Emulsion polymerization heterogeneous particles

Emulsion Polymerization. Emulsion and suspension reactions are doubly heterogeneous the polymer is insoluble in the monomer and both are insoluble in water. Suspension reactions are similar in behavior to slurry reactors. Oil-soluble initiators are used, so the monomer—polymer droplet is like a small mass reaction. Emulsion polymerizations are more complex. Because the monomer is insoluble in the polymer particle, the simple Smith-Ewart theory does not apply (34). 

Heterogeneous polymerization processes (emulsion, miniemulsion, non-aqueous dispersion) offer another possibility for reducing the rate of termination through what are known as compartmcntalization effects. In emulsion polymerization, it is believed that the mechanism for chain stoppage within the particles is not radical-radical termination but transfer to monomer (Section 5.2.1.5). These possibilities have provided impetus for the development ofliving heterogeneous polymerization (Sections 9.3.6.6, 9.4.3.2, 9.5.3.6). 

In an emulsion polymerization, the reaction mixture is initially heterogeneous due to the poor solubility of the monomer in the continuous phase. In order for a reaction to take advantage of the desirable Smith-Ewart kinetics [96], the monomer and initiator must be segregated with the initiator preferentially dissolved in the continuous phase and not the monomer phase. Because of the kinetics of an emulsion polymerization, high molecular weight polymer can be produced at high rates. The polymer which results from an emulsion polymerization exists as spherical particles typically smaller than one pm in diameter. However, due to the high solubility of most vinyl monomers in C02, emulsion polymerization in C02 probably will not be a very useful process for commercially important monomers. 

Dispersion polymerization involves an initially homogeneous system of monomer, organic solvent, initiator, and particle stabilizer (usually uncharged polymers such as poly(A-vinyl-pyrrolidinone) and hydroxypropyl cellulose). The system becomes heterogeneous on polymerization because the polymer is insoluble in the solvent. Polymer particles are stabilized by adsorption of the particle stabilizer [Yasuda et al., 2001], Polymerization proceeds in the polymer particles as they absorb monomer from the continuous phase. Dispersion polymerization usually yields polymer particles with sizes in between those obtained by emulsion and suspension polymerizations—about 1-10 pm in diameter. For the larger particle sizes, the reaction characteristics are the same as in suspension polymerization. For the smallest particle sizes, suspension polymerization may exhibit the compartmentalized kinetics of emulsion polymerization. 

Surfactants play a major role in the preparation of suspensions of polymer particles by heterogeneous nucleation. In emulsion polymerization, the monomer is emulsified in a nonsolvent (usually water) using a surfactant, whereas the initiator is dissolved in the continuous phase. The role of surfactants in this process is obvious since nucleation may occur in the swollen surfactant micelle. Indeed, the number of particles formed and their size depend on the nature of surfactant and its concentration (which determines the number of micelles formed). 

Dispersion polymerization differs from emulsion polymerization in that the reaction mixture, consisting of monomer, initiator, and solvent (aqueous or nonaque-ous), is usually homogeneous. As polymerization proceeds, polymer separates out and the reaction continues in a heterogeneous manner. A polymeric surfactant of the block or graft type (referred to as protective colloid ) is added to stabilize the particles once formed. 

Emulsion polymerization is a free radical initiated chain polymerization in which a monomer or a mixture of monomers is polymerized in aqueous solution of a surfactant to form a product, known as a latex. The most important feature of emulsion polymerization is its heterogeneity from the beginning to the end of the polymerization, to yield in a batch process submicron-sized polymeric particles, often of excellent monodispersity. The main ingredients for conducting... 

The preceding discussion has led us to the conclusion that the surface is the only locus of polymerization which needs to be considered in the heterogeneous polymerization of acrylonitrile. Radicals arrive at the surface at a rate determined by the decomposition of the initiator and efficiency of initiation. Propagation occurs on the surface at a rate determined by the activity of monomer at the surface. By analogy with emulsion polymerization, where monomer diffuses into the particles rapidly enough to maintain near equilibrium activity (14), we assume that the activity of the monomer adsorbed on the particle surface is approximately equal to the mole fraction in solution. The propagation rate constant is presumably influenced somewhat by the presence of the solid surface. 

There are four main types of liquid-phase heterogeneous free-radical polymerization microemulsion polymerization, emulsion polymerization, miniemulsion polymerization and dispersion polymerization, all of which can produce nano- to micron-sized polymeric particles. Emulsion polymerization is sometimes called macroemulsion polymerization. In recent years, these heterophase polymerization reactions have become more and more important... 

The prediction of the evolution of the PSD in Interval II is simpler than that in the ether intervals and it was for this reason that it was discussed first. Even the qualitative features of particle formation in Interval I are in doubt and the relative importance of homogeneous (ije., oligomeric precipitation) versus heterogeneous (i.e., micellar) nucleation mechanisms are not fully understood. For tbis reason, detailed solutions to Eq. (S) in this Interval, when c is nonzero, appear to be premature. Moreover, in many emulsion polymerizations, the precise details of events occurring in Interval I are masked by the subsequent particle growth in Intervals II and III. 

