Polymerization free-radically initiated

Preparation of Polymeric Free-Radical Initiators by Anionic Synthesis Polymeric Azo Derivatives... 

Scheme 1.5 Grafting polymerization of polymeric free radical initiators...

The preparation of waterborne latices by emulsion polymerization usually employs polymerization in aqueous micellar surfactant solutions. The simplest manifestation of the process involves the presence in an aqueous medium of emulsified monomer drops, micellar surfactant, and a water-soluble polymerization (free-radical) initiator. A combination of monomers is often used, exemplified by combinations of compounds such as methyl methacrylate, butyl acrylate, and styrene. Typically monomers have only slight water solubility. The classic qualitative picture of this process was described by Harkins [2] more than 60 years ago. A schematic of that process is shown in Figure 9.1. The key step is solubilization of the monomers in the micelles where polymerization is initiated. Both the low solubility of the monomer and the relatively low surface area of the monomer emulsion drops means that initiation of polymerization is essentially confined to the micelles. Polymerization now proceeds as more monomer is transported to the swelling micelles from the... 

In suspension polymerization, free-radical initiation, due to decomposition of a peroxide or azo initiator, generally occurs in droplets. As PVC is insoluble in monomer, submicron-sized particles precipitate in the droplets virtually immediately. These particles migrate to the surface of the droplet and very quickly form a him at the interface called the pericellular membrane. Polymeriza-hon and precipitahon conhnue to occur in the droplet unhl the droplets are converted from solids-in-liquid to liquid-sorbed-in-solid ( 20% conversion). 

Polymerization reactions. There are two broad types of polymerization reactions, those which involve a termination step and those which do not. An example that involves a termination step is free-radical polymerization of an alkene molecule. The polymerization requires a free radical from an initiator compound such as a peroxide. The initiator breaks down to form a free radical (e.g., CH3 or OH), which attaches to a molecule of alkene and in so doing generates another free radical. Consider the polymerization of vinyl chloride from a free-radical initiator R. An initiation step first occurs ... 

Poly(acrylic acid) and Poly(methacrylic acid). Poly(acryHc acid) (8) (PAA) may be prepared by polymerization of the monomer with conventional free-radical initiators using the monomer either undiluted (36) (with cross-linker for superadsorber appHcations) or in aqueous solution. Photochemical polymerization (sensitized by benzoin) of methyl acrylate in ethanol solution at —78° C provides a syndiotactic form (37) that can be hydrolyzed to syndiotactic PAA. From academic studies, alkaline hydrolysis of the methyl ester requires a lower time than acid hydrolysis of the polymeric ester, and can lead to oxidative degradation of the polymer (38). Po1y(meth acrylic acid) (PMAA) (9) is prepared only by the direct polymerization of the acid monomer it is not readily obtained by the hydrolysis of methyl methacrylate. 

Other fairly recent commercial products, poly(vinyl amine) and poly(vinyl amine vinyl alcohol), have addressed the need for primary amines and their selective reactivity. Prior efforts to synthesize poly(vinyl amine) have been limited because of the difficulty hydrolyzing the intermediate polymers. The current product is prepared from /V-ethenylformamide (20) formed from the reaction of acetaldehyde and formamide. The vinyl amide is polymerized with a free-radical initiator, then hydrolyzed (eq. 7). 

Unsaturated Group Reactions. In addition to a comprehensive review of these reactions (16), there are excellent texts (17,18). Free-radical-initiated polymerization of the double bond is the most common reaction and presents one of the more troublesome aspects of monomer manufacture and purification. 

Usually, free-radical initiators such as azo compounds or peroxides are used to initiate the polymerization of acrylic monomers. Photochemical (72—74) and radiation-initiated (75) polymerizations are also well known. At a constant temperature, the initial rate of the bulk or solution radical polymerization of acrylic monomers is first order with respect to monomer concentration and one-half order with respect to the initiator concentration. Rate data for polymerization of several common acrylic monomers initiated with 2,2 -azobisisobutyronittile (AIBN) [78-67-1] have been determined and are shown in Table 6. The table also includes heats of polymerization and volume percent shrinkage data. 

Vlayl fluoride undergoes free-radical polymerization. The first polymerization iavolved heating a saturated solutioa of VF ia tolueae at 67°C uader 600 MPa (87,000 psi) for 16 h (24). A wide variety of ioitiators and polymerization conditions have been explored (25—27). Examples of bulk (28,29) and solution (25,28,30,31) polymerizations exist however, aqueous suspension or emulsion methods are generally preferred (26,32—40). VF volatiflty dictates that moderately high pressures be used. Photopolymerizations, usually incorporating free-radical initiators, are also known (26,28,29,35). 

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. 

The reactions of alkyl hydroperoxides with ferrous ion (eq. 11) generate alkoxy radicals. These free-radical initiator systems are used industrially for the emulsion polymerization and copolymerization of vinyl monomers, eg, butadiene—styrene. The use of hydroperoxides in the presence of transition-metal ions to synthesize a large variety of products has been reviewed (48,51). 

DADC HomopolymeriZation. Bulk polymerization of CR-39 monomer gives clear, colorless, abrasion-resistant polymer castings that offer advantages over glass and acryHc plastics in optical appHcations. Free-radical initiators are required for thermal or photochemical polymerization. 

Etherification and esterification of hydroxyl groups produce derivatives, some of which are produced commercially. Derivatives may also be obtained by graft polymerization wherein free radicals, initiated on the starch backbone by ceric ion or irradiation, react with monomers such as vinyl or acrylyl derivatives. A number of such copolymers have been prepared and evaluated in extmsion processing (49). A starch—acrylonitrile graft copolymer has been patented (50) which rapidly absorbs many hundred times its weight in water and has potential appHcations in disposable diapers and medical suppHes. 

Continuous Polymerization. A typical continuous flow diagram for the vinyl acetate polymerisation is shown in Figure 12. The vinyl acetate is fed to the first reactor vessel, in which the mixture is purged with an inert gas such as nitrogen. Alternatively, the feed may be purged before being introduced to the reactor (209). A methanol solution containing the free-radical initiator is combined with the above stream and passed directiy and continuously into the first reactor from which a stream of the polymerisation mixture is continuously withdrawn and passed to subsequent reactors. More initiator can be added to these reactors to further increase the conversion. 

VEs such as MVE polymerize slowly in the presence of free-radical initiators to form low mol wt products of no commercial importance (9). Examples of anionic polymerization are unknown, whereas cationic initiation promotes rapid polymerization to high mol wt polymers in excellent yield and has been extensively studied (10). 

Initiation. Free-radical initiators are produced by several processes. The high temperatures and shearing stresses required for compounding, extmsion, and molding of polymeric materials can produce alkyl radicals by homolytic chain cleavage. Oxidatively sensitive substrates can react directly with oxygen, particularly at elevated temperatures, to yield radicals. 

Miscellaneous Reactions. Epoxy compounds yield chlorosubstituted carbonates (45). The reaction of chloroformates with hydrogen peroxide or metal peroxides results in the formation of peroxydicarbonates that are used as free-radical initiators of polymerization of vinyl chloride, ethylene, and other unsaturated monomers (46,47). 

Various techniques have been studied to increase sohds content. Hydroxy-functional chain-transfer agents, such as 2-mercaptoethanol [60-24-2], C2HgOS, reduce the probabihty of nonfunctional or monofunctional molecules, permitting lower molecular-weight and functional monomer ratios (44). Making low viscosity acryhc resins by free-radical initiated polymerization requires the narrowest possible molecular-weight distribution. This requires carehil control of temperature, initiator concentration, and monomer concentrations during polymerization. 

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. 

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