Emulsion-polymerized material

Vinylidene fluoride (b.p. — 84°C) is free-radically polymerized in suspension or emulsion at 10-300 bar and 10-150°C. Suspension-polymerized material contains less branching and consequently a narrower molecular-weight distribution than the emulsion-polymerized material. For this reason, the suspension-polymerized material has higher crystallinity, greater mechanical strength, and better chemical stability. Materials from both polymerization methods contain a considerable proportion of head-to-head linkages. 

Ding, X. Zhao, J. Liu, Y. Zhang, H. Wang, Z. (2004). Silica Nanopartides Encapsulated by Polystyrene via Surface Grafting and in situ Emulsion Polymerization. Material Letters, 58,3126-3130... 

The emulsion process yields material with vinyl acetate content between 45% and 100%. Emulsion-polymerized material is rarely used in the mbber industry, but rather in thermoplastic applications as an impact modifier. 

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). 

Soap-starved recipes have been developed that yield 60 wt % soHds low viscosity polymer emulsions without concentrating. It is possible to make latices for appHcation as membranes and similar products via emulsion polymerization at even higher soHds (79). SoHds levels of 70—80 wt % are possible. The paste-like material is made in batch reactors and extmded as product. 

Specialty sulfonic acid-based surfactants make up a rather large portion of surfactant production in the United States. Approximately 136,000 metric tons of specialty sulfonic acid-based surfactants were produced in 1992, which included alpha-olefin sulfonates, sulfobetaines, sulfosuccinates, and alkyl diphenyl ether disulfonates (64). These materials found use in the areas of household cleaning products, cosmetics (qv), toiletries, emulsion polymerization, and agricultural chemical manufacture. 

Ethoxylated andSulfatedAlkylphenols. Because these aLkylphenols degrade less readily than the sulfated alcohol ethoxylates, their anticipated expansion failed to materialize, although by 1965 they were widely used in retail detergent products. Sulfated alkylphenol ethoxylates are used in hospital cleaning products, textile processing, and emulsion polymerization. Sulfated alkyphenol ethoxylates are sold as colorless, odorless aqueous solutions at concentrations of >30%. The presence of ethylene oxide in the molecule increases resistance to hardness ions and reduces skin irritation. Representative commercial sulfated alkylphenol ethoxylates are given in Table 12. 

Emulsion polymerizations of vinyl acetate in the presence of ethylene oxide- or propylene oxide-based surfactants and protective coUoids also are characterized by the formation of graft copolymers of vinyl acetate on these materials. This was also observed in mixed systems of hydroxyethyl cellulose and nonylphenol ethoxylates. The oxyethylene chain groups supply the specific site of transfer (111). The concentration of insoluble (grafted) polymer decreases with increase in surfactant ratio, and (max) is observed at an ethoxylation degree of 8 (112). 

Random copolymers of vinyl chloride and other monomers are important commercially. Most of these materials are produced by suspension or emulsion polymerization using free-radical initiators. Important producers for vinyl chloride—vinyUdene chloride copolymers include Borden, Inc. and Dow. These copolymers are used in specialized coatings appHcations because of their enhanced solubiUty and as extender resins in plastisols where rapid fusion is required (72). Another important class of materials are the vinyl chloride—vinyl acetate copolymers. Principal producers include Borden Chemicals Plastics, B. F. Goodrich Chemical, and Union Carbide. The copolymerization of vinyl chloride with vinyl acetate yields a material with improved processabihty compared with vinyl chloride homopolymer. However, the physical and chemical properties of the copolymers are different from those of the homopolymer PVC. Generally, as the vinyl acetate content increases, the resin solubiUty in ketone and ester solvents and its susceptibiUty to chemical attack increase, the resin viscosity and heat distortion temperature decrease, and the tensile strength and flexibiUty increase slightly. 

Flexible batch. Both the formula and the processing instructions can change from batch to batch. Emulsion polymerization reactors are a good example of a flexible batch facility. The recipe for each produc t must detail Both the raw materials required and how conditions within the reac tor must be sequenced in order to make the desired product. 

