Emulsion polymerization: From fundamental mechanisms to process developments

Real-Time Monitoring of Particle Size in Emulsion Polymerization: Simultaneous Turbidity and Photon Density Wave Spectroscopy

Particle size evolution in seeded semibatch emulsion polymerization is monitored by two real-time monitoring techniques: online turbidity spectroscopy (TUS) and inline photon density wave spectroscopy (PDWS). An automatic dilution system that withdraws a sample from the reactor and upon dilution transfers to the measurement cell is used for the online TUS analysis. A PDWS probe is immersed in the reactor and collects inline the scattered light directly from the reacting latex. The particle sizes retrieved from TUS and PDWS are compared to offline dynamic light scattering (DLS) values. The particle size obtained by TUS is close to the intensity-average particle size obtained offline by DLS, while the particle size obtained by PDWS lies closer to the number-average particle size from DLS.

Facile Access to High Solid Content Monodispersed Microspheres via Dual-Component Surfactants Regulation toward High-Performance Colloidal Photonic Crystals

Monodispersed microspheres play a major role in optical science and engineering, providing ideal building blocks for structural color materials. However, the method toward high solid content (HSC) monodispersed microspheres has remained a key hurdle. Herein, a facile access to harvest monodispersed microspheres based on the emulsion polymerization mechanism is demonstrated, where anionic and nonionic surfactants are employed to achieve the electrostatic and steric dual-stabilization balance in a synergistic manner. Monodispersed poly(styrene-butyl acrylate-methacrylic acid) colloidal latex with 55 wt% HSC is achieved, which shows an enhanced self-assembly efficiency of 280% compared with the low solid content (10 wt%) latex. In addition, Ag-coated colloidal photonic crystal (Ag@CPC) coating with near-zero refractive index is achieved, presenting the characteristics of metamaterials. And an 11-fold photoluminescence emission enhancement of CdSe@ZnS quantum dots is realized by the Ag@CPC metamaterial coating. Taking advantage of high assembly efficiency, easily large-scale film-forming of the 55 wt% HSC microspheres latex, robust Ag@CPC metamaterial coatings could be easily produced for passive cooling. The coating demonstrates excellent thermal insulation performance with theoretical cooling power of 30.4 W m-2, providing practical significance for scalable CPC architecture coatings in passive cooling.

Modern Trends in Polymerization-Induced Self-Assembly

Polymerization-induced self-assembly (PISA) is a powerful and versatile technique for producing colloidal dispersions of block copolymer particles with desired morphologies. Currently, PISA can be carried out in various media, over a wide range of temperatures, and using different mechanisms. This method enables the production of biodegradable objects and particles with various functionalities and stimuli sensitivity. Consequently, PISA offers a broad spectrum of potential commercial applications. The aim of this review is to provide an overview of the current state of rational synthesis of block copolymer particles with diverse morphologies using various PISA techniques and mechanisms. The discussion begins with an examination of the main thermodynamic, kinetic, and structural aspects of block copolymer micellization, followed by an exploration of the key principles of PISA in the formation of gradient and block copolymers. The review also delves into the main mechanisms of PISA implementation and the principles governing particle morphology. Finally, the potential future developments in PISA are considered.

Stimuli-Responsive Polymers for Engineered Emulsions

Emulsions are complex. Dispersing two immiscible phases, thus expanding an interface, requires effort to achieve and the resultant dispersion is thermodynamically unstable, driving the system toward coalescence. Furthermore, physical instabilities, including creaming, arise due to presence of dispersed droplets of different densities to a continuous phase. Emulsions allow the formulation of oils, can act as vehicles to solubilize both hydrophilic and lipophilic molecules, and can be tailored to desirable rheological profiles, including "gel-like" behavior and shear thinning. The usefulness of emulsions can be further expanded by imparting stimuli-responsive or "smart" behaviors by inclusion of a stimuli-responsive emulsifier, polymer or surfactant. This enables manipulation like gelation, breaking, or aggregation, by external triggers such as pH, temperature, or salt concentration changes. This platform generates functional materials for pharmaceuticals, cosmetics, oil recovery, and colloid engineering, combining both smart behaviors and intrinsic benefit of emulsions. However, with increased functionality comes greater complexity. This review focuses on the use of stimuli-responsive polymers for the generation of smart emulsions, motivated by the great adaptability of polymers for this application and their efficacy as steric stabilizers. Stimuli-responsive emulsions are described according to the trigger used to provide the reader with an overview of progress in this field.

