Polystyrene emulsion polymerization

An important step in tire progress of colloid science was tire development of monodisperse polymer latex suspensions in tire 1950s. These are prepared by emulsion polymerization, which is nowadays also carried out industrially on a large scale for many different polymers. Perhaps tire best-studied colloidal model system is tliat of polystyrene (PS) latex [9]. This is prepared with a hydrophilic group (such as sulphate) at tire end of each molecule. In water tliis produces well defined spheres witli a number of end groups at tire surface, which (partly) ionize to... 

Styrene is a colorless Hquid with an aromatic odor. Important physical properties of styrene are shown in Table 1 (1). Styrene is infinitely soluble in acetone, carbon tetrachloride, benzene, ether, / -heptane, and ethanol. Nearly all of the commercial styrene is consumed in polymerization and copolymerization processes. Common methods in plastics technology such as mass, suspension, solution, and emulsion polymerization can be used to manufacture polystyrene and styrene copolymers with different physical characteristics, but processes relating to the first two methods account for most of the styrene polymers currendy (ca 1996) being manufactured (2—8). Polymerization generally takes place by free-radical reactions initiated thermally or catalyticaHy. Polymerization occurs slowly even at ambient temperatures. It can be retarded by inhibitors. 

Monosized polystyrene particles in the size range of 2-10 /am have been obtained by dispersion polymerization of styrene in polar solvents such as ethyl alcohol or mixtures of alcohol with water in the presence of a suitable steric stabilizer (59-62). Dispersion polymerization may be looked upon as a special type of precipitation polymerization and was originally meant to be an alternative to emulsion polymerization. The components of a dispersion polymerization include monomers, initiator, steric stabilizer, and the dispersion medium... 

Figure 2 A typical scanning electron micrograph of the submicron size (0.2 / tm), uniform polystyrene micro-spheres produced by the emulsion polymerization of styrene. Magnification 20,000 x.

The polymerization reaction is conducted at the desired temperature with a slow stirring regime for a certain period. A typical recipe for the emulsion polymerization of styrene is exemplified in Table 1 [40]. As seen here, potassium persulfate and sodium dodecyl sulfate were used as the initiator and the stabilizer, respectively. This recipe provides uniform polystyrene particles 0.22 /Lim in size. 

Sheu and coworkers [111] produced polysty-rene-polydivinylbenzene latex interpenetrating polymer networks by the seeded emulsion polymerization of styrene-divinylbenzene in the crosslinked uniform polystyrene particles. In this study, a series of uniform polystyrene latexes with different sizes between 0.6 and 8.1... 

The soapless seeded emulsion copolymerization method was used for producing uniform microspheres prepared by the copolymerization of styrene with polar, functional monomers [115-117]. In this series, polysty-rene-polymethacrylic acid (PS/PMAAc), poly sty rene-polymethylmethacrylate-polymethacrylic acid (PS/ PMMA/PMAAc), polystyrene-polyhydroxyethylmeth-acrylate (PS/PHEMA), and polystyrene-polyacrylic acid (PS/PAAc) uniform copolymer microspheres were synthesized by applying a multistage soapless emulsion polymerization process. The composition and the average size of the uniform copolymer latices prepared by multistage soapless emulsion copolymerization are given in Table 11. 

In another study, uniform composite polymethyl-methacrylate/polystyrene (PMMA/PS) composite particles in the size range of 1-10 fim were prepared by the seeded emulsion polymerization of styrene [121]. The PMMA seed particles were initially prepared by the dispersion polymerization of MMA by using AIBN as the initiator. In this polymerization, poly(7V-vinyl pyrolli-done) and methyl tricaprylyl ammonium chloride were used as the stabilizer and the costabilizer, respectively, in the methanol medium. Seed particles were swollen with styrene monomer in a medium comprised of seed particles, styrene, water, poly(7V-vinyl pyrollidone), Polywet KX-3 and aeorosol MA emulsifiers, sodium bicarbonate, hydroquinone inhibitor, and azobis(2-methylbu-... 

