Radical polymerization styrenes

As known from studies on the mechanism of styrene radical polymerization, the generated carbon radicals may stabilize by (i-elimination of hydrogen, producing conjugated double bonds in the polymer chain or bond together, creating a crosslinked three-dimensional network. 

Scheme 4 Termination mechanisms in styrene radical polymerization.

The elastomer produced in greatest amount is styrene-butadiene rubber (SBR) Annually just under 10 lb of SBR IS produced in the United States and al most all of it IS used in automobile tires As its name suggests SBR is prepared from styrene and 1 3 buta diene It is an example of a copolymer a polymer as sembled from two or more different monomers Free radical polymerization of a mixture of styrene and 1 3 butadiene gives SBR... 

Section 1117 Polystyrene is a widely used vinyl polymer prepared by the free radical polymerization of styrene... 

One of the key benefits of anionic PS is that it contains much lower levels of residual styrene monomer than free-radical PS (167). This is because free-radical polymerization processes only operate at 60—80% styrene conversion, whereas anionic processes operate at >99% styrene conversion. Removal of unreacted styrene monomer from free-radical PS is accompHshed using continuous devolatilization at high temperature (220—260°C) and vacuum. This process leaves about 200—800 ppm of styrene monomer in the product. Taking the styrene to a lower level requires special devolatilization procedures such as steam stripping (168). 

There are two problems in the manufacture of PS removal of the heat of polymeriza tion (ca 700 kj /kg (300 Btu/lb)) of styrene polymerized and the simultaneous handling of a partially converted polymer symp with a viscosity of ca 10 mPa(=cP). The latter problem strongly aggravates the former. A wide variety of solutions to these problems have been reported for the four mechanisms described earlier, ie, free radical, anionic, cationic, and Ziegler, several processes can be used. Table 6 summarizes the processes which have been used to implement each mechanism for Hquid-phase systems. Free-radical polymerization of styrenic systems, primarily in solution, is of principal commercial interest. Details of suspension processes, which are declining in importance, are available (208,209), as are descriptions of emulsion processes (210) and summaries of the historical development of styrene polymerization processes (208,211,212). 

In the manufacture of highly resident flexible foams and thermoset RIM elastomers, graft or polymer polyols are used. Graft polyols are dispersions of free-radical-polymerized mixtures of acrylonitrile and styrene partially grafted to a polyol. Polymer polyols are available from BASF, Dow, and Union Carbide. In situ polyaddition reaction of isocyanates with amines in a polyol substrate produces PHD (polyhamstoff dispersion) polyols, which are marketed by Bayer (21). In addition, blending of polyether polyols with diethanolamine, followed by reaction with TDI, also affords a urethane/urea dispersion. The polymer or PHD-type polyols increase the load bearing properties and stiffness of flexible foams. Interreactive dispersion polyols are also used in RIM appHcations where elastomers of high modulus, low thermal coefficient of expansion, and improved paintabiUty are needed. 

Mechanisms. Because of its considerable industrial importance as well as its intrinsic interest, emulsion polymerization of vinyl acetate in the presence of surfactants has been extensively studied (75—77). The Smith-Ewart theory, which describes emulsion polymerization of monomers such as styrene, does not apply to vinyl acetate. Reasons for this are the substantial water solubiUty of vinyl acetate monomer, and the different reactivities of the vinyl acetate and styrene radicals the chain transfer to monomer is much higher for vinyl acetate. The kinetics of the polymerization of vinyl acetate has been studied and mechanisms have been proposed (78—82). 

The Q-e Scheme. The magnitude of and T2 can frequentiy be correlated with stmctural effects, such as polar and resonance factors. For example, in the free-radical polymerization of vinyl acetate with styrene, both styrene and vinyl acetate radicals preferentially add styrene because of the formation of the resonance stabilized polystyrene radical. 

Impact polystyrene (IPS) is one of a class of materials that contains mbber grafted with polystyrene. This composition is usually produced by polymerizing styrene (by mass or solution free-radical polymerization) in the presence of a small amount (ca 5%) of dissolved elastomer. Some of the important producers of impact-resistant polystyrenes are BASE (Polystyrol), Dow (Styron), and Monsanto (Lustrex). The 1988 U.S. production of impact polystyrene was more than 1 million t (92). 

The reaction between benzoyl peroxide and A,A-dimethylaniline has been the subject of many examinations over the years. The following mechanism of initiation is fairly well accepted in the polymerization of styrene. It seems likely that a similar mechanism is followed for other free-radical polymerizations (Scheme 5). 

The radical mechanism is supported by a number of findings for instance, when the electrolysis is carried out in the presence of an olefin, the radicals add to the olefinic double bond styrene does polymerize under those conditions. Side products can be formed by further oxidation of the alkyl radical 2 to an intermediate carbenium ion 5, which then can react with water to yield an alcohol 6, or with an alcohol to yield an ether 7 ... 

Free radical polymerization is a key method used by the polymer industry to produce a wide range of polymers [37]. It is used for the addition polymerization of vinyl monomers including styrene, vinyl acetate, tetrafluoroethylene, methacrylates, acrylates, (meth)acrylonitrile, (meth)acrylamides, etc. in bulk, solution, and aqueous processes. The chemistry is easy to exploit and is tolerant to many functional groups and impurities. 

