature of these propagating centres has been verified by C-n.m.r. spectroscopy. Methyl substitution alters the polymerizability of the homologous 1,3-dioxepanes significantly and steric hindrance in the initiator can influence both the homopolymerization and copolymerization of cyclic acetals. ... 

In particular the polymerization of 1.2.- and 1.3-epoxides (l)-(5) (18) (19) tetrahydrofurane (1)-(4) (6) (2o) Hioxolane (2177(22) and trioxane (11) (23)-X26) was thoroughly TnvestTgated. For reviews see (7T (8) (27) (28) (3o). It should be emphasized, that different oxacyclic monomers can also be copolymerized by cationic catalysts. Of great practical importance is e.g. the copolymerization of trioxane with ethylene oxide or dioxolane (31). Macromolecules with a statistic distribution of oxymethylene- and oxy-ethylene-units are formed in this way. On the other hand, however, the homopolymerization of dioxolane yields a polymer consisting of strictly alternating oxymethylene- and oxyethylene units (21) (32) therefore it can formally be considered as an alternating copolymer (eq.i). 

According to Astle (4o) et al. trioxocane can be obtained by condensation of diethylene glycol with paraformaldehyde it is easily polymerizable by cationic catalysts or by electrochemical initiation (41). Copolymerization with e.g. trioxane or dioxolane are possible, too (41). Kinetics, thermodynamics and mechanism of homopolymerization have been studied in detail by several authors. According to the analytic results of Weichert (42) the structure of the polymers of /2/... 

Figure 4 Schematic illustration of the cationic dispersion copolymerization of 1,3,5-trioxane and 1,3-dioxolane. (a) - solution before beginning of the polymerization, (b) - polymerization in solution, length of polymer chains is shorter than the critical one, (c) - chain-to-globule transition and formation of the primary particles, (d) - formation of aggregates of the primary particles, polymerization in aggregates, (e) - escape of growing species from particle aggregates to solution and formation of new primary particles, (f) - formation of new aggregates.

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