A research group in Lehigh University has extensively studied the synthesis and characterization of uniform macroporous styrene-divinylbenzene copolymer particles [125,126]. In their studies, uniform porous polymer particles were prepared via seeded emulsion polymerization in which linear polymer (polystyrene seed) or a mixture of linear polymer and solvent were used as inert diluents [125]. The average pore diameter was on the order of 1000 A with pore volumes up to... 

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. 

Hollow and porous polymer capsules of micrometer size have been fabricated by using emulsion polymerization or through interfacial polymerization strategies [79,83-84, 88-90], Micron-size, hollow cross-linked polymer capsules were prepared by suspension polymerization of emulsion droplets with polystyrene dissolved in an aqueous solution of poly(vinyl alcohol) [88], while latex capsules with a multihollow structure were processed by seeded emulsion polymerization [89], Ceramic hollow capsules have also been prepared by emulsion/phase-separation procedures [14,91-96] For example, hollow silica capsules with diameters of 1-100 micrometers were obtained by interfacial reactions conducted in oil/water emulsions [91],... 

Polystyrene is unusual among commodity polymers in that we can prepare it in a variety of forms by a diversity of polymerization methods in several types of reaction vessel. j Polystyrene may be atactic, isotactic, or syndiotactic. Polymerization methods include free radical, cationic, anionic, and coordination catalysis. Manufacturing processes include bulk, solution, suspension, and emulsion polymerization. We manufacture random copolymers ... 

We have considerable latitude when it comes to choosing the chemical composition of rubber toughened polystyrene. Suitable unsaturated rubbers include styrene-butadiene copolymers, cis 1,4 polybutadiene, and ethylene-propylene-diene copolymers. Acrylonitrile-butadiene-styrene is a more complex type of block copolymer. It is made by swelling polybutadiene with styrene and acrylonitrile, then initiating copolymerization. This typically takes place in an emulsion polymerization process. 

Adsorption behavior and the effect on colloid stability of water soluble polymers with a lower critical solution temperature(LCST) have been studied using polystyrene latices plus hydroxy propyl cellulose(HPC). Saturated adsorption(As) of HPC depended significantly on the adsorption temperature and the As obtained at the LCST was 1.5 times as large as the value at room temperature. The high As value obtained at the LCST remained for a long time at room temperature, and the dense adsorption layer formed on the latex particles showed strong protective action against salt and temperature. Furthermore, the dense adsorption layer of HPC on silica particles was very effective in the encapsulation process with polystyrene via emulsion polymerization in which the HPC-coated silica particles were used as seed. 

It was apparent that the dense adsorption layer of HPC which was formed on the silica particles at the LCST plays a part in the preparation of new composite polymer latices, i.e. polystyrene latices with silica particles in the core. Figures 10 and 11 show the electron micrographs of the final silica-polystyrene composite which resulted from seeded emulsion polymerization using as seed bare silica particles, and HPC-coated silica particles,respectively. As may be seen from Fig.10, when the bare particles of silica were used in the seeded emulsion polymerization, there was no tendency for encapsulation of silica particles, and indeed new polymer particles were formed in the aqueous phase. On the other hand, encapsulation of the seed particles proceeded preferentially when the HPC-coated silica particles were used as the seed and fairly monodisperse composite latices including silica particles were generated. This indicated that the dense adsorption layer of HPC formed at the LCST plays a role as a binder between the silica surface and the styrene molecules. 

Figure 13. Gel permeation chromatogram of polystyrene latex, (PL), prepared by emulsifier-free emulsion polymerization at 1 5 °C(in the absence of silica particles).

Various novel imprinting techniques have also been presented recently. For instance, latex particles surfaces were imprinted with a cholesterol derivative in a core-shell emulsion polymerization. This was performed in a two-step procedure starting with polymerizing DVB over a polystyrene core followed by a second polymerization with a vinyl surfactant and a surfactant/cholesterol-hybrid molecule as monomer and template, respectively. The submicrometer particles did bind cholesterol in a mixture of 2-propanol (60%) and water [134]. Also new is a technique for the orientated immobilization of templates on silica surfaces [ 135]. Molecular imprinting was performed in this case by generating a polymer covering the silica as well as templates. This step was followed by the dissolution of the silica support with hydrofluoric acid. Theophylline selective MIP were obtained. 