Synthesis of Polymers with Narrow Molecular Mass Distribution through Interface-Initiated Room-Temperature Polymerization in Emulsion Gels

Homopolymers of n-butyl acrylate, methyl methacrylate, styrene, and their random copolymers were prepared via interface-initiated polymerization of emulsion gels at 20 °C. The polymerization was conducted in a free radical polymerization manner without inert gas protection. Compared with the polymers synthesized at 60 °C, the polymerization of emulsion gels at 20 °C produced homo- and copolymers with a higher molecular mass and a narrower molecular mass distribution. The polydispersity indices for the polymers synthesized at 20 °C were found to be between 1.12 and 1.37. The glass transition temperatures for the as-synthesized butyl acrylate copolymers agree well with the prediction from the Gordon-Taylor equation. Interface-initiated room-temperature polymerization is a robust, energy-saving polymerization technique for synthesizing polymers with a narrow molecular mass distribution.

Advances in Organic-Inorganic Hybrid Latex Particles via In Situ Emulsion Polymerization

Hybrid latex particles combine the unique properties of inorganic nano/micro particles with the inherent properties of polymers, exhibiting tremendous potential for a variety of applications. Recent years have witnessed an increased interest in the design and preparation of hybrid latex particles with well-defined size, structure and morphology. Due to its simplicity, versatility and environmental friendliness, the in situ (Pickering) emulsion polymerization has been demonstrated to be a powerful approach for the large-scale preparation of hybrid latex particles. In this review, the strategies and applications of in situ (Pickering) emulsion polymerization for the preparation of hybrid latex particles are systematically summarized. A particular focus is placed on the strategies for the preparation of hybrid latex particles with enhanced properties and well-defined core-shell, yolk-shell, multinuclear, raspberry-like, dumbbell-shaped, multipod-like or armored morphologies. We hope that the considerable advances, examples and principles presented in this review can motivate future contributions to provide a deeper understanding of current preparation technologies, develop new processes, and enable further exploitation of hybrid latex particles with outstanding characteristics and properties.

Microemulsion and microsuspension polymerization of methyl methacrylate in surfactant-free microemulsions (SFME)

HYPOTHESIS

This article presents a free-radical polymerization method in a mesostructured system - free of any surfactants, protective colloids, or other auxiliary agents. It is applicable for a large variety of industrially relevant vinylic monomers. The aim of this work is to study the impact of surfactant-free mesostructuring on the polymerization kinetics and the polymer derived.

EXPERIMENTS

So-called surfactant-free microemulsions (SFME) were investigated as reaction media with a simple composition comprising water, a hydrotrope (ethanol, n-propanol, isopropanol, tert-butyl alcohol), and the monomer as the reactive oil phase (methyl methacrylate). Polymerization reactions were performed using oil-soluble, thermal- and UV-active initiators (surfactant-free microsuspension polymerization) and water-soluble, redox-active initiators (surfactant-free microemulsion polymerization). Structural analysis of the SFMEs used and the polymerization kinetics were followed by dynamic light scattering (DLS). Dried polymers were analyzed with regard to their conversion yield by mass balance, the corresponding molar masses were determined using gel permeation chromatography (GPC), and the morphology was investigated by light microscopy.

FINDINGS

All alcohols are suitable hydrotropes to form SFMEs, except for ethanol, which forms a molecularly disperse system. We observe significant differences in the polymerization kinetics and the molar masses of the polymers obtained. Ethanol leads to significantly higher molar masses. Within a system, higher concentrations of the other alcohols investigated give rise to less pronounced mesostructuring, lower conversions, and lower average molar masses. It could be demonstrated that the effective concentration of alcohol in the oil-rich pseudophases as well as the repulsive effect of the surfactant-free, alcohol-rich interphases constitute the relevant factors influencing polymerization. Concerning the morphology, the polymers derived range from powder-like polymers in the so-called "pre-Ouzo region" over porous-solid polymers in the bicontinuous region to dense, almost compacted, transparent polymers in unstructured regions, comparable to the findings for surfactant-based systems reported in the literature. Polymerizations in SFME comprise a new intermediate between well-known solution (i.e., molecularly dispersed) and microemulsion respectively microsuspension polymerization processes.

