Free radical emulsion polymerization

The emulsion free-radical polymerization carried out in different steps ensures a precise control of the particle size and particle size distribution. The particle diameter can be adjusted between 100 nm and 1000 nm, with a low polydispersity (generally less than 1.1) (Chapter 8). Rubber particles with sizes lower than 100 nm are ineffective for toughening purposes (Sec. 13.3.2b). 

Published procedures did not indicate existing equipment for bulk and emulsion free radical polymerization could be used There was confusion over the definition of the term ATRP and its mechanism... 

Three events are involved with chain-growth polymerization catalytic initiation, propagation, and termination [3], Monomers with double bonds (—C=C—R1R2—) or sometimes triple bonds, and Rj and R2 additive groups, initiate propagation. The sites can be anionic or cationic active, free-radical. Free-radical catalysts allow the chain to grow when the double (or triple) bonds break. Types of free-radical polymerization are solution free-radical polymerization, emulsion free-radical polymerization, bulk free-radical polymerization, and free-radical copolymerization. Free-radical polymerization consists of initiation, termination, and chain transfer. Polymerization is initiated by the attack of free radicals that are formed by thermal or photochemical decomposition by initiators. When an organic peroxide or azo compound free-radical initiator is used, such as i-butyl peroxide, benzoyl peroxide, azo(bis)isobutylonitrile, or diazo- compounds, the monomer s double bonds break and form reactive free-radical sites with free electrons. Free radicals are also created by UV exposure, irradiation, or redox initiation in aqueous solution, which break the double bonds [3]. 

The polymers produced through emulsion free radical polymerization are synthesized from modified alkenes (eg, styrene, methyl methacrylate, methyl acrylate, butyl acrylate, vinyl acetate) and are characterized by the presence of C—C bonds that bind the monomers used. As a result, the obtained materials can be biocompatible [as for poly(methyl methacrylate)], but they are not biodegradable [9]. 

The intrinsic nature of the emulsion free radical polymerization, starting from a monomer functionalized with a C—C double bond, leads to a final product in the form of a polymer latex. This polymer is more or less a stable dispersion of polymer... 

Finally, NPs obtained via a sequence of ROP and emulsion free radical polymerization (see Fig. 12.6) are already used in pharmaceutical and medical fields from the biodistribution analysis [32,33], to the study of loading and release of pharmaceutically active principles in oncology [34—36], neuroscience [37—39], and nephrology [14] and for the synthesis of composite materials made of NPs and hydrogels or inorganic materials [40—43]. 

There is a great deal more that could be said about emulsion polymerization or, for that matter, about free-radical polymerization in general. We shall conclude our discussion of the free-radical aspect of chain-growth polymerization at this point, however. This is not the end of chain-growth polymerization, however. There are four additional topics to be considered ... 

Emulsion Adhesives. The most widely used emulsion-based adhesive is that based upon poly(vinyl acetate)—poly(vinyl alcohol) copolymers formed by free-radical polymerization in an emulsion system. Poly(vinyl alcohol) is typically formed by hydrolysis of the poly(vinyl acetate). The properties of the emulsion are derived from the polymer employed in the polymerization as weU as from the system used to emulsify the polymer in water. The emulsion is stabilized by a combination of a surfactant plus a coUoid protection system. The protective coUoids are similar to those used paint (qv) to stabilize latex. For poly(vinyl acetate), the protective coUoids are isolated from natural gums and ceUulosic resins (carboxymethylceUulose or hydroxyethjdceUulose). The hydroHzed polymer may also be used. The physical properties of the poly(vinyl acetate) polymer can be modified by changing the co-monomer used in the polymerization. Any material which is free-radically active and participates in an emulsion polymerization can be employed. Plasticizers (qv), tackifiers, viscosity modifiers, solvents (added to coalesce the emulsion particles), fillers, humectants, and other materials are often added to the adhesive to meet specifications for the intended appHcation. Because the presence of foam in the bond line could decrease performance of the adhesion joint, agents that control the amount of air entrapped in an adhesive bond must be added. Biocides are also necessary many of the materials that are used to stabilize poly(vinyl acetate) emulsions are natural products. Poly(vinyl acetate) adhesives known as "white glue" or "carpenter s glue" are available under a number of different trade names. AppHcations are found mosdy in the area of adhesion to paper and wood (see Vinyl polymers). 

Vlayl fluoride undergoes free-radical polymerization. The first polymerization iavolved heating a saturated solutioa of VF ia tolueae at 67°C uader 600 MPa (87,000 psi) for 16 h (24). A wide variety of ioitiators and polymerization conditions have been explored (25—27). Examples of bulk (28,29) and solution (25,28,30,31) polymerizations exist however, aqueous suspension or emulsion methods are generally preferred (26,32—40). VF volatiflty dictates that moderately high pressures be used. Photopolymerizations, usually incorporating free-radical initiators, are also known (26,28,29,35). 

