Emulsion polymerization emulsifier-free

Different approaches are used to prepare polymer particles with attaching to surface-functionalized groups. In majority of the cases, they consist of step-batch or -semibatch polymerizations in dispersed media, being among them pulsion polymerization (emulsifier-free or not) the most used polymerization process (i) emulsion homopolymerization of a monomer containing the desired functional group (functionalized monomer), (ii) emulsion copolymerization of styrene (usually) with the functionalized monomer, (iii) seeded copolymerization to produce composite functionalized latexes, and (iv) surface modification of preformed latexes. 

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). 

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). 

Emulsion Polymerization. Poly(vinyl acetate)-based emulsion polymers are produced by the polymerization of an emulsified monomer through free-radicals generated by an initiator system. Descriptions of the technology may be found in several references (35—39). 

When the emulsion polymerization is conducted in the absence of an emulsifier, this process is termed emulsifier free or soapless emulsion polymerization [68-73]. In this case, the particle formation occurs by the precipitation of growing macroradicals within the continuous... 

Recently, Smigol et al. [75] extensively studied emulsifier-free emulsion polymerization of different monomers including styrene, methyl methacrylate, and glycidyl methacrylate in an aqueous medium by using potassium peroxydisulfate as the initiator. In this study. 

PS/PHEM A particles in micron-size range were also obtained by applying the single-stage soapless emulsion copolymerization method [124]. But, this method provided copolymer particles with an anomalous shape with an uneven surface. PS or PHEMA particles prepared by emulsifier-free emulsion polymerization were also used as seed particles with the respective comonomer to achieve uniform PS/PHEMA or PHEMA/PS composite particles. PS/PHEMA and PHEMA/PS particles in the form of excellent spheres were successfully produced 1 iLitm in size in the same study. 

Preparation of uniform seed particles Soapless emulsion polymerization is usually preferred for the preparation of uniform seed particles since this technique provides emulsifier-free, larger, and highly uniform micropheres relative to those that can be obtained by the conventional emulsion recipes including emulsifiers and various additives. The size of uniform seed particles with the soapless emulsion procedure is in the range of 0.6-1.2 tm depending on the polymerization conditions [75,108]. 

MAIs may also be formed free radically when all azo sites are identical and have, therefore, the same reactivity. In this case the reaction with monomer A will be interrupted prior to the complete decomposition of all azo groups. So, Dicke and Heitz [49] partially decomposed poly(azoester)s in the presence of acrylamide. The reaction time was adjusted to a 37% decomposition of the azo groups. Surface active MAIs (M, > 10 ) consisting of hydrophobic poly(azoester) and hydrophilic poly(acrylamide) blocks were obtained (see Scheme 22) These were used for emulsion polymerization of vinyl acetate—in the polymerization they act simultaneously as emulsifiers (surface activity) and initiators (azo groups). Thus, a ternary block copolymer was synthesized fairly elegantly. 

There are many variations on this theme. Fed-batch and continuous emulsion polymerizations are common. Continuous polymerization in a CSTR is dynamically unstable when free emulsifier is present. Oscillations with periods of several hours will result, but these can be avoided by feeding the CSTR with seed particles made in a batch or tubular reactor. 

For the characterization of Langmuir films, Fulda and coworkers [75-77] used anionic and cationic core-shell particles prepared by emulsifier-free emulsion polymerization. These particles have several advantages over those used in early publications First, the particles do not contain any stabihzer or emulsifier, which is eventually desorbed upon spreading and disturbs the formation of a particle monolayer at the air-water interface. Second, the preparation is a one-step process leading directly to monodisperse particles 0.2-0.5 jim in diameter. Third, the nature of the shell can be easily varied by using different hydrophilic comonomers. In Table 1, the particles and their characteristic properties are hsted. Most of the studies were carried out using anionic particles with polystyrene as core material and polyacrylic acid in the shell. 

Figure 13. Gel permeation chromatogram of polystyrene latex, (PL), prepared by emulsifier-free emulsion polymerization at 1 5 °C(in the absence of silica particles).

