Suspension polymerization, polymer

Since the surface tension y of mercury is 0.485 N m at 20 °C with a contact angle of 9= 130°, a pore of d= 1 pm and greater will be filled if a pressure p of 1.25 MPa is applied. Hence, the amount of mercury forced into pores increases with pressure (intrusion), but releasing the pressure, the pores are emptied again (extra-sion). Typical intrusion and extrusion curves are represented schematically in Fig. 1.16A. The intrusion branches in this illustration are typical for samples such as suspension polymerized polymer particles ( 200 pm). 

In suspension polymerization, polymer particle size decreases with the conversion of monomer due to the conversion of a less dense monomer to a higher density polymer. Another effect on particle diameter is agglomeration which causes a dramatic increase in size after a certain conversion is obtained [22],... 

X. Huang, W.J. Brittain, Synthesis of a PMMA-layered silicate nanocomposite by suspension polymerization, Polymer Preprints 2000, 41, 521-522. 

De Roo, T., Wieme, J., Heynderickx, G.J., Matin, G.B., 2005. Estimation of intrinsic rate coefficients in vinyl chloride suspension polymerization. Polymer 45, 8340-8354. 

Pujari, N.S., Vishwakarma, A.R., Pathak, T.S., Mule, S.A., and Ponrathnam, S. (2004) Frontal copolymerization of 2-hydroxyethyl methacrylate and ethylene glycol dimethacrylate without porogen comparison with suspension polymerization. Polym. Int., 53, 2045-2050. 

The radiation-initiated polymerization of vinylidene fiuoride is used on a laboratory scale only. The effect of polymerization conditions on the chain defects, content, and changes in the crystalline phases have been studied [528,536,537,544]. Doll and Lando [544] used a °Co source with an average dose rate of 0.33 Mrad/h. The polymerization was carried out between 0 and 400 °C at a pressure equal to the vapor pressure of the solvent-vinylidene fluoride mixture. Esters and ketones (acetone, methyl ethyl ketone, ethyl acetate, acetophenone), DMF, DMSO, and y-butyrolactone were used as solvents. All these solvents are good chain-transfer agents for vinylidene fluoride. The molding characteristics of the resulting polymers were very poor and the intrinsic viscosity of the sample polymerized in acetone solution was low (0.183 dL/g) compared to that of a suspension-polymerized polymer (1.68 dL/g) [544]. 

Suspension Polymerization. Suspension polymerisation yields polymer in the form of tiny beads, which ate primarily used as mol ding powders and ion-exchange resins. Most suspension polymers prepared as mol ding powders are poly(methyl methacrylate) copolymers containing up to 20% acrylate for reduced btittieness and improved processibiUty are also common. 

Because the polymerization occurs totally within the monomer droplets without any substantial transfer of materials between individual droplets or between the droplets and the aqueous phase, the course of the polymerization is expected to be similar to bulk polymerization. Accounts of the quantitative aspects of the suspension polymerization of methyl methacrylate generally support this model (95,111,112). Developments in suspension polymerization, including acryUc suspension polymers, have been reviewed (113,114). 

The discovery of PTFE (1) in 1938 opened the commercial field of perfluoropolymers. Initial production of PTFE was directed toward the World War II effort, and commercial production was delayed by Du Pont until 1947. Commercial PTFE is manufactured by two different polymerization techniques that result in two different types of chemically identical polymer. Suspension polymerization produces a granular resin, and emulsion polymerization produces the coagulated dispersion that is often referred to as a fine powder or PTFE dispersion. 

Suspension polymerization of VDE in water are batch processes in autoclaves designed to limit scale formation (91). Most systems operate from 30 to 100°C and are initiated with monomer-soluble organic free-radical initiators such as diisopropyl peroxydicarbonate (92—96), tert-huty peroxypivalate (97), or / fZ-amyl peroxypivalate (98). Usually water-soluble polymers, eg, cellulose derivatives or poly(vinyl alcohol), are used as suspending agents to reduce coalescence of polymer particles. Organic solvents that may act as a reaction accelerator or chain-transfer agent are often employed. The reactor product is a slurry of suspended polymer particles, usually spheres of 30—100 pm in diameter they are separated from the water phase thoroughly washed and dried. Size and internal stmcture of beads, ie, porosity, and dispersant residues affect how the resin performs in appHcations. 