Another problem involves the classification of these metal-based heterogeneous systems into suspension, dispersion, and emulsion polymerizations similarly to conventional systems. This is due to not only a lack of detailed analysis of reaction mechanisms and particle sizes but also fundamental differences in several aspects such as the locus of initiation and the molecular weight of polymers in comparison with the conventional counterparts. The terms suspension and emulsion will be used in the following sections for simple classification but are not based on the strict definition for conventional free radical systems. 

Emulsion polymerization is a heterogenous reaction process in which unsaturated monomers are dispersed in continuous phase with the aid of emulsifiers and polymerized by free-radical initiators. The resulting product is a dispersion of polymer particles, typically smaller than 1 pm in size, in water and is referred to as polymer latex. 

Spherical beads possess better hydrodynamic and diffusion properties than irregularly shaped particles. It is, hence, desirable to apply MIPs in a spherical bead format, especially for flow-through applications. Methods to synthesize spherical polymer beads are often classified according to the initial state of the polymerization mixture (i) homogeneous (i.e. precipitation polymerization and dispersion polymerization) or (ii) heterogeneous (i.e. emulsion polymerization and suspension polymerization). In addition, several other techniques have been applied for the preparation of spherical MIP beads. The techniques of two-step swelling polymerization, core-shell polymerization, and synthesis of composite beads will be detailed here. 

Smith and Ewart (13a. 13b) quantified the Harkins theory by the equation R = k MpN/2 where Rp is the rate of propagation, kp is the rate constant for propagation, M is the monomer concentration in growing chain particles, and N the number of polymer particles per unit volume. If M is the constant, this equation is reduced to R = k N. Thus, the rate of emulsion polymerization should solely be a function of the number of polymer particles. In actuality, the reaction rate increases up to 20-25% conversion because of the increase in the number of growing radical chains then the rate steadies as does the number of polymer particles up to 70-80% conversion. Beyond this point, the rate drops off because of low monomer concentration. Thus, as Talamini (13c. 13d) has noted, available evidence indicates that emulsion polymerization of vinyl chloride does not resemble true emulsion polymerization as described by Smith and Ewart, but shows the general behavior of heterogeneous polymerization. 

On the other hand, when dealing with heterogeneous systems (e.g., suspension or emulsion polymerizations), it is important not to confuse thermodynamic effects of monomer partitioning among phases with variations in reactivity ratios. For the calculation of these, the concentrations of the monomers at the reaction site should be considered (at the particles) instead of global concentrations in the system. 

One of the most important outcomes of the heterogeneity of the emulsion polymerization process is the high level of radical segregation within the polymerization system, namely the polymer particles swollen with monomer. 

There are many unique polymerization processes which share a conunon heritage with emulsion polymerization, but which often are unrecognized as such. It is the purpose of this review to describe some of these emulsion polymerization-like processes and their products. Some further definition is in order unconventional emulsion polymerizations can be described as those processes whereby the product is a polymer latex that physically resembles latex from emulsion polymerization and cannot be grouped into any other recognized form of heterogeneous polymerization. In many cases the reasons why a process is not recognized as an emulsion polymerization is that the polymerization is not via a free-radical process. This review (hscusses four distinct types of polymerization processes, all of which have examples that produce latex particles and in many ways can be described as unconventional emulsion polymerizations. These are free-radical polymerization, ionic polymerization, transition metal catalyzed polymerization and enzyme-catalyzed polymerization. The precise systems discussed in this review are described in Table 23.1. 

The heterogeneity of emulsion polymerization systems offers unique possibilities of structural control of emulsion (co)polymers, on a molecular scale (intermolecular and intramolecular microstructure) as well as on a parficle-size scale (particle morphology). The kinetic and mechanistic features of emulsion (co)polymerization are strongly reflected in molecular size and its distribution, chemical conqxisition and its distribufion, particle moiphology, and product properties. A further fine tuning of polymer properties calls for advanced characterization techniques enable of revealing delicate structural details in emulsion (co)poIymers. 

An emulsion has been defined above as a thermodynamically unstable heterogeneous system of two immiscible liquids where one is dispersed in the other. There are two principal possibilities for preparing emulsions the destruction of a larger volume into smaller sub-units (comminution method) or the construction of emulsion droplets from smaller units (condensation method). Both methods are of technical importance for the preparation of emulsions for polymerization processes and will be discussed in more detail below. To impart a certain degree of kinetic stability to emulsions, different additives are employed which have to fulfil special demands in the particular applications. The most important class of such additives, which are also called emulsifying agents, are surface-active and hence influence the interfacial properties. In particular, they have to counteract the rapid coalescence of the droplets caused by the van der Waals attraction forces. In the polymerization sense, these additives can be roughly subdivided into surfactants for emulsion polymerization, polymers for suspension and dispersion polymerization, finely dispersed insoluble particles (also for suspension polymerization), and combinations thereof (cf. below). 

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