Crosslinking in Semi-Batch Seeded Emulsion Polymerization: Effect of Linear and Non-Linear Monomer Feeding Rate Profiles on Gel Formation

Waterborne latex is often called a product-of-process. Here, the effect of semi-batch monomer feed rate on the kinetics and gel formation in seeded emulsion polymerization was investigated for the copolymerization of n-butyl methacrylate (n-BMA) and ethylene glycol dimethacrylate (EGDMA). Strikingly, the gel fraction was observed to be significantly influenced by monomer feed rate, even while most of the experiments were performed under so-called starve-fed conditions. More flooded conditions from faster monomer feed rates, including seeded batch reactions, counterintuitively resulted in significantly higher gel fraction. Chain transfer to polymer was intentionally suppressed here via monomer selection so as to focus mechanistic insights to relate only to the influence of a divinyl monomer, as opposed to being clouded by contributions to topology from long chain branching. Simulations revealed that the dominant influence on this phenomenon was the sensitivity of primary intramolecular cyclization to the instantaneous unreacted monomer concentration, which is directly impacted by monomer feed rate. The rate constant for cyclization for these conditions was determined to be first order and 4000 s-1, approximately 4 times that typically observed for backbiting in acrylates. This concept has been explored previously for bulk and solution polymerizations, but not for emulsified reaction environments and especially for the very low mole fraction divinyl monomer. In addition, while gel fraction could be dramatically manipulated by variations in linear monomer feed rates, it could be markedly enhanced by leveraging non-linear feed profiles built from combination sequences of flooded and starved conditions. For a 2 h total feed time, a fully linear profile resulted in 30% gel while a corresponding non-linear profile with an early fast-feed segment resulted in 80% gel.

Fundamentals of Emulsion Polymerization

A comprehensive overview of the fundamentals of emulsion polymerization and related processes is presented with the object of providing theoretical and practical understanding to researchers considering use of these methods for synthesis of polymer colloids across a wide range of applications. Hence, the overview has been written for a general scientific audience with no prior knowledge assumed. Succinct introductions are given to key topics of background science to assist the reader. Importance is placed on ensuring mechanistic understanding of these complex polymerizations and how the processes can be used to create polymer colloids that have particles with well-defined properties and morphology. Mathematical equations and associated theory are given where they enhance understanding and learning and where they are particularly useful for practical application. Practical guidance also is given for new researchers so that they can begin using the various processes effectively and in ways that avoid common mistakes.

Revisiting the morphology development of solvent-swollen composite polymer particles at thermodynamic equilibrium

Morphology of polystyrene (PS)/poly(methyl methacrylate) (PMMA)/toluene droplets, in which phase separation proceeds, dispersed in SDS aqueous solution was examined. It changed from ex-centered PS-core/PMMA-shell to hemisphere with increasing SDS concentration. At low polymer weight fraction (wp), PS and PMMA phases contained non-negligible amount of PMMA and PS, respectively. The small amount of PS and PMMA in PMMA and PS phases, respectively, affected significantly the interfacial tension between polymer/toluene and aqueous solutions. Interfacial tension between PS and PMMA phases at low wp was measured by the spinning drop method, showing a quite low value ( approximately 10-2 mN/m). Predicted morphology obtained from calculation of minimum total interfacial free energy of the droplets using the interfacial tensions agreed well with the experimental observation.