There are two problems in the manufacture of PS removal of the heat of polymeriza tion (ca 700 kj /kg (300 Btu/lb)) of styrene polymerized and the simultaneous handling of a partially converted polymer symp with a viscosity of ca 10 mPa(=cP). The latter problem strongly aggravates the former. A wide variety of solutions to these problems have been reported for the four mechanisms described earlier, ie, free radical, anionic, cationic, and Ziegler, several processes can be used. Table 6 summarizes the processes which have been used to implement each mechanism for Hquid-phase systems. Free-radical polymerization of styrenic systems, primarily in solution, is of principal commercial interest. Details of suspension processes, which are declining in importance, are available (208,209), as are descriptions of emulsion processes (210) and summaries of the historical development of styrene polymerization processes (208,211,212). 

Free-Radical Polymerization. The best method for polymerising isoprene by a free-radical process is emulsion polymerisation. Using potassium persulfate [7727-21-1] as initiator at 50°C, a 75% conversion to polyisoprene in 15 h was obtained (76). A typical emulsion polymerisation recipe is given as follows (77). 

An emulsion polymerization reaction follows three conventional steps, namely, initiation, propagation, and termination. These steps can be described by the conventional reactions that are valid for any free radical polymerization. Smith and Ewart [10] proposed that a forming latex particle in an ideal emulsion polymeriza-... 

Water is extensively used to produce emulsion polymers with a sodium stearate emulsifrer. The emulsion concentration should allow micelles of large surface areas to form. The micelles absorb the monomer molecules activated by an initiator (such as a sulfate ion radical 80 4 ). X-ray and light scattering techniques show that the micelles start to increase in size by absorbing the macromolecules. For example, in the free radical polymerization of styrene, the micelles increased to 250 times their original size. 

Vinyl chloride Free radical polymerization in bulk or emulsion rapid in presence of peroxides susceptible to photochemical polymerization —CH2—CH— 75 Largely amorphous, except when highly oriented by stretching. Hard. Soluble in ketones and esters... 

Chemical methods for structure determination in diene pol3 mers have in large measure been superseded by infrared absorption techniques. By comparing the infrared absorption spectra of polybutadiene and of the olefins chosen as models whose ethylenic structures correspond to the respective structural units, it has been possible to show that the bands occurring at 910.5, 966.5, and 724 cm. are characteristic of the 1,2, the mns-1,4, and the m-1,4 units, respectively. Moreover, the proportion of each unit may be determined within 1 or 2 percent from measurements of the absorption intensity in each band. The extinction coefficients characteristic of each structure must, of course, be known these may be assigned from intensity measurements on model compounds. Since the proportions of the various units depend on the rates of competitive reactions, their percentages may be expected to vary with the polymerization temperature. The 1,2 unit occurs to the extent of 18 to 22 percent of the total, almost independent of the temperature, in free-radical-polymerized (emulsion or mass) poly butadiene. The ratio of trans-1,4 to cfs-1,4, however,... 

Free-radical polymerization of alkenes has been carried out in aqueous conditions.115 Aqueous emulsion and suspension polymerization is carried out today on a large scale by free-radical routes. Polymer latexes can be obtained as products (i.e., stable aqueous dispersions... 

The principle free radical polymerization techniques are bulk, solution, suspension, and emulsion. Tables 6.5 and 6.6 briefly describe these techniques. 

These superabsorbents are synthesized via free radical polymerization of acrylic acid or its salts in presence of a crosslinker (crosslinking copolymerization). Initiators are commonly used, water-soluble compounds (e.g., peroxodi-sulfates, redox systems). As crosslinking comonomers bis-methacrylates or N,hT-methylenebis-(acrylamide) are mostly applied. The copolymerization can be carried out in aqueous solution (see Example 5-11 or as dispersion of aqueous drops in a hydrocarbon (inverse emulsion polymerization, see Sect. 2.2.4.2). 

Because the size of the emulsion droplets dictates the diameter of the resulting capsules, it is possible to use miniemulsions to make nanocapsules. To cite a recent example, Carlos Co and his group developed relatively monodisperse 200-nm capsules by interfacial free-radical polymerization (Scott et al. 2005). Dibutyl maleate in hexadecane was dispersed in a miniemulsion of poly(ethylene glycol)-1000 (PEG-1000) divinyl ether in an aqueous phase. They generated the miniemulsion by sonication and used an interfacially active initiator, 2,2 -azobis(A-octyl-2-methyl-propionamidine) dihydrochloride, to initiate the reaction, coupled with UV irradiation. 

