Polymerization medium

Aqueous media, such as emulsion, suspension, and dispersion polymerization, are by far the most widely used in the acryUc fiber industry. Water acts as a convenient heat-transfer and cooling medium and the polymer is easily recovered by filtration or centrifugation. Fiber producers that use aqueous solutions of thiocyanate or zinc chloride as the solvent for the polymer have an additional benefit. In such cases the reaction medium can be converted directiy to dope to save the costs of polymer recovery. Aqueous emulsions are less common. This type of process is used primarily for modacryUc compositions, such as Dynel. Even in such processes the emulsifier is used at very low levels, giving a polymerization medium with characteristics of both a suspension and a tme emulsion. 

An alternative polymerization process utilizes a slurry of calcium chloride in NMP as the polymerization medium. The solubiHty of calcium chloride is only 6% at 20°C however, the salt continues to dissolve as conversion of monomers to polymer proceeds and calcium chloride/polyamide complexes are formed. Polymer molecular weight is further increased by the addition of /V, /V- dim ethyl a n i1 in e as an acid acceptor. This solvent system produces fiber-forming polymer of molecular weights comparable to that formed in HMPA/NMP. 

Solution Polymerization. Two solution polymerization technologies ate practiced. Processes of the first type utilize heavy solvents those of the second use molten PE as the polymerization medium (57). Polyethylene becomes soluble ia saturated C —hydrocarbons above 120—130°C. Because the viscosity of HDPE solutions rapidly iacrease with molecular weight, solution polymerization is employed primarily for the production of low mol wt resias. Solution process plants were first constmcted for the low pressure manufacture of PE resias ia the late 1950s they were later exteasively modified to make their operatioa economically competitive. 

Solution Polymerization. Two types of solution polymerization technologies are used for LLDPE synthesis. One process utilizes heavy solvents the other is carried out in mixtures of supercritical ethylene and molten PE as a polymerization medium. Original solution processes were introduced for low pressure manufacture of PE resins in the late 1950s subsequent improvements of these processes gradually made them economically competitive with later, more advanced technologies. 

NMP are examples of suitable solvents for PES and PPSF polymerizations. Chlorobenzene or toluene are used as cosolvents at low concentrations. These cosolvents form an azeotrope with water as they distill out of the reaction mixture, thereby keeping the polymerization medium dehydrated. Potassium carbonate is a suitable choice for base. The synthesis of PES and PPSE differ from the PSE case in that the reaction is carried out in a single-step process. In other words, the formation of the dipotassium salt of the bisphenol is not completed in a separate first step. Equations 2 and 3 represent polymerizations based on the dipotassium salts of bisphenol S and biphenol to make PES and PPSE, respectively. 

The influence of temperature on the copolymerization was investigated at constant absorbed dose of 0.12 and 0.16 KGy for copolymerization of AM-AANa [17,54] and AM-DAEA-HCl [22], respectively. The results are shown in Figs. 9 and 10, which show that the Rp values increase while the intrinsic viscosity and the degree of polymerization decrease with increasing the polymerization temperature. However, the increase in the temperature of the polymerization medium increases the swell-... 

The increase in the temperature reduces the viscosity of the polymerization medium which increases the termination reactions. This is attributed to an increase in chain transfer reactions higher than that of propagation reactions [16,51]. Consequently, the weight-average molecular weight of the formed polymer decreases. 

The progression of an ideal emulsion polymerization is considered in three different intervals after forming primary radicals and low-molecular weight oligomers within the water phase. In the first stage (Interval I), the polymerization progresses within the micelle structure. The oligomeric radicals react with the individual monomer molecules within the micelles to form short polymer chains with an ion radical on one end. This leads to the formation of a new phase (i.e., polymer latex particles swollen with the monomer) in the polymerization medium. 

Based on the Smith-Ewart theory, the number of latex particles formed and the rate of polymerization in Interval II is proportional with the 0,6 power of the emulsifier concentration. This relation was also observed experimentally for the emulsion polymerization of styrene by Bartholomeet al. [51], Dunn and Al-Shahib [52] demonstrated that when the concentrations of the different emulsifiers were selected so that the micellar concentrations were equal, the same number of particles having the same size could be obtained by the same polymerization rates in Interval II in the existence of different emulsifiers [52], The number of micelles formed initially in the polymerization medium increases with the increasing emulsifier concentration. This leads to an increase in the total amount of monomer solubilized by micelles. However, the number of emulsifier molecules in one micelle is constant for a certain type of emulsifier and does not change with the emulsifier concentration. The monomer is distributed into more micelles and thus, the... 