Figure 10.4 (Plate 8) Polystyrene spheres prepared by emulsion polymerization methods. Because they may be packed together to form columns or beds, these spheres find applications in separations, ion exchange, and as supports for catalysts. (Photographs by John Olive)...

Emulsion polymerization is used for 10-15% of global polymer production, including such industrially important polymers as poly(acrylonitrile-butadiene-styrene) (ABS), polystyrene, poly(methyl methacrylate), and poly (vinyl acetate) [196]. These are made from aqueous solutions with high concentrations of suspended solids. The important components have unsaturated carbon-carbon double bonds. Raman spectroscopy is well-suited to address these challenges, though the heterogeneity of the mixture sometimes presents challenges. New sample interfaces, such as WAI and transmission mode, that have shown promise in pharmaceutical suspensions are anticipated to help here also. 

The column set was calibrated with a series of polystyrene stan rds with weight average molecular weights (Mw) between 2X10 and 4.1X10°. The standards were supplied by Pressure Chemical Co., Pittsburgh, Pa. and ArRo Laboratories, Inc., Joliet, 111. Other systems used in this work included the NBS-706 polystyrene standard and an emulsion polymerized polymethyl methacrylate sample. 

Monomer and initiator must be soluble in the liquid and the solvent must have the desired chain-transfer characteristics, boiling point (above the temperature necessary to carry out the polymerization and low enough to allow for ready removal if the polymer is recovered by solvent evaporation). The presence of the solvent assists in heat removal and control (as it also does for suspension and emulsion polymerization systems). Polymer yield per reaction volume is lower than for bulk reactions. Also, solvent recovery and removal (from the polymer) is necessary. Many free radical and ionic polymerizations are carried out utilizing solution polymerization including water-soluble polymers prepared in aqueous solution (namely poly(acrylic acid), polyacrylamide, and poly(A-vinylpyrrolidinone). Polystyrene, poly(methyl methacrylate), poly(vinyl chloride), and polybutadiene are prepared from organic solution polymerizations. 

Emulsion polymerization is one of the major examples where detergents are applied to create microreactions. For instance, to polymerize styrene (which is insoluble in water), an initiator is added to the aqueous phase. The polymer (polystyrene [PS]) is formed, and the suspension is stabilized by using suitable emulsifiers. The latex thus formed is used in various industrial applications. 

Emulsion polymerization is important for ABS production (Chap. 4) but not for polystyrene itself. 

Most polystyrene products are not homopolystyrene since the latter is relatively brittle with low impact and solvent resistance (Secs. 3-14b, 6-la). Various combinations of copolymerization and blending are used to improve the properties of polystyrene [Moore, 1989]. Copolymerization of styrene with 1,3-butadiene imparts sufficient flexibility to yield elastomeric products [styrene-1,3-butadiene rubbers (SBR)]. Most SBR rubbers (trade names Buna, GR-S, Philprene) are about 25% styrene-75% 1,3-butadiene copolymer produced by emulsion polymerization some are produced by anionic polymerization. About 2 billion pounds per year are produced in the United States. SBR is similar to natural rubber in tensile strength, has somewhat better ozone resistance and weatherability but has poorer resilience and greater heat buildup. SBR can be blended with oil (referred to as oil-extended SBR) to lower raw material costs without excessive loss of physical properties. SBR is also blended with other polymers to combine properties. The major use for SBR is in tires. Other uses include belting, hose, molded and extruded goods, flooring, shoe soles, coated fabrics, and electrical insulation. 

Materials. The polystyrene latex, with a mean diameter of 0.42 fim, was synthesized by emulsifier-free emulsion polymerization. Potassium persulfate was used as initiator and the surface charge that stabilizes the latex particles thus originates from sulfate radicals. The synthesis was carried out at the Department of Polymer Technology at Abo Akademi, Finland. 

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