Polymer Colloids: Current Challenges, Emerging Applications, and New Developments

Polymer colloids are complex materials that have the potential to be used in a vast array of applications. One of the main reasons for their continued growth in commercial use is the water-based emulsion polymerization process through which they are generally synthesized. This technique is not only highly efficient from an industrial point of view but also extremely versatile and permits the large-scale production of colloidal particles with controllable properties. In this perspective, we seek to highlight the central challenges in the synthesis and use of polymer colloids, with respect to both existing and emerging applications. We first address the challenges in the current production and application of polymer colloids, with a particular focus on the transition toward sustainable feedstocks and reduced environmental impact in their primary commercial applications. Later, we highlight the features that allow novel polymer colloids to be designed and applied in emerging application areas. Finally, we present recent approaches that have used the unique colloidal nature in unconventional processing techniques.

Graphitization by Metal Particles

Graphitization of carbon offers a promising route to upcycle waste biomass and plastics into functional carbon nanomaterials for a range of applications including energy storage devices. One challenge to the more widespread utilization of this technology is controlling the carbon nanostructures formed. In this work, we undertake a meta-analysis of graphitization catalyzed by transition metals, examining the available electron microscopy data of carbon nanostructures and finding a correlation between different nanostructures and metal particle size. By considering a thermodynamic description of the graphitization process on transition-metal nanoparticles, we show an energy barrier exists that distinguishes between different growth mechanisms. Particles smaller than ∼25 nm in radius remain trapped within closed carbon structures, while nanoparticles larger than this become mobile and produce nanotubes and ribbons. These predictions agree closely with experimentally observed trends and should provide a framework to better understand and tailor graphitization of waste materials into functional carbon nanostructures.

How Effective are Nano-Based Dressings in Diabetic Wound Healing? A Comprehensive Review of Literature

Chronic wound caused by diabetes is an important cause of disability and seriously affects the quality of life of patients. Therefore, it is of great clinical significance to develop a wound dressing that can accelerate the healing of diabetic wounds. Nanoparticles have great advantages in promoting diabetic wound healing due to their antibacterial properties, low cytotoxicity, good biocompatibility and drug delivery ability. Adding nanoparticles to the dressing matrix and using nanoparticles to deliver drugs and cytokines to promote wound healing has proven to be effective. This review will focus on the effects of diabetes on wound healing, introduce the properties, preparation methods and action mechanism of nanoparticles in wound healing, and describe the effects and application status of various nanoparticle-loaded dressings in diabetes-related chronic wound healing.

Trends in non-isocyanate polyurethane (NIPU) development

The transition towards safer and more sustainable production of polymers has led to a growing body of academic research into non-isocyanate polyurethanes (NIPUs) as potential replacements for conventional, isocyanate-based polyurethane materials. This perspective article focuses on the opportunities and current limitations of NIPUs produced by the reaction between biobased cyclic carbonates with amines, which offers an interesting pathway to renewable NIPUs. While it was initially thought that due to the similarities in the chemical structure, NIPUs could be used to directly replace conventional polyurethanes (PU), this has proven to be more challenging to achieve in practice. As a result, and in spite of the vast amount of academic research into this topic, the market size of NIPUs remains negligible. In this perspective, we will emphasize the main limitations of NIPUs in comparison to conventional PUs and the most significant advances made by others and us to overcome these limitations. Finally, we provide our personal view of where research should be directed to promote the transition from the academic to the industrial sector.

Single-Ion Conducting Polymer Nanoparticles as Functional Fillers for Solid Electrolytes in Lithium Metal Batteries

