Emulsion polymerization components

Uses Surfactant for closed systems, emulsion polymerization component of food-contact paper/paperboard... 

Uses Defoamerfor metalworking, cosmetic, phannaceuticals, paper, textiles base for low foaming surfactants, antifoams, dishwash, dispersing and wetting agents for paints, drilling muds, emulsifiers, petrol, demulsifiers, emulsion polymerization component for sugar beet and yeast defoamers Properties Liq. m.w. 2000 HLB 3.0 cloud pt. 24 C (1% aq.) 100% act. 

Other solubilization and partitioning phenomena are important, both within the context of microemulsions and in the absence of added immiscible solvent. In regular micellar solutions, micelles promote the solubility of many compounds otherwise insoluble in water. The amount of chemical component solubilized in a micellar solution will, typically, be much smaller than can be accommodated in microemulsion fonnation, such as when only a few molecules per micelle are solubilized. Such limited solubilization is nevertheless quite useful. The incoriDoration of minor quantities of pyrene and related optical probes into micelles are a key to the use of fluorescence depolarization in quantifying micellar aggregation numbers and micellar microviscosities [48]. Micellar solubilization makes it possible to measure acid-base or electrochemical properties of compounds otherwise insoluble in aqueous solution. Micellar solubilization facilitates micellar catalysis (see section C2.3.10) and emulsion polymerization (see section C2.3.12). On the other hand, there are untoward effects of micellar solubilization in practical applications of surfactants. Wlren one has a multiphase... 

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. 

Basic Components. The principal components in emulsion polymerization are deionized water, monomer, initiator, emulsifier, buffer, and chain-transfer agent. A typical formula consists of 20—60% monomer, 2—10 wt % emulsifier on monomer, 0.1—1.0 wt % initiator on monomer, 0.1—1.0 wt % chain-transfer agent on monomer, various small amounts of buffers and bacteria control agents, and the balance deionized water. 

The basic constituents of all commercial emulsion polymerization recipes are monomers, emulsifiers, and polymerization initiators. Other common components are modifiers, inorganic salts and free alkaH, and shortstops. The function of these different components and the mechanism of emulsion polymerization have been described (43,44). 

Neutral or alkaline salts, eg, KCl, K SO, K CO, or Na PO, are often present in synthetic latices in quantities of - <1%, based on the weight of the mbber. During emulsion polymerization the salts help control viscosity of the latex and, in the case of alkaline salts, the pH of the system. Many polymerizations are carried out at high pH, requiring the use of fixed alkaH, eg, KOH or NaOH. Very small amounts of ferrous salts can be employed as a component of the initiator system, in which case a sequesteriag agent, eg, ethyldiaminotetraacetic acid (EDTA) may be iacluded to complex the iron. Water-soluble shortstops, eg, potassium dithiocarbamate, may also be iacluded ia very small amounts (ca 0.1 parts). 

In addition to appHcations in dyeing, sodium formaldehyde sulfoxylate is used as a component of the redox system in emulsion polymerization of styrene—butadiene mbber recipes. 

Internal surfactants, i.e., surfactants that are incorporated into the backbone of the polymer, are commonly used in PUD s. These surfactants can be augmented by external surfactants, especially anionic and nonionic surfactants, which are commonly used in emulsion polymerization. Great attention should be paid to the amount and type of surfactant used to stabilize urethane dispersions. Internal or external surfactants for one-component PUD s are usually added at the minimum levels needed to get good stability of the dispersion. Additional amounts beyond this minimum can cause problems with the end use of the PUD adhesive. At best, additional surfactant can cause moisture sensitivity problems with the PUD adhesive, due to the hydrophilic nature of the surfactant. Problems can be caused by excess (or the wrong type of) surfactants in the interphase region of the adhesive, affecting the ability to bond. 

Monosized polystyrene particles in the size range of 2-10 /am have been obtained by dispersion polymerization of styrene in polar solvents such as ethyl alcohol or mixtures of alcohol with water in the presence of a suitable steric stabilizer (59-62). Dispersion polymerization may be looked upon as a special type of precipitation polymerization and was originally meant to be an alternative to emulsion polymerization. The components of a dispersion polymerization include monomers, initiator, steric stabilizer, and the dispersion medium... 

There are some applications for a-sulfo fatty acid esters in the production and processing of synthetic materials or natural rubber. Emulsifiers are needed for the emulsion polymerization, antistatic agents improve the properties of polymers, and wetting agents are needed as parting components for elastomers. 