The incidence of these defects is best determined by high resolution F nmr (111,112) infrared (113) and laser mass spectrometry (114) are alternative methods. Typical commercial polymers show 3—6 mol % defect content. Polymerization methods have a particularly strong effect on the sequence of these defects. In contrast to suspension polymerized PVDF, emulsion polymerized PVDF forms a higher fraction of head-to-head defects that are not followed by tail-to-tail addition (115,116). Crystallinity and other properties of PVDF or copolymers of VDF are influenced by these defect stmctures (117). 

In a suspension polymerization, monomer is suspended ia water as 0.1—5 mm droplets, stabilized by protective coUoids or suspending agents. Polymerization is initiated by a monomer-soluble initiator and takes place within the monomer droplets. The water serves as both the dispersion medium and a heat-transfer agent. Particle size is controlled primarily by the rate of agitation and the concentration and type of suspending aids. The polymer is obtained as small beads of about 0.1—5 mm in diameter, which are isolated by filtration or centrifugation. 

Slurry (Suspension) Polymerization. This polymerization technology is the oldest used for HDPE production and is widely employed because of process engineering refinement and flexibHity. In a slurry process, catalyst and polymer particles are suspended in an inert solvent, ie, a light or a... 

Hydroxyhydroquinone and pyrogaHol can be used for lining reactors for vinyl chloride suspension polymerization to prevent formation of polymer deposits on the reactor walls (98). Hydroxyhydroquinone and certain of its derivatives are useful as auxiUary developers for silver haUde emulsions in photographic material their action is based on the dye diffusion-transfer process. The transferred picture has good contrast and stain-free highlights (99). 5-Acylhydroxyhydroquinones are useful as stabilizer components for poly(alkylene oxide)s (100). 

The product of a successful suspension polymerization is small, uniform polymer spheres. For certain appHcations, they are used directly, eg, as the precursors for ion-exchange resins or bead foams. For others, they may be extmded and chopped to form larger, more easily handled mol ding pellets. 

Processes that are essentially modifications of laboratory methods and that allow operation on a larger scale are used for commercial preparation of vinyhdene chloride polymers. The intended use dictates the polymer characteristics and, to some extent, the method of manufacture. Emulsion polymerization and suspension polymerization are the preferred industrial processes. Either process is carried out in a closed, stirred reactor, which should be glass-lined and jacketed for heating and cooling. The reactor must be purged of oxygen, and the water and monomer must be free of metallic impurities to prevent an adverse effect on the thermal stabiUty of the polymer. 

Suspension Polymerization. At very low levels of stabilizer, eg, 0.1 wt %, the polymer does not form a creamy dispersion that stays indefinitely suspended in the aqueous phase but forms small beads that setde and may be easily separated by filtration (qv) (69). This suspension or pearl polymerization process has been used to prepare polymers for adhesive and coating appHcations and for conversion to poly(vinyl alcohol). Products in bead form are available from several commercial suppHers of PVAc resins. Suspension polymerizations are carried out with monomer-soluble initiators predominantly, with low levels of stabilizers. Suspension copolymerization processes for the production of vinyl acetate—ethylene bead products have been described and the properties of the copolymers determined (70). Continuous tubular polymerization of vinyl acetate in suspension (71,72) yields stable dispersions of beads with narrow particle size distributions at high yields. 

In the suspension polymerization of PVC, droplets of monomer 30—150 p.m in diameter are dispersed in water by agitation. A thin membrane is formed at the water—monomer interface by dispersants such as poly(vinyl alcohol) or methyl cellulose. This membrane, isolated by dissolving the PVC in tetrahydrofuran and measured at 0.01—0.02-p.m thick, has been found to be a graft copolymer of polyvinyl chloride and poly(vinyl alcohol) (4,5). Early in the polymerization, particles of PVC deposit onto the membrane from both the monomer and the water sides, forming a skin 0.5—5-p.m thick that can be observed on grains sectioned after polymerization (4,6). Primary particles, 1 p.m in diameter, deposit onto the membrane from the monomer side (Pig. 1), whereas water-phase polymer, 0.1 p.m in diameter, deposits onto the skin from the water side of the membrane (Pig. 2) (4). These domain-sized water-phase particles may be one source of the observed domain stmcture (7). 