Composite solid electrolytes including inorganic nanoparticles or nanofibers which improve the performance of polymer electrolytes due to their superior mechanical, ionic conductivity, or lithium transference number are actively being researched for applications in lithium metal batteries. However, inorganic nanoparticles present limitations such as tedious surface functionalization and agglomeration issues and poor homogeneity at high concentrations in polymer matrixes. In this work, we report on polymer nanoparticles with a lithium sulfonamide surface functionality (LiPNP) for application as electrolytes in lithium metal batteries. The particles are prepared by semibatch emulsion polymerization, an easily up-scalable technique. LiPNPs are used to prepare two different families of particle-reinforced solid electrolytes. When mixed with poly(ethylene oxide) and lithium bis(trifluoromethane)sulfonimide (LiTFSI/PEO), the particles invoke a significant stiffening effect (E' > 10⁶ Pa vs 10⁵ Pa at 80 °C) while the membranes retain high ionic conductivity (σ = 6.6 × 10^-4 S cm^-1). Preliminary testing in LiFePO₄ lithium metal cells showed promising performance of the PEO nanocomposite electrolytes. By mixing the particles with propylene carbonate without any additional salt, we obtain true single-ion conducting gel electrolytes, as the lithium sulfonamide surface functionalities are the only sources of lithium ions in the system. The gel electrolytes are mechanically robust (up to G' = 10⁶ Pa) and show ionic conductivity up to 10^-4 S cm^-1. Finally, the PC nanocomposite electrolytes were tested in symmetrical lithium cells. Our findings suggest that all-polymer nanoparticles could represent a new building block material for solid-state lithium metal battery applications.

Synthesis of Poly(methacrylic acid)-block-Polystyrene Diblock Copolymers at High Solid Contents via RAFT Emulsion Polymerization

The combination of polymerization-induced self-assembly (PISA) and reversible-addition fragmentation chain transfer (RAFT) emulsion polymerization offers a powerful technique to synthesize diblock copolymers and polymeric nanoparticles in a controlled manner. The RAFT emulsion diblock copolymerization of styrene and methacrylic acid (MAA) by using a trithiocarbonate as surfactant and RAFT agent was investigated. The Z-group of the RAFT agent was modified with a propyl-, butyl- and dodecyl- sidechain, increasing the hydrophobicity of the RAFT agent to offer well-controlled polymerization of poly(methacrylic acid)-block-polystyrene (PMAA-b-PS) diblock copolymers at high solid contents between 30-50 wt% in water. The kinetic data of the PMAA homopolymerization with the three different RAFT agents for various solvents was investigated as well as the RAFT emulsion polymerization of the diblock copolymers in pure water. While the polymerization of PMAA-b-PS with a propyl terminus as a Z-group suffered from slow polymerization rates at solid contents above 30 wt%, the polymerization with a dodecyl sidechain as a Z-group led to full conversion within 2 h, narrow molar mass distributions and all that at a remarkable solid content of up to 50 wt%.

Preparation of Emulsifier-Free Styrene-Acrylic Emulsion via Reverse Iodine Transfer Polymerization

Styrene-acrylic emulsions containing hydroxyl functional monomer unit's component are widely used for maintenance coating. In this paper, a stable emulsifier-free styrene-acrylic emulsion with solid content over 43% could be obtained in 210 min via reverse iodine transfer polymerization (RITP). By adding a mixture of methacrylic acid (MAA) and poly(ethylene glycol)methyl ether methacrylate (PEGMA) into a system containing a high content of hydroxyl functional monomer component (19.4 wt.% of the total monomer mass), styrene (St) could be copolymerized with methyl methacrylate (MMA); the modified film exhibited good hardness properties, good adhesive properties, and low water absorption. An increase in the amount of PEGMA decreased the glass transition temperature (Tg). When 1.4 times the reference amount of initiator was added, the highest molecular weight Mn could reach 40,000 g.·mol-1 with 0.25 times the reference amount of iodine in the emulsion. The largest tensile strength of the dried emulsion film over 5.5 MPa endowed the material with good mechanical properties. Living polymerization was proven by the kinetics of RITP emulsion and chain extension reaction. TEM micrographs manifest the emulsification of the seed random copolymer. This paper may provide a potential methodology for preparing polymer materials with excellent mechanical properties.

Biopesticide Encapsulation Using Supercritical CO2: A Comprehensive Review and Potential Applications

As an alternative to synthetic pesticides, natural chemistries from living organisms, are not harmful to nontarget organisms and the environment, can be used as biopesticides, nontarget. However, to reduce the reactivity of active ingredients, avoid undesired reactions, protect from physical stress, and control or lower the release rate, encapsulation processes can be applied to biopesticides. In this review, the advantages and disadvantages of the most common encapsulation processes for biopesticides are discussed. The use of supercritical fluid technology (SFT), mainly carbon dioxide (CO₂), to encapsulate biopesticides is highlighted, as they reduce the use of organic solvents, have simpler separation processes, and achieve high-purity particles. This review also presents challenges to be surpassed and the lack of application of SFT for biopesticides in the published literature is discussed to evaluate its potential and prospects.