In emulsion polymerization, a solution of monomer in one solvent forms droplets, suspended in a second, immiscible solvent. We often employ surfactants to stabilize the droplets through the formation of micelles containing pure monomer or a monomer in solution. Micelles assemble when amphiphilic surfactant molecules (containing both a hydrophobic and hydrophilic end) organize at a phase boundary so that their hydrophilic portion interacts with the hydrophilic component of the emulsion, while their hydrophobic part interacts with the hydrophobic portion of the emulsion. Figure 2.14 illustrates a micellized emulsion structure. To start the polymerization reaction, a phase-specific initiator or catalyst diffuses into the core of the droplets, starting the polymerization. 

According to the first method, each micelle in an emulsion behaves like a separate micro-continuous reactor which contains all the components, i.e. monomers and radicals from the aqueous phase. Thus, analogous to the latex particles in emulsion polymerization, microgels formed by emulsion polymerization are distributed in the whole available volume. 

In normal emulsion polymerization the diffusion of monomers from droplets allows particles to grow. The polymerization is usually initiated in the aqueous phase and the oligomeric radicals either enter micelles or merge with other growing species. In the crosslinking ECP of EUP the ratio EUP/comonomer and the solubility or insolubility of both components and the initiator in the aqueous and non-aqueous phases respectively are parameters which decide whether diffusion of the reactants in the aqueous phase plays a role and where the initiation takes place. 

Emulsion polymerization is used for 10-15% of global polymer production, including such industrially important polymers as poly(acrylonitrile-butadiene-styrene) (ABS), polystyrene, poly(methyl methacrylate), and poly (vinyl acetate) [196]. These are made from aqueous solutions with high concentrations of suspended solids. The important components have unsaturated carbon-carbon double bonds. Raman spectroscopy is well-suited to address these challenges, though the heterogeneity of the mixture sometimes presents challenges. New sample interfaces, such as WAI and transmission mode, that have shown promise in pharmaceutical suspensions are anticipated to help here also. 

The physical picture of emulsion polymerization is based on the original qualitative picture of Harkins [1947] and the quantitative treatment of Smith and Ewart [1948] with subsequent contributions by other workers [Blackley, 1975 Casey et al., 1990 Gao and Penlidis, 2002 Gardon, 1977 Gilbert, 1995, 2003 Hawkett et al., 1977 Piirma, 1982 Poehlein, 1986 Ugelstad and Hansen, 1976]. Table 4-1 shows a typical recipe for an emulsion polymerization [Vandenberg and Hulse, 1948]. This formulation, one of the early ones employed for the production of styrene-1,3-butadiene rubber (trade name GR-S), is typical of all emulsion polymerization systems. The main components are the monomer(s), dispersing medium, emulsifier, and water-soluble initiator. The dispersing medium is the liquid, usually water,... 

Describe the components of an emulsion polymerization system on a macroscopic level. Compare the pros and cons of emulsion polymerization as a process condition in comparison to bulk and solution polymerization. 

The ingredients for an emulsion polymerization consist essentially of four components ... 

Most emulsion polymerizations are performed with water-soluble initiators however, the following experiment describes a redox polymerization where one component (dibenzoyl peroxide) is water-insoluble, while the other is water-soluble. 

As mentioned earlier, the necessary components for emulsion polymerization are monomer, emulsifier, initiator, and water. The monomer is insoluble in water in principle, although a small amount of water-soluble monomer can be used as a comonomer in some practical cases. On the other hand, the initiator is usually water soluble. These relations mean that the loci for radical formation and radical polymerization are different, that is, in aqueous and organic phases, respectively. This might look irrational, but the unique advantages of emulsion polymerization lie in it. When radicals are formed from a water-soluble initiator in an aqueous medium in Figure 11.1.2, top, left, each radical undergoes one of the following reactions ... 

Emulsifier is not a necessary component for emulsion polymerization if ihe following conditions are satisfied The particles are formed by homogeneous nucleation mechanism, and the particles are stabilized by factor(s) olher than emulsifier. As to the latter, the sulfate end group that is the residue of persulfate initiator serves for stabilization of dispersion via interparticle electrorepulsive force (20). When the stabilization mechanism works well, a small number of particles grow during polymerization without aggregation, keeping the size distribution narrow. Finally stable, monodisperse, anionic particles are obtained. 

Large volumes of soap are used in industrial applications as gelling agents lor kerosene, paint driers, and as surfactants in emulsion polymerization. See also Soaps. Concern over water eutrophication resulted in a ban of phosphorus in laundry detergents. Phosphates have been effectively replaced by combinations of zeolite, citrate, and polymers, coupled with rebalanced synthetic active systems. Soap itself is generally present only as a minor component of surfactants. 

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