For acrylic polymers produced via emulsion polymerization, a set of two or more 30-cm-long columns with 10-ju,m or less packing material will usually ensure that the observed polydispersities are minimally influenced by column band broadening. 

Water-soluble polymers eomprise a major elass of polymerie materials and are used in a wide variety of applieations. Synthetie water-soluble polymers inelude poly(vinyl aleohol), poly(aerylamide), poly(aerylie aeid), poly(ethylene oxide), poly(vinyl pyrrolidone), eellulosies, and many eopolymers of these types. Their end uses are quite varied and their applieations depend mainly on their viseosify-ing, rheologieal, and surfaee-aetive properties (1). For example, poly (vinyl aleohol) is used in adhesives, fibers, textile and paper sizing, paekaging, as a stabilizer for emulsion polymerization, and as a preeursor for the manufaeture of poly(vinyl butyral), whieh is used in automotive windshields. Poly(vinyl aleohol) is also the world s largest volume, eommodity, water-soluble polymer. 

The polymers obtained by emulsion polymerization are seldom prepared in a powdered form because the material is highly hydroscopic and does not allow easy preparation of aqueous solutions. If it is necessary to obtain a finely dispersed powder, a precipitating agent is added to the latex on continuous stirring (methanol, isopropanol, etc.), and the precipitate formed is then filtered and dried. 

Following is a typical procedure for the emulsion polymerization of hydrophobic monomers in batch fashion. The first step in this process is the preparation of the continuous phase solution. As mentioned before, water is usually selected as the base material of the continuous phase for the emulsion polymerization of hydrophobic... 

History. The first attempts to desensitize RDX were reported by Frankel and Carle ton (Refs 1 thru 5) who made use of polymeric materials such as polyurethanes to coat expl crysts by means of emulsion or soln techniques. The first true PB-RDX was developed in 1952 at the Univ of Califs Los Alamos Lab and consisted of RDX coated with polystyrene plasticized with DOP (Refs 6 21). Since then the Lawrence Livermore Lab has evolved a series of PBX formulations, many of which are listed in Tables 3,4 5. These compns are described in Ref 77... 

Many of the materials used for boiler water antifoams are also employed as synthetic lubricant replacements for mineral oils, brake fluids, emulsion polymerizers, emolients, solvents for inks, cleaners, and antifoams for saltwater evaporators. These materials have been... 

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. 

This paper presents the physical mechanism and the structure of a comprehensive dynamic Emulsion Polymerization Model (EPM). EPM combines the theory of coagulative nucleation of homogeneously nucleated precursors with detailed species material and energy balances to calculate the time evolution of the concentration, size, and colloidal characteristics of latex particles, the monomer conversions, the copolymer composition, and molecular weight in an emulsion system. The capabilities of EPM are demonstrated by comparisons of its predictions with experimental data from the literature covering styrene and styrene/methyl methacrylate polymerizations. EPM can successfully simulate continuous and batch reactors over a wide range of initiator and added surfactant concentrations. 

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. 

Preparation of nanoparticles can be by a variety of different ways. The most important and frequently used is emulsion polymerization others include interfacial polymerization, solvent evaporation, and desolvation of natural proteins. The materials used to prepare nanoparticles are also numerous, but most commonly they are polymers such as poly-alklcyanoacrylate, polymethylmethacrylate, poly-butylcyanoacrylate, or are albumin or gelatin. Distribution patterns of the particles in the body can vary depending on their size, composition, and surface charge [83-85]. In particular, nanoparticles of polycyanoacrylate have been found to accumulate in certain tumors [86,87]. 

Models for emulsion polymerization reactors vary greatly in their complexity. The level of sophistication needed depends upon the intended use of the model. One could distinguish between two levels of complexity. The first type of model simply involves reactor material and energy balances, and is used to predict the temperature, pressure and monomer concentrations in the reactor. Second level models cannot only predict the above quantities but also polymer properties such as particle size, molecular weight distribution (MWD) and branching frequency. In latex reactor systems, the level one balances are strongly coupled with the particle population balances, thereby making approximate level one models of limited value (1). 

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