Free-radical dispersion polymerization initiation

The peroxide-initiated, free radical, dispersion polymerization of the single monomer is assumed to progress according to the simultaneous reactions of initiator decomposition, initiation, propagation and termination with appropriate reaction orders described elsewhere.(2-6)... 

The synthesis of stable latexes requires suitable nucleation of primary particles and subsequent stabilization. In classical free-radical emulsion polymerization water-soluble initiators are used. Chain growth initially affords water-soluble oligomeric radicals, which can nucleate particles by collapsing upon themselves or by entering a surfactant micelle (cf. Section 7.1). Similar considerations appear reasonable for the aforementioned catalytic polymerization to stable latexes by the water-soluble complex 6a (Scheme 7.7) [65, 71]. As a different strategy, a very fine initial dispersion of a hydrophobic catalyst precursor can be achieved as a solution in a large number of toluene/hexadecane miniemulsion droplets (0 ca. 100 nm), dispersed in the continuous aqueous phase [77, 82]. 

Vinyl acetate is polymerized in dispersion form using various initiators. Exanples of ionic initiators commonly used for free-radical emulsion polymerizations are ammonium, sodium or potassium persulfate. Topical nonionic hydrophobic initiators include 2,2 -azobis(isobutyronitrile) (AIBN) and benzoyl peroxide. Water-soluble nonionic initiators such as tertiary-butyl hydroperoxide are also employed. The initiator 4,4 -azobis(4-cyanovaleric acid) in its acid state is oil soluble, while neutralization causes it to become water soluble providing for further diversity in initiators. 

Polychloroprene elastomers are produced by free radical emulsion polymerization of 2-chloro-l,3-butadiene monomer. The emulsion polymerization of chloroprene involves the dispersing of monomer droplets in an aqueous phase by means of suitable surface active agents, generally at a pH of 10-12. Polymerization is initiated by addition of free radical catalyst at 20-50° C. To obtain a bigb conversion in the polymerization reaction and processable polymer, the addition of sulfur, thiuram disulfide, or mercaptans is necessary (Whitehouse 1986). 

Suspension polymerization of VDE in water are batch processes in autoclaves designed to limit scale formation (91). Most systems operate from 30 to 100°C and are initiated with monomer-soluble organic free-radical initiators such as diisopropyl peroxydicarbonate (92—96), tert-huty peroxypivalate (97), or / fZ-amyl peroxypivalate (98). Usually water-soluble polymers, eg, cellulose derivatives or poly(vinyl alcohol), are used as suspending agents to reduce coalescence of polymer particles. Organic solvents that may act as a reaction accelerator or chain-transfer agent are often employed. The reactor product is a slurry of suspended polymer particles, usually spheres of 30—100 pm in diameter they are separated from the water phase thoroughly washed and dried. Size and internal stmcture of beads, ie, porosity, and dispersant residues affect how the resin performs in appHcations. 

A waterborne system for container coatings was developed based on a graft copolymerization of an advanced epoxy resin and an acryHc (52). The acryhc-vinyl monomers are grafted onto preformed epoxy resins in the presence of a free-radical initiator grafting occurs mainly at the methylene group of the aHphatic backbone on the epoxy resin. The polymeric product is a mixture of methacrylic acid—styrene copolymer, soHd epoxy resin, and graft copolymer of the unsaturated monomers onto the epoxy resin backbone. It is dispersible in water upon neutralization with an amine before cure with an amino—formaldehyde resin. 

Because most widely used methods used to prepare classical styrene/divinylben-zene copolymers have always been based on suspension polymerization, it seemed logical that a series of porous PDVB gels using similar methodologies could be developed. In suspension polymerization, divinylbenzene is suspended as a dispersion of small droplets in a continuous phase of water and polymerized by classical free radical initiation. This process produces the spherical beads... 

Monomers may be polymerized using a water-soluble initiator while dispersed, by agitation, in a concentrated soap solution. In this emulsion system initiation occurs in the aqueous phase and propagation occurs in the soap micelles. Since the growing macroradicals are not terminated until a new free radical enters the micelle, high molecular weight products are rapidly obtained. The rate of polymerization and DP is proportional to the number of activated micelles. 

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. 

An intermediate polymerization technique between emulsion polymerization and suspension polymerization has been described. Here, the monomers are first dispersed in water containing a small amount of surfactant and a high molecular weight alcohol to form very small droplets of monomer. The polymerization is effected with a water-soluble free radical initiator, such as potassium per-oxydisulfate (4). 

It is believed that polymerization of hydrophobic monomers is initiated by free radicals in the aqueous phase and that the surface-active oligomers produced migrate to the interior of the emulsifier micelles where propagation continues. Monomer molecules dispersed in the water phase also solubilize by diffusing —to the expanding lamellar micelles. These micelles disappear as the polymerization continues and the rate may be measured by noting the increase in surface tension of llie system. 

Controlled free-radical polymerization methods, like atom-transfer radical polymerization (ATRP), can yield polymer chains that have a very narrow molecular-weight distribution and allow the synthesis of block copolymers. In a collaboration between Matyjaszewski and DeSimone (Xia et al., 1999), ATRP was performed in C02 for the first time. PFOMA-/)-PMMA, PFOMA-fr-PDMAEMA [DMAEMA = 2-(dimethylamino)ethyl methacrylate], and PMMA-/)-PFOA-/)-PM M A copolymers were synthesized in C02 using Cu(0), CuCl, a functionalized bipyridine ligand, and an alkyl halide initiator. The ATRP method was also conducted as a dispersion polymerization of MMA in C02 with PFOA as the stabilizer, generating a kine-... 

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