Polymers copolymerisation

As a rule, LLDPE resins do not contain long-chain branches. However, some copolymers produced with metallocene catalysts in solution processes can contain about 0.002 long-chain branches per 100 ethylene units (1). These branches are formed in auto-copolymerisation reactions of ethylene with polymer molecules containing vinyl double bonds on their ends (2). 

Dow catalysts have a high capabihty to copolymetize linear a-olefias with ethylene. As a result, when these catalysts are used in solution-type polymerisation reactions, they also copolymerise ethylene with polymer molecules containing vinyl double bonds at their ends. This autocopolymerisation reaction is able to produce LLDPE molecules with long-chain branches that exhibit some beneficial processing properties (1,2,38,39). Distinct from other catalyst systems, Dow catalysts can also copolymerise ethylene with styrene and hindered olefins (40). 

Organic peroxides are used in the polymer industry as thermal sources of free radicals. They are used primarily to initiate the polymerisation and copolymerisation of vinyl and diene monomers, eg, ethylene, vinyl chloride, styrene, acryUc acid and esters, methacrylic acid and esters, vinyl acetate, acrylonitrile, and butadiene (see Initiators). They ate also used to cute or cross-link resins, eg, unsaturated polyester—styrene blends, thermoplastics such as polyethylene, elastomers such as ethylene—propylene copolymers and terpolymers and ethylene—vinyl acetate copolymer, and mbbets such as siUcone mbbet and styrene-butadiene mbbet. 

Poly(lactide-coglycolide). Mixtures of lactide and glycolide monomers have been copolymerised in an effort to extend the range of polymer properties and rates of in vivo absorption. Poly(lactide- (9-glycolide) polymers undergo a simple hydrolysis degradation mechanism, which is sensitive to both pH and the presence of ensymes (32). 

Another important use of BCl is as a Ftiedel-Crafts catalyst ia various polymerisation, alkylation, and acylation reactions, and ia other organic syntheses (see Friedel-Crafts reaction). Examples include conversion of cyclophosphasenes to polymers (81,82) polymerisation of olefins such as ethylene (75,83—88) graft polymerisation of vinyl chloride and isobutylene (89) stereospecific polymerisation of propylene (90) copolymerisation of isobutylene and styrene (91,92), and other unsaturated aromatics with maleic anhydride (93) polymerisation of norhornene (94), butadiene (95) preparation of electrically conducting epoxy resins (96), and polymers containing B and N (97) and selective demethylation of methoxy groups ortho to OH groups (98). 

Chain-Growth Gopolymerization Theory. The theory of chain-growth (eg, radical, anionic, etc) copolymerisation has received more attention than that of step-growth or other copolymerisations. In the case of chain-growth copolymerisation, growing polymer chains must choose between more than one monomer. Such a choice or relative reactivity has been quantitatively treated by the reactivity ratio (6,7) and the Q-e schemes (8). 

The ratio describes the relative reactivity of polymer chain M toward monomer M and monomer M2. Likewise, describes the relative reactivity of polymer chain M2 toward M2 and M. With a steady-state assumption, the copolymerisation equation can be derived from the propagation steps in equations 3—6. 

The earliest study describing vulcanised polymers of esters of acryUc acid was carried out in Germany by Rohm (2) before World War I. The first commercial acryUc elastomers were produced in the United States in the 1940s (3—5). They were homopolymers and copolymers of ethyl acrylate and other alkyl acrylates, with a preference for poly(ethyl acrylate) [9003-32-17, due to its superior balance of properties. The main drawback of these products was the vulcanisation. The fully saturated chemical stmcture of the polymeric backbone in fact is inactive toward the classical accelerators and curing systems. As a consequence they requited the use of aggressive and not versatile compounds such as strong bases, eg, sodium metasiUcate pentahydrate. To overcome this limitation, monomers containing a reactive moiety were incorporated in the polymer backbone by copolymerisation with the usual alkyl acrylates. 