Thus, a mixture of simple carbonyls Me(CO)n and halides should behave as a photoinitiator of free radical polymerization. Many such systems have been found to function in this way. Complexes formed by irradiation of Fe(CO)5 in the presence of a vinyl monomer (M) (such as MMA, styrene, vinyl acetate, propylene, and vinyl ether) have been studied by Koerner Von Grustrof and colleagues [12,13] and shown to have the chemical struc-... 

Studies in the photoinitiation of polymerization by transition metal chelates probably stem from the original observations of Bamford and Ferrar [33]. These workers have shown that Mn(III) tris-(acety]acetonate) (Mn(a-cac)3) and Mn (III) tris-(l,l,l-trifluoroacetyl acetonate) (Mn(facac)3) can photosensitize the free radical polymerization of MMA and styrene (in bulk and in solution) when irradiated with light of A = 365 at 25°C and also abstract hydrogen atom from hydrocarbon solvents in the absence of monomer. The initiation of polymerization is not dependant on the nature of the monomer and the rate of photodecomposition of Mn(acac)3 exceeds the rate of initiation and the initiation species is the acac radical. The mechanism shown in Scheme (14) is proposed according to the kinetics and spectral observations ... 

In contrast to /3-PCPY, ICPY did not initiate copolymerization of MMA with styrene [39] and AN with styrene [40]. However, it accelerated radical polymerization by increasing the rate of initiation in the former case and decreasing the rate of termination in the latter case. The studies on photocopolymerization of MMA with styrene in the presence of ICPY has also been reported [41], /8-PCPY also initiated radical copolymerization of 4-vinylpyridine with methyl methacrylate [42]. However, the ylide retarded the polymerization of N-vinylpyrrolidone, initiated by AIBN at 60°C in benzene [44]. (See also Table 2.)... 

Previously, the same author [52] reported that compounds containing the tricoordinated sulfur cation, such as the triphenylsulfonium salt, worked as effective initiators in the free radical polymerization of MMA and styrene [52]. Because of the structural similarity of sulfonium salt and ylide, diphenyloxosulfonium bis-(me-thoxycarbonyl) methylide (POSY) (Scheme 28), which contains a tetracoordinated sulfur cation, was used as a photoinitiator by Kondo et al. [63] for the polymerization of MMA and styrene. The photopolymerization was carried out with a high-pressure mercury lamp the orders of reaction with respect to [POSY] and [MMA] were 0.5 and 1.0, respectively, as expected for radical polymerization. 

Dimethyl sulfonium-2-pyridyl carbonyl methylide (Ypy-5) [65] initiated radical polymerization of styrene in dimethyl sulfoxide at 85 0.1°C for 6 h under a nitrogen blanket. (See Table 4.)... 

Water is extensively used to produce emulsion polymers with a sodium stearate emulsifrer. The emulsion concentration should allow micelles of large surface areas to form. The micelles absorb the monomer molecules activated by an initiator (such as a sulfate ion radical 80 4 ). X-ray and light scattering techniques show that the micelles start to increase in size by absorbing the macromolecules. For example, in the free radical polymerization of styrene, the micelles increased to 250 times their original size. 

When an unsymmetrically substituted vinyl monomer such as propylene or styrene is polymerized, the radical addition steps can take place at either end of the double bond to yield either a primary radical intermediate (RCH2-) or a secondary radical (R2CH-). Just as in electrophilic addition reactions, however, we find that only the more highly substituted, secondary radical is formed. 

There are some indications that the situation described above has been realized, at least partially, in the system styrene-methyl methacrylate polymerized by metallic lithium.29 29b It is known51 that in a 50-50 mixture of styrene and methyl methacrylate radical polymerization yields a product of approximately the same composition as the feed. On the other hand, a product containing only a few per cent of styrene is formed in a polymerization proceeding by an anionic mechanism. Since the polymer obtained in the 50-50 mixture of styrene and methyl methacrylate polymerized with metallic lithium had apparently an intermediate composition, it has been suggested that this is a block polymer obtained in a reaction discussed above. Further evidence favoring this mechanism is provided by the fact that under identical conditions only pure poly-methyl methacrylate is formed if the polymerization is initiated by butyl lithium and not by lithium dispersion. This proves that incorporation of styrene is due to a different initiation and not propagation. 

There are several reports scattered in the literature of the retarding effect of simple furan derivatives in the polymerization of a specific monomer. Hardy69, U6 found that furan, 2-furoic acid and its esters, and 5-substituted-2-furoie acids were strong retarders in the radical polymerization of vinyl acetate, but did not act likewise with styrene. He proposed that as a result of the reactions of the free radicals with the furan derivatives, dihydro- and tetrahydrofurans would form, but he did not produce any evidence to support these speculations. Clarke, Howard and Stock-... 

For example, the molecular weight of unsaturated polyesters is controlled to less than 5000 g/mol. The low molecular weight of the unsaturated polyester allows solvation in vinyl monomers such as styrene to produce a low-viscosity resin. Unsaturated polyesters are made with monomers containing carbon-carbon double bonds able to undergo free-radical crosslinking reactions with styrene and other vinyl monomers. Crosslinking the resin by free-radical polymerization produces the mechanical properties needed in various applications. 

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