Polymerization Kinetics of Mass and Suspension PVC. The polymerization kinetics of mass and suspension PVC are considered together because a droplet of monomer in suspension polymerization can be considered to be a mass polymerization in a very tiny reactor. During polymerization, the polymer precipitates from the monomer when the chain size reaches 10—20 monomer units. The precipitated polymer remains swollen with monomer, but has a reduced radical termination rate. This leads to a higher concentration of radicals in the polymer gel and an increased polymerization rate at higher polymerization conversion. 

Poly(vinyl chloride). Poly(vinyl chloride) (PVC) [9002-86-2] is a thermoplastic for building products. It is prepared by either the bulk or the suspension polymerization process. In each process residual monomer is removed because it is carcinogenic. Oxygen must be avoided throughout the process (see Vinyl polymers). 

Suspension Polymerization. This method (10) might be considered as a number of bulk polymerizations carried out simultaneously in the monomer droplets with water acting as a heat-transfer medium. A monomer-soluble initiator, eg, a peroxide or azo compound, and a protective coUoid like poly(vinyl alcohol) or bentonite, are requited. After completion of the polymerization, the excess of monomer(s) is steam stripped, and the beads of polymer are collected and washed on a centrifiige or filter and dried on a vibrating screen or by means of an expeUer—extmder. 

Suspension polymerization of water-insoluble monomers (e.g., styrene and divinylbenzene) involves the formation of an oil droplet suspension of the monomer in water with direct conversions of individual monomer droplets into the corresponding polymer beads. Preparation of beaded polymers from water-soluble monomers (e.g., acrylamide) is similar, except that an aqueous solution of monomers is dispersed in oil to form a water-in-oil (w/o) droplet suspension. Subsequent polymerization of the monomer droplets produces the corresponding swollen hydrophilic polyacrylamide beads. These processes are often referred to as inverse suspension polymerization. 

Among the various suspension systems mentioned, the details of oil-inwater (o/w) suspension polymerizations are fully known. The criteria of droplet formation, droplet stabilization, and droplet hardening, as will be discussed for the o/w suspension system, can apply equally to the preparation of beaded polymer particles in w/o systems. 

The most important feature of o/w suspension polymerization is the formation of an oil droplet suspension of the monomer in the water and the maintenance of the individual droplets throughout the polymerization process. Droplet formation in an oil-in-water mixture is accomplished and controlled by two major factors mechanical stirring and the volume ratio of the monomer phase to water. The stirring speed is a key factor in controlling the size of oil droplets and the final size of the polymers. The stirring speed usually needs to be over... 

Styrene-based polymer supports are produced by o/w suspension polymerization of styrene and divinylbenzene. Suspension polymerization is usually carried out by using a monomer-soluble initiator such as benzoperoxide (BPO) or 2,2-azo-bis-isobutylnitrile (AIBN) at a temperature of 55-85°C (19). A relatively high initiator concentration of 1-5% (w/w) based on the monomer is used. The time required for complete monomer conversion must be determined by preliminary experiments and is usually between 5 and 20 h, depending on the initiator concentration, the temperature, and the exact composition of the monomer mixture (11-18). 

New templated polymer support materials have been developed for use as re versed-phase packing materials. Pore size and particle size have not usually been precisely controlled by conventional suspension polymerization. A templated polymerization is used to obtain controllable pore size and particle-size distribution. In this technique, hydrophilic monomers and divinylbenzene are formulated and filled into pores in templated silica material, at room temperature. After polymerization, the templated silica material is removed by base hydrolysis. The surface of the polymer may be modified in various ways to obtain the desired functionality. The particles are useful in chromatography, adsorption, and ion exchange and as polymeric supports of catalysts (39,40). 

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