It may be noted here that it is frequently possible to polymerise two monomers together so that residues from both monomers occur together in the same polymer chain. In addition polymerisation this normally occurs in a somewhat random fashion and the product is known as a binary copolymer. It is possible to copolymerise more than two monomers together and in the case of three monomers the product is referred to as a ternary copolymer or terpolymer. The term homopolymer is sometimes used to refer to a polymer made from a single monomer. 

Polymers containing oxazoline groups are obtained either by grafting the 2-oxazoline onto a suitable existing polymer such as polyethylene or polyphenylene oxide or alternatively by copolymerising a monomer such as styrene or methyl methacrylate with a small quantity (<1%) of a 2-oxazoline. The grafting reaction may be carried out very rapidly (3-5 min) in an extruder at temperatures of about 200°C in the presence of a peroxide such as di-t-butyl peroxide Figure 7.13). 

The more recently developed so-called linear low-density polyethylenes are virtually free of long chain branches but do contain short side chains as a result of copolymerising ethylene with a smaller amount of a higher alkene such as oct-1-ene. Such branching interferes with the ability of the polymer to crystallise as with the older low-density polymers and like them have low densities. The word linear in this case is used to imply the absence of long chain branches. 

One unfortunate characteristic property of polypropylene is the dominating transition point which occurs at about 0°C with the result that the polymer becomes brittle as this temperature is approached. Even at room temperature the impact strength of some grades leaves something to be desired. Products of improved strength and lower brittle points may be obtained by block copolymerisation of propylene with small amounts (4-15%) of ethylene. Such materials are widely used (known variously as polyallomers or just as propylene copolymers) and are often preferred to the homopolymer in injection moulding and bottle blowing applications. 

Many monomers have been copolymerised with ethylene using a variety of polymerisation systems, in some cases leading to commercial products. Copolymerisation of ethylene with other olefins leads to hydrocarbon polymers with reduced regularity and hence lower density, inferior mechanical properties, lower softening point and lower brittle point. 

Ethylene has also been copolymerised with a number of non-olefinic monomers and of the copolymers produced those with vinyl acetate have so far proved the most significant commercially . The presence of vinyl acetate residues in the chain reduces the polymer regularity and hence by the vinyl acetate content the amount of crystallinity may be controlled. Copolymers based on 45% vinyl acetate are rubbery and may be vulcanised with peroxides. They are commercially available (Levapren). Copolymers with about 30% vinyl acetate residues (Elvax-Du Pont) are flexible resins soluble in toluene and benezene at room temperature and with a tensile strength of about lOOOlbf/in (6.9 MPa) and a density of about 0.95 g/cm. Their main uses are as wax additives and as adhesive ingredients. 

As already mentioned in previous sections ethylene may also be copolymerised with several non-hydrocarbon polymers. Some of these copolymers are elastomeric and they also have a measure of oil resistance. Two monomers used commercially are vinyl acetate and, the structurally very similar, methyl acrylate ... 

As with other rigid amorphous thermoplastic polymers such as PVC and polystyrene (see the next chapter) poly(methyl methacrylate) is somewhat brittle and, as with PVC and polystrene, efforts have been made to improve the toughness by molecular modification. Two main approaches have been used, both of which have achieved a measure of success. They are copolymerisation of methyl methacrylate with a second monomer and the blending of poly(methyl methacrylate) with a rubber. The latter approach may also involve some graft copolymerisation. 

Over the years many attempts have been made to produce commercial acrylic polymers with a higher softening point than PMMA. The usual approach was to copolymerise MMA with a second monomer such as maleic anhydride or an N-substituted maleimide which gave homopolymers with a higher Tg than PMMA. In this way copolymers with Vicat softening points as high as 135°C could be obtained. 