Stable particles in sufficient number, all the oligo-radi-cals and nuclei generated in the continuous phase are captured by the mature particles, no more particles form, and the particle formation stage is completed. The primary particles formed by the nucleation process are swollen by the unconverted monomer and/or polymerization medium. The polymerization taking place within the individual particles leads to resultant uniform microspheres in the size range of 0.1-10 jjLvn. Various dispersion polymerization systems are summarized in Table 4. 

The most obvious reason for the polymerization rate variation with time is the change in the number of propagation centers (88, 89). According to Zakharov et al. (115) this change may be determined by the concurrence of the following reactions in the polymerization medium ... 

In the case of catalysts activated with the help of reduction by CO, reactions (8) and (9) are excluded from the kinetic scheme. Such catalysts contain the centers Nr before their contact with the polymerization medium. 

The experimental evidence for the availability of the coordinative insufficiency of the transition metal ion in the propagation centers was obtained (175) in the study of the deactivation of the propagation centers by coordination inhibitors. On the introduction of such inhibitors as phosphine and carbon monoxide into the polymerization medium, the reaction stops, but the metal-polymer bond is retained. It shows that in this case the interaction of the inhibitor with the propagation center follows the scheme ... 

Clearly, unless monomer is the intended photoinitiator, it is important to choose an initiator that absorbs in a region of the UV-visible spectrum clear from the absorptions of monomer and other components of the polymerization medium. Ideally, one should choose a monochromatic light source that, is specific for the chromophorc of the photoinitiator or photosensitizer. It is also important in many experiments that the total amount of light absorbed by the sample is small. Otherwise the rate of initiation will vary with the depth of light penetration into the sample. 

The initiator in radical polymerization is often regarded simply as a source of radicals. Little attention is paid to the various pathways available for radical generation or to the side reactions that may accompany initiation. The preceding discussion (see 3.2) demonstrated that in selecting initiators (whether thermal, photochemical, redox, etc.) for polymerization, they must be considered in terms of the types of radicals formed, their suitability for use with the particular monomers, solvent, and the other agents present in the polymerization medium, and for the properties they convey to the polymer produced. 

Tire elTecl observed is dependent on the reactivity of the monomer and other agents present in the polymerization medium towards hydropeioxy radicals 29. If addition of 29 to monomer is slow, in relation to normal propagation, then retardation or inhibition will be observed. It should also be noted that, polymeric peroxides, one of the products of reaction with oxygen are potentially sources of additional radicals. These may complicate polymerization and can impair the properties of the final polymer (Section 8.2). 

The vinyl ether transfer agents, like other vinyl ethers, can show marked acid sensitivity. They are not suited for use with acid monomers. Even traces of acidic impurities in the monomer or the polymerization medium can catalyze decomposition of the transfer agent. 

Any understanding of the kinetics of copolymerization and the structure of copolymers requires a knowledge of the dependence of the initiation, propagation and termination reactions on the chain composition, the nature of the monomers and radicals, and the polymerization medium. This section is principally concerned with propagation and the effects of monomer reactivity on composition and monomer sequence distribution. The influence of solvent and complcxing agents on copolymerization is dealt with in more detail in Section 8.3.1. 

The reactivity of macromonomers in copolymerizalion is strongly dependent on the particular comonomer-macromonomer pair. Solvent effects and the viscosity of the polymerization medium can also be important. Propagation may become diffusion controlled such that the propagation rate constant and reactivity ratios depend on the molecular weight of the macromonomer and the viscosity or, more accurately, the free volume of the medium. 

The very small number of growing polymer chains, when compared to the monomer concentration results in a very low overall concentration of free control agent and leads to inefficient capping of chain ends. One solution to this problem is the addition of a free or unbound control agent to the polymerization medium. This can take the form of a low molecular weight alkoxyamine, ATRP initiator, RAFT agent or, alternatively, free deactivator such as nitroxide or Cu(II). This species is often called a sacrificial agent. This solution also leads to the formation of free polymer that must ultimately be removed from the brush. 

Kinetic studies on the bulk polyesterification of a,o-dicarboxy poly(hexamethylene adipate) with a,[Pg.76]

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