Vinyl chloride copolymerization

The first successful one consisted of 90 percent vinyl chloride copolymerized with 10 percent vinyl acetate. It was dry-spun from acetone and given the trade name Vinyon by its producer, Union Carbide Corporation. (In 1960, vinyon was accepted as a generic name for fibers containing not less than 85 percent vinyl chloride.) It has never been produced in large volume it is used for heat-sealable compositions. 

Figure 3, Monomer-polymer composition curve for ethylene-vinyl chloride copolymerization made at 90° C. and 15,000 p.s.i.

History of Production Manufacture of Vinyl Chloride Monomer Polymerization of Vinyl Chloride Copolymerization of Vinyl Chloride Characterization of Poly(vinyl chloride)... 

MA-styrene copolymerization, 274 MA-vinyl chloride copolymerization, 274 Chain transfer reactions, MA copolymerization, 282, 308, 329, 331, 390, 396, 407 Charge-transfer complexes AIBN-MA pair, 298 detection methods, 208-210 in Diels-Alder reaction, 140 difluoromaleic anhydride with styrene, 394 difluoromaleic anhydride with vinyl ethers, 394 ene reaction intermediate, 168 equilibrium constants, 332, 390-402, 409, 411, 415-417, 454... 

Poly(vinyl chloride), copolymeric Chlorofiber Vinyon PVM ... 

Isopropenyl acetate gives spinnable fibres on copolymerization with vinyl chloride. 

Copolymerization can be carried out with styrene, acetonitrile, vinyl chloride, methyl acrylate, vinylpyridines, 2-vinylfurans, and so forth. The addition of 2-substituted thiazoles to different dienes or mixtures of dienes with other vinyl compounds often increases the rate of polymeriza tion and improves the tensile strength and the rate of cure of the final polymers. This allows vulcanization at lower temperature, or with reduced amounts of accelerators and vulcanizing agents. 

An example of a commercial semibatch polymerization process is the early Union Carbide process for Dynel, one of the first flame-retardant modacryhc fibers (23,24). Dynel, a staple fiber that was wet spun from acetone, was introduced in 1951. The polymer is made up of 40% acrylonitrile and 60% vinyl chloride. The reactivity ratios for this monomer pair are 3.7 and 0.074 for acrylonitrile and vinyl chloride in solution at 60°C. Thus acrylonitrile is much more reactive than vinyl chloride in this copolymerization. In addition, vinyl chloride is a strong chain-transfer agent. To make the Dynel composition of 60% vinyl chloride, the monomer composition must be maintained at 82% vinyl chloride. Since acrylonitrile is consumed much more rapidly than vinyl chloride, if no control is exercised over the monomer composition, the acrylonitrile content of the monomer decreases to approximately 1% after only 25% conversion. The low acrylonitrile content of the monomer required for this process introduces yet another problem. That is, with an acrylonitrile weight fraction of only 0.18 in the unreacted monomer mixture, the low concentration of acrylonitrile becomes a rate-limiting reaction step. Therefore, the overall rate of chain growth is low and under normal conditions, with chain transfer and radical recombination, the molecular weight of the polymer is very low. 

Poly(vinyhdene chloride) (PVDC) film has exceUent barrier properties, among the best of the common films (see Barrier polymers). It is formulated and processed into a flexible film with cling and tacky properties that make it a useful wrap for leftovers and other household uses. As a component in coatings or laminates it provides barrier properties to other film stmctures. The vinyUdene chloride is copolymerized with vinyl chloride, alkyl acrylates, and acrylonitrile to get the optimum processibUity and end use properties (see Vinylidene chloride monomer and polymers). 

Internal Plasticizers. There has been much dedicated work on the possibiUty of internally plasticized PVC. However, in achieving this by copolymerization significant problems exist (/) the affinity of the growing polymer chain for vinyl chloride rather than a comonomer implies that the incorporation of a comonomer into the chain requites significant pressure (2) since the use of recovered monomer in PVC production is standard practice, contamination of vinyl chloride with comonomer in this respect creates additional problems and (J) the increasing complexity of the reaction can lead to longer reaction times and hence increased costs. Thus, since standard external plasticizers are relatively cheap they are normally preferred. 