Asymmetric-Flow Field-Flow Fractionation of complex waterborne polymer dispersions: Effect of the concentration of water in the measurement of molar mass distributions

Asymmetric-Flow Field-Flow Fractionation is a very powerful technique for measuring the molar mass distribution of polymers with complex microstructures. The analysis of some samples such as self-crosslinkable latexes requires to directly dissolve the polymer dispersion in the eluent (THF) without drying it, and this work studies the effect of the presence of this water in those analysis. Taking a polystyrene latex as model system, it was observed that the measured molar mass and radius of gyration increased as the concentration of water in the sample increased. This was an effect of a decrease in the compatibility between the solvent mixture (THF and water) and the polymer, which formed aggregates, and could be predicted calculating the polymer-solvent interaction parameter. When the study was extended to poly(methyl methacrylate), poly(n-butyl acrylate) and poly(vinyl acetate) the same general trend was observed, however, the impact of the water was less significant as the hydrophilicity of the polymer increased. Most importantly, if the samples with the highest water content were first dissolved in THF and afterwards dried using MgSO₄ the measured molar mass and radius of gyration values were the same as for the reference sample (dried in the oven), providing a method to analyze samples that cannot be dried into a film and remove the negative effect of the water at the same time.

Backbone-Degradable Vinyl Acetate Latex: Coatings for Single-Use Paper Products

We report an approach to waterborne and degradable latex polymers. Emulsion polymerization of vinyl acetate (VA) with the cyclic ketene acetal 2-methylene-1,3-dioxepane (MDO) yields polymer particles and latex-based coatings that are hydrolytically degradable due to the presence of backbone ester groups. Polymerization under mildly basic conditions (pH 8) and at low temperature (40 °C) is critical: if the in-process pH is too acidic or the temperature too high, MDO is lost to hydrolysis, but when the media is too alkaline, VA monomer rapidly hydrolyzes. When coated onto commercial paper, films of these degradable particle dispersions show excellent oil and grease resistance as compared to non-degradable, VA-only compositions. This new class of latex is therefore well-suited for the design of next-generation, biodegradable and compostable single-use food service products, as well as for other applications where the erosion or degradation of polymer-based films and coatings is required.

Influence of the Polymer Microstructure over the Phase Separation of Thermo-Responsive Nanoparticles

Thermo-responsive nanoparticles (NPs), i.e., colloids with a sharp and often reversible phase separation in response to thermal stimuli, are coming to the forefront due to their dynamic behavior, useful in applications ranging from biomedicine to advanced separations and smart optics. What is guiding the macroscopic behavior of these systems above their critical temperature is mainly the microstructure of the polymer chains of which these NPs are comprised. Therefore, a comprehensive understanding of the influence of the polymer properties over the thermal response is highly required to reproducibly target a specific behavior. In this study, we synthesized thermo-responsive NPs with different size, polymeric microstructure and hydrophilic-lipophilic balance (HLB) and investigated the role of these properties over their phase separation. We first synthesized four different thermo-responsive oligomers via Reversible Addition-Fragmentation Chain Transfer (RAFT) Polymerization of poly(ethylene glycol)methyl ether methacrylate. Then, exploiting the RAFT living character, we chain-extended these oligomers with butyl methacrylate obtaining a library of NPs. Finally, we investigated the NP thermo-responsive behavior, their physical state above the cloud point (Tcp) as well as their reversibility once the stimulus is removed. We concluded that the solid content plays a minor role compared to the relative length of the two blocks forming the polymer chains. In particular, the longer the stabilizer, the more favored the formation of a gel. At the same time, the reversibility is mainly achieved at high HLB, independently from the absolute lengths of the block copolymers.

