Seeded Emulsion Polymerizations

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... 

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... 

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],... 

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. 

ASA structural latexes have been synthesized in a two stage seeded emulsion polymerization. In the first stage, partially crosslinked poly(n-butyl acrylate) and poly( -butyl acrylate-sfaf-2-ethylhexyl acrylate) rubber cores are synthesized. In the second stage, a hard styrene acrylonitrile copolymer (SAN) shell is grafted onto the rubber seeds (16). 

S. Tolue, M.R. Moghbeli, and S.M. Ghafelebashi, Preparation of ASA (acrylonitrile-styrene-acrylate) structural latexes via seeded emulsion polymerization, Enr. Polym. ]., 45(3) 714-720, March 2009. 

All three types of emulsion polymerization can be carried out using seeded emulsion polymerization, i.e., by adding monomer, initiator, and emulsifier to a previously-prepared small-particle-size latex, the particles of which grow in size without initiation of a new crop of particles. The purpose of seeded emulsion polymerization is to avoid the uncertainties of the particle initiation stage, obtain better batch-to-batch reproducibility, and give a stable latex of the desired particle size. 

Azad and Fitch (5) investigated the effect of low molecular weight hydrocarbon additives on the formation of colloidafr particles in suspension polymerization of methyl methacrylate and vinyl acetate. It was found that the additives n-octane, n-dodecane, n-octadecane, n-tetracosane and mineral oil exerted a thermodynamic affect depending upon water-solubility and molecular weight. Since these effects on emulsion polymerization have not been considered by the earlier investigators, we have chosen n-pentane and ethyl benzene as additives with limited water-solubility and n-octadecane, and n-tetracosane as water-insoluble ones. Seeded emulsion polymerization was chosen so that the number of particles could be kept constant throughout the experiments and only the effect of the other parameters on the rate could be determined. 

We now report on some experiments using seeded emulsion polymerization of styrene in which conditions were carefully chosen to ensure that Smith-Ewart Case 2 kinetics (6) would obtain throughout, in the absence of chain transfer/radical desorption effects. Various hydrocarbons were investigated for their effects on kinetics of polymerization and equilibrium swelling of the latex particles. 

Effect of Additives on the Rate of Seeded Emulsion Polymerization of Styrene... 

Figure 1 gives the conversion-time curves for the seeded emulsion polymerization of styrene in the absence and presence of various low molecular weight additives. Table I summarizes the results given in Figure 1. The rates of polymerization were determined from the straight line portion of the conversion-time curves (below 40% conversion) by least squares analysis of the experimental points. Table I also gives the calculated rates assuming a mere dilution of the monomer in the seed by the additive. It is clear that in every case the rate of polymerization is retarded much more than that due to dilution alone.

Figure 1. Effect of addition of low molecular weight hydrocarbons as additives upon the progress of the seeded emulsion polymerization of styrene at 50°C.

Kinetics of the Seeded Emulsion Polymerization of Styrene in the Presence of Ethylbenzene, at 30°C... 

Figure 4. Effect of added ethyl benzene on the monomer concentration in seed particles ((O) data obtained from swelling experiments (%) data obtained from seeded emulsion polymerization at start)...

These results explain the findings of Blackley and Haynes who also showed that the molecular weight of the polymer formed in the presence of ethyl benzene was lower than that in its absence. Calculation from their experimental data shows that their n varied from 0.005 to 0.039 radicals per particle, well into Case 1. Thus, their explanation on the basis of the Trommsdorff "gel" effect cannot be correct since this requires the mutual termination of two macroradicals in a particle, which obtains only under Case 3 kinetics. Similar experiments on the effect of the diluents on "insitu" (unseeded) and seeded emulsion polymerization indicates that n decreases due to desorption of free radicals from the particles (27). 

When water-insoluble compounds are mixed with the monomer in styrene seeded emulsion polymerizations, the rate of polymerization is lowered below a simple dilution effect. Since the additive is not transported through the water, it remains in the droplets of monomer,... 

The comparison of seeded emulsion polymerization, Rp, of three monomers (vinyl acetate, vinyl tri-deuteroacetate, and trideuterovfnyl acetate) at various initiator concentrations. The polymerization was run at 60°C with K2 2 8 as n t ator ... 

Bartholme t al. (22) found for styrene with persulfate initiation and a sodium alkyl benzene sulfonate emulsifier that there was a discrepancy between their measured value of E (21.7 kJ mol- ) and that calculated (on the assumption that Att = 0) from the expression EN = /5(E - E ). However their value of E (which was derived from measuremlnts of the rate of seeded emulsion polymerization experiments in which N was the same at all temperatures) now seems to be too high probably because the average number of radicals per particle, n < 0.5 at the lower temperatures taking E =32.5 kJ mol-1 as the best estimate, AHg can be calculated rom AHg = /2(E (exp) - E (calc))... 

The objective of this study was to investigate the feasibility of using a tubular reactor for the seeded emulsion polymerization of vinyl acetate, and to study the effect of process variables on conversion rate and latex properties. 

This study of the continuous, tubular, seeded emulsion polymerization of vinyl acetate has led to the following conclusions ... 

Recently Uniqema has introduced commercially a Surfmer under the trade name of Maxemul 5011. Maxemul is produced by esterification of an unsaturated fatty anhydride with a methoxy PEG such that the reactive group is close to the hydrophilic moiety [ 34 ]. Stable latexes with a solid content of 52% were produced in the seeded emulsion polymerization of film-forming methyl methacrylate/butyl acrylate/acrylic acid (3% Surfmer on monomers, constant monomer feeding rate over 4 h, potassium persulfate/sodium metabisulfate redox initiator). The latexes were stable to electrolytes but not to freeze-thaw. 

In the seeded emulsion polymerization of some monomers —e.g., styrene—it is possible to obtain final latexes with uniform, large particles by adjusting, during polymerization, the quantity of added emulsifier the formation of new particles is prevented by the limited amount of emulsifier. For vinyl chloride, limited emulsifier is not sufficient to prevent the formation of new particles in fact, to obtain a monodispersed latex, the surface of the particles seeded in a given water volume must be controlled. It is assumed that the growth of new nuclei is related either to the rate of formation of primary useful radicals or to the rate that these are taken by the surface of sized particles. 

Few works have appeared on the seeded emulsion polymerization of vinyl chloride (VC). Giskehaug (5) recently used this technique in a kinetic study of the emulsion polymerization of VC, but he has not determined the number and distribution of particles in the final latexes. Kotlyar et al. (6) do not give sufficient experimental data for an exhaustive analysis of the results moreover, most of the growth experiments seem to have been carried out in the presence of free emulsifier. The data reported in some industrial patents (1,9) point out only the impor-... 

Recently, core-shell type microgels, which contain a hydrophobic core and a hydrophilic thermosensitive shell, have become attractive for scientists because such systems can combine the properties characteristic of both the core and the shell [53], We have prepared core-shell microgel particles consisting of a poly(styrene) core onto which a shell of polyCA-isopropylacrylamide) (PS-PNIPA) has been affixed in a seeded emulsion polymerization [54-56], In this case, the ends of the crosslinked PNIPA chains are fixed to a solid core, which defines a solid boundary of the network. In this respect, these core-shell latex particles present crosslinked polymer brushes on defined spherical surfaces. The solvent quality can be changed from good solvent conditions at room temperature to poor solvent conditions at a temperature... 

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