The following experiment describes the background of free radical polymerizations of vinyl monomers. This information will be experimentally illustrated in experiments involving bulk and emulsion polymerizations of styrene. 

Free radical polymerization processes [41] are carried out in bulk, solution, suspension, emulsion, or by precipitation techniques. In all cases the monomer used should be free of solvent and inhibitor or else a long induction period will result. In some cases this may be overcome by adding excess initiator. 

Finally, addition polymerization of suitably substituted furans allows incorporation of the furan nucleus into heterocyclic polymers (77MH1102). 2-Vinylfuran apparently exhibits free radical polymerizability comparable with that of styrene, although rates, yields and degrees of polymerization are low under all conditions except for emulsion polymerization. Cationic polymerization is quite facile and leads not only to the poly(vinylfuran) structure (59), as found in free radically produced polymers, but also to structures such as (60) and (61) in which the furan nucleus has become involved. Furfuryl acrylate and methacrylate undergo free radical polymerization in the manner characteristic of other acrylic esters. 

As with most synthetic plastic materials, they commence with the monomers Any of the common processes, including bulk, solution, emulsion, or suspension systems may be used in the free-radical polymerization or copolymerization of acrylic monomers. The molecular weight and physical properties of the products may be varied over a wide range by proper selection of acrylic monomer and monomer mixes, type of process, and process conditions. 

Emulsion Adhesives The most widely used emulsion-based adhesive is that based upon poly(vinyl acetate)-poly(vinyl alcohol) copolymers formed by free-radical polymerization in an emulsion system. Poly(vinyl alcohol) is typically formed by hydrolysis of the poly(vmyl acetate). This is also known as white glue. ... 

Free-radical initiation of emulsion copolymers produces a random polymerization m which the trans/ds ratio cannot be controlled. The nature of ESBR free-radical polymerization results in the polymer being heterogeneous, with a broad molecular weight distribution and random copolymer composition. The microstructurc is not amenable to manipulation, although the temperature of the polymerization affects the ratio of trans to cis somewhat... 

Homopolymerization. The free-radical polymerization of VDC has been carried out by solution, slurry, suspension, and emulsion methods. Slurry polymerizations are usually used only in the laboratory. The heterogeneity of the reaction makes stirring and heat transfer difficult consequently, these reactions cannot be easily controlled on a large scale. Aqueous emulsion or suspension reactions are preferred for large-scale operations. The spontaneous polymerization of VDC, so often observed when the monomer is stored at room temperature, is caused by peroxides formed from the reaction of VDC with oxygen, fery pure monomer does not polymerize under these conditions. Heterogeneous polymerization is characteristic of a number of monomers, including vinyl chloride and acrylonitrile. 

Acrylic Monomers. The physical properties of a polymer are dependent upon the monomers used in the polymerization. Impurities contained in the monomers also affect the physical properties. Acrylosilane resins and crosslinkable emulsions can be prepared using 3-(Diethoxymethylsilyl) propyl methacrylate (I) (H)). Free-radical polymerization using (I) will yield a resin... 

The emulsion polymerization methodology is one of the most important commercial processes. The simplest system for an emulsion (co)polymerization consists of water-insoluble monomers, surfactants in a concentration above the CMC, and a water-soluble initiator, when all these species are placed in water. Initially, the system is emulsified. This results in the formation of thermodynamically stable micelles or microemulsions built up from monomer (nano)droplets stabilized by surfactants. The system is then agitated, e.g., by heating it. This leads to thermal decomposition of the initiator and free-radical polymerization starts [85]. Here, we will consider a somewhat unusual scenario, when a surfactant behaves as a polymerizing comonomer [25,86]. 

Polymer colloids involve dispersions containing polymer particles having sizes greater than about 1 nm. If dispersed in aqueous solution, such a polymer dispersion is called a latex. These are usually synthetic polymer particles formed by free radical polymerization [784], Many kinds of polymerization systems exist, involving almost all of the possible kinds of colloidal dispersion, including emulsion polymerization, hence the more general term heterophase polymerization is sometimes used. Several reviews are available [785-789]. Emulsion polymerization provides a convenient means of controlling the polymerization of monomers and is used to make, for example, synthetic rubber which is mostly a co-polymer of butadiene and styrene. 

Microemulsion polymerization, as the name implies, involves free-radical polymerization in extremely small size, microemulsified monomer droplets of about 1-10 nm diameter [792], The produced polymer particles tend to be small (10 nm) and have higher molar mass (106-107 g/mol) than can be obtained from conventional emulsion polymerization [792]. 

Homopolymerization. The free-radical polymerization of VDC has been carried out by solution, slurry, suspension, and emulsion methods. 

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