Emulsion Polymerizations for a Sustainable Preparation of Efficient TEMPO-based Electrodes

Organic polymer-based batteries represent a promising alternative to present-day metal-based systems and a valuable step toward printable and customizable energy storage devices. However, most scientific work is focussed on the development of new redox-active organic materials, while straightforward manufacturing and sustainable materials and production will be a necessary key for the transformation to mass market applications. Here, a new synthetic approach for 2,2,6,6-tetramethyl-4-piperinidyl-N-oxyl (TEMPO)-based polymer particles by emulsion polymerization and their electrochemical investigation are reported. The developed emulsion polymerization protocol based on an aqueous reaction medium allowed the sustainable synthesis of a redox-active electrode material, combined with simple variation of the polymer particle size, which enabled the preparation of nanoparticles from 35 to 138 nm. Their application in cell experiments revealed a significant effect of the size of the active-polymer particles on the performance of poly(2,2,6,6-tetramethyl-4-piperinidyl-N-oxyl methacrylate) (PTMA)-based electrodes. In particular rate capabilities were found to be reduced with larger diameters. Nevertheless, all cells based on the different particles revealed the ability to recover from temporary capacity loss due to application of very high charge/discharge rates.

General method for emulsion polymerization to yield functional terpolymers

Copolymerization methods are used to impart specific, desired functional properties (e.g. mechanical or bioactive) to a material for targeted applications in biomedicine, food and agriculture, consumer products, advanced manufacturing, and more. Many polymerization methods exist to achieve tailored copolymer architectures. Of them, emulsion polymerization offers unique and industrially convenient features that make for easily scalable processes because the synthesis occurs in water and the latexes usually do not need further purification. Because of the breadth of copolymer architectures and thus wide range of potential applications for latexes produced by emulsion polymerization, there is great value in defining general methods for emulsion polymerizations to yield copolymers, including routes for synthesis of functional monomer building blocks, to permit consistency and optimization of these processes. Herein we present a general emulsion polymerization method for synthesis of a copolymer consisting of three functional monomers, suitable for adaptation to alternate base chemistries, curing chemistries, and functional ligands. This protocol includes the synthesis of the functional monomers glycidyl methacrylate-iminodiacetic acid (GMA-IDA) and 4-benzolylphneyl methacrylate (BPM).•

Our synthesized copolymer includes a glycidyl methacrylate (GMA) monomer functionalized with a metal-chelating iminodiacetic acid (IDA) ligand, a UV-curable monomer, 4-benzoylphenyl methacrylate (BPM), and an inert hydrophobic monomer, n‑butyl acrylate (BA).

•

The presented synthesis route demonstrates a general polymerization method that can be modified to copolymerize alternative functional monomers to create multi-functional polymers.

3D Printing Latex: A Route to Complex Geometries of High Molecular Weight Polymers

Vat photopolymerization (VP) additive manufacturing fabricates intricate geometries with excellent resolution; however, high molecular weight polymers are not amenable to VP due to concomitant high solution and melt viscosities. Thus, a challenging paradox arises between printability and mechanical performance. This report describes concurrent photopolymer and VP system design to navigate this paradox with the unprecedented use of polymeric colloids (latexes) that effectively decouple the dependency of viscosity on molecular weight. Photocrosslinking of a continuous-phase scaffold, which surrounds the latex particles, combined with in situ computer-vision print parameter optimization, which compensates for light scattering, enables high-resolution VP of high molecular weight polymer latexes as particle-embedded green bodies. Thermal post-processing promotes coalescence of the dispersed particles throughout the scaffold, forming a semi-interpenetrating polymer network without loss in part resolution. Printing a styrene-butadiene rubber latex, a previously inaccessible elastomer composition for VP, exemplified this approach and yielded printed elastomers with precise geometry and tensile extensibilities exceeding 500%.

Miniemulsion photopolymerization in a continuous tubular reactor: particle size controlviamembrane emulsification

Synthesis of polymeric nanoparticles of adjustable size in the submicron-range 200–950 nm has been conductedviamembrane emulsification combined with photoinduced miniemulsion polymerization in a continuous tubular flow reactor.

Colloidal molecules and patchy particles: complementary concepts, synthesis and self-assembly

About the latest developments regarding self-assembly of textured colloids and its prospects.

Light and latex: advances in the photochemistry of polymer colloids

Unparalleled temporal and spatial control of colloidal chemical processes introduces immense potential for the manufacturing, modification, and manipulation of latex particles.