Vinyl resins ie, copolymers of vinyl chloride and vinyl acetate which contain hydroxyl groups from the partial hydrolysis of vinyl acetate and/or carboxyl groups, eg, from copolymerized maleic anhydride, may be formulated with alkyd resins to improve their appHcation properties and adhesion. The blends are primarily used in making marine top-coat paints. 

Fig. 2. Relationship between relative rate and monomer composition in the copolymerization of DAP with vinyl monomers A, styrene or methyl methacrylate B, methyl acrylate or acrylonitrile C, vinyl chloride D, vinyl acetate, and E, ethylene (41).

Polymerization. The most important reaction of vinyl chloride is its polymerization and copolymerization in the presence of a radical-generating initiator. 

The principal solution to fabrication difficulties is copolymerization. Three types of comonomers are commercially important vinyl chloride acrylates, including alkyl acrylates and alkyimethacrylates and acrylonitrile. When extmsion is the method of fabrication, other solutions include formulation with plasticizers, stabilizers, and extmsion aids plus applying improved extmsion techniques. The Hterature on vinyHdene chloride copolymers through 1972 has been reviewed (1). 

GopolymeriZation. The importance of VDC as a monomer results from its abiHty to copolymerize with other vinyl monomers. Its Rvalue equals 0.22 and its e value equals 0.36. It most easily copolymerizes with acrylates, but it also reacts, more slowly, with other monomers, eg, styrene, that form highly resonance-stabiHzed radicals. Reactivity ratios (r and r, with various monomers are Hsted in Table 2. Many other copolymers have been prepared from monomers for which the reactivity ratios are not known. The commercially important copolymers include those with vinyl chloride (VC),... 

Vinyhdene chloride copolymerizes randomly with methyl acrylate and nearly so with other acrylates. Very severe composition drift occurs, however, in copolymerizations with vinyl chloride or methacrylates. Several methods have been developed to produce homogeneous copolymers regardless of the reactivity ratio (43). These methods are appHcable mainly to emulsion and suspension processes where adequate stirring can be maintained. Copolymerization rates of VDC with small amounts of a second monomer are normally lower than its rate of homopolymerization. The kinetics of the copolymerization of VDC and VC have been studied (45—48). 

The properties of PVDC (Table 3) ate usually modified by copolymerization. Copolymers of high VDC content have lower melting temperatures than PVDC. Copolymers containing mote than mol % acrylate or methacrylate ate amorphous. Substantially mote acrylonitrile (25%) or vinyl chloride (45%) is required to destroy crystallinity completely. 

Although they lack commercial importance, many other poly(vinyl acetal)s have been synthesized. These include acetals made from vinyl acetate copolymerized with ethylene (43—46), propjiene (47), isobutjiene (47), acrylonitrile (48), acrolein (49), acrylates (50,47), aHyl ether (51), divinyl ether (52), maleates (53,54), vinyl chloride (55), diaHyl phthalate (56), and starch (graft copolymer) (47). 

Liquid trichloroethylene has been polymerized by irradiation with Co y-rays or 20-keV x-rays (9). Trichloroethylene has a chain-transfer constant of <1 when copolymerized with vinyl chloride (10) and is used extensively to control the molecular weight of poly(vinyl chloride) polymer. 

Vinyls. Vinyl resins are thermoplastic polymers made principally from vinyl chloride other monomers such as vinyl acetate or maleic anhydride are copolymerized to add solubUity, adhesion, or other desirable properties (see Maleic anhydride, maleic acid, and fumaric acid). Because of the high, from 4,000 to 35,000, molecular weights large proportions of strong solvents are needed to achieve appHcation viscosities. Whereas vinyls are one of the finest high performance systems for steel, many vinyl coatings do not conform to VOC requirements (see Vinyl polymers). 