The common feature of these materials was that all contained a high proportion of acrylonitrile or methacrylonitrile. The Vistron product, Barex 210, for example was said to be produced by radical graft copolymerisation of 73-77 parts acrylonitrile and 23-27 parts by weight of methyl acrylate in the presence of a 8-10 parts of a butadiene-acrylonitrile rubber (Nitrile rubber). The Du Pont product NR-16 was prepared by graft polymerisation of styrene and acrylonitrile in the presence of styrene-butadiene copolymer. The Monsanto polymer Lopac was a copolymer of 28-34 parts styrene and 66-72 parts of a second monomer variously reported as acrylonitrile and methacrylonitrile. This polymer contained no rubbery component. 

By copolymerising the vinylidene chloride with about 10-15% of vinyl chloride, processable polymers may be obtained which are used in the manufacture of filaments and films. These copolymers have been marketed by the Dow Company since 1940 under the trade name Saran. Vinylidene chloride-acrylonitrile copolymers for use as coatings of low moisture permeability are also marketed (Saran, Viclan). Vinylidene chloride-vinyl chloride copolymers in which the vinylidene chloride is the minor component (2-20%) were mentioned in Chapter 12. 

Both polymers are linear with a flexible chain backbone and are thus both thermoplastic. Both the structures shown Figure 19.4) are regular and since there is no question of tacticity arising both polymers are capable of crystallisation. In the case of both materials polymerisation conditions may lead to structures which slightly impede crystallisation with the polyethylenes this is due to a branching mechanism, whilst with the polyacetals this may be due to copolymerisation. 

Whilst the Tg of poly(dimethylsiloxane) rubbers is reported to be as low as -123°C they do become stiff at about -60 to -80°C due to some crystallisation. Copolymerisation of the dimethyl intermediate with a small amount of a dichlorodiphenylsilane or, preferably, phenylmethyldichlorosilane, leads to an irregular structure and hence amorphous polymer which thus remains a rubber down to its Tg. Although this is higher than the Tg of the dimethylsiloxane it is lower than the so that the polymer remains rubbery down to a lower temperature (in some cases down to -100°C). The Tg does, however, increase steadily with the fraction of phenylsiloxane and eventually rises above that of the of the dimethylsilicone rubber. In practice the use of about 10% of phenyldichlorosilane is sufficient to inhibit crystallisation without causing an excess rise in the glass transition temperature. As with the polydimethylsilox-anes, most methylphenyl silicone rubbers also contain a small amount of vinyl groups. 

The polymer is based on a simple head-to-tail arrangement of monomer units and is amorphous, since the specific position of the benzene ring is somewhat variable and hence inhibits crystallisation. Despite its generally desirable properties, for many applications it is considered too brittle. Because of this, a number of approaches have been made to modify the mechanical properties of poly (styrene). The most successful of these have been (i) copolymerisation and (ii) the addition of rubbery fillers. 

In a copolymerisation involving two monomers, A and B, reacting polymer chains can have either monomer A or monomer B at the growing end. As a result, there are four possible reactions Chain-end A (written A ) with monomer A or monomer B, and chain-end B ( B ) with A or with B. Each has a different rate constant, which can be designated and... 

Finally where both reactivity ratios take the value of zero, the monomers do not react at all, with growing polymer chains terminated in their own kind of monomer unit. This results in alternating copolymerisation. A few typical monomer reactivity ratios are given in Table 2.2. 

Data from L. J. Young, Copolymerisation Reactivity Ratios in Polymer Handbook , 2nd Edn., ed. J. Brandrup and E. H. Immergut, Wiley—Interscience, New York, 1975, pp. 11-105—386. 

Non-crystalline polymers are those which include high levels of irregularity within their structure. Typical sources of such irregularity are copolymerisation with significant amounts of at least two co-monomers and also complete absence of stereoregularity, i.e. atactic polymers. 

IPNs are found in many applications though this is not always recognised. For example conventional crosslinked polyester resins, where the polyester is unsaturated and crosslinks are formed by copolymerisation with styrene, is a material which falls within the definition of an interpenetrating polymer network. Experimental polymers for use as surface coatings have also been prepared from IPNs, such as epoxy-urethane-acrylic networks, and have been found to have promising properties. 

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