Materials. The polystyrene latex, with a mean diameter of 0.42 fim, was synthesized by emulsifier-free emulsion polymerization. Potassium persulfate was used as initiator and the surface charge that stabilizes the latex particles thus originates from sulfate radicals. The synthesis was carried out at the Department of Polymer Technology at Abo Akademi, Finland. 

PBAA and PBAN. Synthesis. PBAA and PBAN are prepared by an emulsion polymerization process initiated by a free radical mechanism. Using a quaternary ammonium salt as the emulsifier and azobisisobutyro-nitrile as the initiator, the reaction for the synthesis of PBAN proceeds according to ... 

In the case of more water-soluble monomers and (amphiphilic) macromonomers, the Smith-Ewart [16] expression does not satisfactorily describe the particle nucleation. The HUFT [9,10] theory, however, satisfactorily describes the polymerization behavior or the particle nucleation of such unsaturated hydrophilic and amphiphilic monomers. The HUFT approach implies that primary particles are formed in the aqueous phase by precipitation of oligomer radicals above a critical chain length. The basic principals of the HUFT theory is that formation of primary particles will take place up to a point where the rate of formation of radicals in the aqueous phase is equal to the rate of disappearance of radicals by capture of radicals by particles already formed. Stabilization of primary particles in emulsifier-free emulsion polymerization may be achieved if the monomer (or macromonomer) contains surface active groups. Besides, the charged radical fragments of initiator increases the colloidal stability of the polymer particles. 

Thus in the emulsifier-free emulsion copolymerization the emulsifier (graft copolymer, etc.) is formed by copolymerization of hydrophobic with hydrophilic monomers in the aqueous phase. The ffee-emulsifier emulsion polymerization and copolymerization of hydrophilic (amphiphilic) macromonomer and hydro-phobic comonomer (such as styrene) proceeds by the homogeneous nucleation mechanism (see Scheme 1). Here the primary particles are formed by precipitation of oligomer radicals above a certain critical chain length. Such primary particles are colloidally unstable, undergoing coagulation with other primary polymer particles or, later, with premature polymer particles and polymerize very slowly. 

Poly(ethylene oxide) (PEO) macromonomers constitute a new class of surface active monomers which give, by emulsifier-free emulsion polymerization or copolymerization, stable polymer dispersions and comb-like materials with very interesting properties due to the exceptional properties of ethylene oxide (EO) side chains. They are a basis for a number of various applications which take advantage of the binding properties of PEO [39], its hydrophilic and amphipathic behavior [40], as well as its bio compatibility and non-absorbing character towards proteins [41]. Various types of PEO macromonomers have been proposed and among them the most popular are the acrylates and methacrylates [42]. 

Fig. 4. Dependence of monomer conversion (open symbols) and the rate of polymerization (closed symbols) in the emulsifier-free emulsion polymerization of PEO-VB macromonomers on reaction time and the PEO-VB type [85]. Recipe [PEO-VB] =0.045 mol dm-3, [AVA]=0.45xl0-3 mol dm"3,60 °C. In water Cr(EO)38-C7-VB (O, ), Cr-(EO)25-VB (A,A)...

The emulsifier-free emulsion terpolymerization of PEO-MA macromonomer, BA, and acrylic acid (AA) led to the formation of graft copolymers and stable latexes [101]. At the beginning of terpolymerization, the PEO-MA macromonomer polymerized more quickly than BA or AA. Conversion of the macromonomer increased with increasing initiator concentration and with decreasing mo-... 

Fig. 5. Dependence of the rate of polymerization [Rp/%Conv./min)] in the free-radical emulsion polymerization of butyl acrylate in the presence of PEO-MA macromonomer on emulsifier (E, p-nonyl phenol ethoxylate) concentration [100]. Temp. 50 °C...

In the emulsifier free-emulsion polymerization the reaction loci are formed by nucleation of amphiphilic macromomer micelles (micellar mechanism) or by... 

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]. 

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