O.JVI. Scott Sons. The O.M. Scott Sons Co. (Scotts) has developed a series of coated products which utilize copolymer blends of vinyHdene chloride copolymerized with methyl methacrylates, acrylonitriles, methyl acrylates, and/or vinyHdene—vinyl chloride monomers. 

Random copolymers of vinyl chloride and other monomers are important commercially. Most of these materials are produced by suspension or emulsion polymerization using free-radical initiators. Important producers for vinyl chloride—vinyUdene chloride copolymers include Borden, Inc. and Dow. These copolymers are used in specialized coatings appHcations because of their enhanced solubiUty and as extender resins in plastisols where rapid fusion is required (72). Another important class of materials are the vinyl chloride—vinyl acetate copolymers. Principal producers include Borden Chemicals Plastics, B. F. Goodrich Chemical, and Union Carbide. The copolymerization of vinyl chloride with vinyl acetate yields a material with improved processabihty compared with vinyl chloride homopolymer. However, the physical and chemical properties of the copolymers are different from those of the homopolymer PVC. Generally, as the vinyl acetate content increases, the resin solubiUty in ketone and ester solvents and its susceptibiUty to chemical attack increase, the resin viscosity and heat distortion temperature decrease, and the tensile strength and flexibiUty increase slightly. 

Liquid organic rubbers with reactive functionality can be prepared by several methods. End-functional oligomers are preferred. Chains attached to the network at only one end do not contribute as much strength to the network as those attached at both ends [34], Urethane chemistry is a handy route to such molecules. A hydroxy-terminated oligomer (commonly a polyester or a polyether) can be reacted with excess diisocyanate, and then with a hydroxy methacrylate to form a reactive toughener [35]. The methacrylate ends undergo copolymerization with the rest of the acrylic monomers. The resulting adhesive is especially effective on poIy(vinyl chloride) shown in Scheme 2. 

Vinyl chloride can be copolymerized with many other monomers to improve its properties. Examples of monomers used commercially are vinyl acetate, propylene, ethylene, and vinylidine chloride. The copolymer with ethylene or propylene (Tg = 80°C), which is rigid, is used for... 

Polyacrylics are produced by copolymerizing acrylonitrile with other monomers such as vinyl acetate, vinyl chloride, and acrylamide. Solution polymerization may be used where water is the solvent in the presence of a redox catalyst. Free radical or anionic initiators may also be used. The produced polymer is insoluble in water and precipitates. Precipitation polymerization, whether self nucleation or aggregate nucleation, has been reviewed by Juba. The following equation is for an acrylonitrile polymer initiated by a free radical ... 

Dynel, a modacrylic fiber, is produced by copolymerizing vinyl chloride with acrylonitrile. Solution spinning is also used where the polymer is dissolved in a solvent such as acetone. After the solvent is evaporated, the fibers are washed and subjected to stretching, which extends the fiber 4-10 times of the original length. 

Up to this point we ve discussed only homopolymers—polymers that are made up of identical repeating units, in practice, however, copolymers are more important commercially. Copolymers are obtained when two or more different monomers are allowed to polymerize together. For example, copolymerization of vinyl chloride with vinylidene chloride (1,1-dichloroethylene) in a 1 4 ratio leads to the polymer Saran. 

Several radical copolymerizations of vinyl 2-furoate with well-known monomers (50 50) were also studied. Complete inhibition was obtained with vinyl acetate, very strong retardation with styrene, vinyl chloride and acrylonitrile methyl methacrylate homopolymerized without appreciable decrease in rate. It is evident that the degree of retardation that vinyl 2-furoate imposes upon the other monomer depends on the stability of the latter s free radical. With styrene and vinyl chloride the small amounts of fairly low molecular-weight products contained units from vinyl 2-furoate which had entered the chain both through the vinyl bond and through the ring (infrared band at 1640 cm-1). 

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