Successful Miniemulsion ATRP Using an Anionic Surfactant: Minimization of Deactivator Loss by Addition of a Halide Salt

Organic nanoparticles with tunable size and rigidity by hyperbranching and cross-linking using microemulsion ATRP

Unlike inorganic nanoparticles, organic nanoparticles (oNPs) offer the advantage of "interior tailorability," thereby enabling the controlled variation of physicochemical characteristics and functionalities, for example, by incorporation of diverse functional small molecules. In this study, a unique inimer-based microemulsion approach is presented to realize oNPs with enhanced control of chemical and mechanical properties by deliberate variation of the degree of hyperbranching or cross-linking. The use of anionic cosurfactants led to oNPs with superior uniformity. Benefitting from the high initiator concentration from inimer and preserved chain-end functionality during atom transfer radical polymerization (ATRP), the capability of oNPs as a multifunctional macroinitiator for the subsequent surface-initiated ATRP was demonstrated. This facilitated the synthesis of densely tethered poly(methyl methacrylate) brush oNPs. Detailed analysis revealed that exceptionally high grafting densities (~1 nm-2) were attributable to multilayer surface grafting from oNPs due to the hyperbranched macromolecular architecture. The ability to control functional attributes along with elastic properties renders this "bottom-up" synthetic strategy of macroinitiator-type oNPs a unique platform for realizing functional materials with a broad spectrum of applications.

Robust Miniemulsion PhotoATRP Driven by Red and Near-Infrared Light

Photoinduced polymerization techniques have gathered significant attention due to their mild conditions, spatiotemporal control, and simple setup. In addition to homogeneous media, efforts have been made to implement photopolymerization in emulsions as a practical and greener process. However, previous photoinduced reversible deactivation radical polymerization (RDRP) in heterogeneous media has relied on short-wavelength lights, which have limited penetration depth, resulting in slow polymerization and relatively poor control. In this study, we demonstrate the first example of a highly efficient photoinduced miniemulsion ATRP in the open air driven by red or near-infrared (NIR) light. This was facilitated by the utilization of a water-soluble photocatalyst, methylene blue (MB+). Irradiation by red/NIR light allowed for efficient excitation of MB+ and subsequent photoreduction of the ATRP deactivator in the presence of water-soluble electron donors to initiate and mediate the polymerization process. The NIR light-driven miniemulsion photoATRP provided a successful synthesis of polymers with low dispersity (1.09 ≤ Đ ≤ 1.29) and quantitative conversion within an hour. This study further explored the impact of light penetration on polymerization kinetics in reactors of varying sizes and a large-scale reaction (250 mL), highlighting the advantages of longer-wavelength light, particularly NIR light, for large-scale polymerization in dispersed media owing to its superior penetration. This work opens new avenues for robust emulsion photopolymerization techniques, offering a greener and more practical approach with improved control and efficiency.

Composition-Orientation Induced Mechanical Synergy in Nanoparticle Brushes with Grafted Gradient Copolymers

Gradient poly(methyl methacrylate/n-butyl acrylate) copolymers, P(MMA/BA), with various compositional ratios, were grafted from surface-modified silica nanoparticles (SiO2-g-PMMA-grad-PBA) via complete conversion surface-initiated activator regenerated by electron transfer (SI-ARGET) atom transfer radical polymerization (ATRP). Miniemulsion as the reaction medium effectively confined the interparticle brush coupling within micellar compartments, preventing macroscopic gelation and enabling complete conversion. Isolation of dispersed and gelled fractions revealed dispersed particle brushes to feature a higher Young's modulus, toughness, and ultimate strain compared with those of the "gel" counterparts. Upon purification, brush nanoparticles from the dispersed phase formed uniform microstructures. Uniaxial tension testing revealed a "mechanical synergy" for copolymers with MMA/BA = 3:2 molar ratio to concurrently exhibit higher toughness and stiffness. When compared with linear analogues of similar composition, the brush nanoparticles with gradient copolymers had better mechanical properties, attributed to the synergistic effects of the combination of composition and propagation orientation, highlighting the significance of architectural design for tethered brush layers of such hybrid materials.

Selective copper-catalysed atom transfer radical addition (ATRA) in water under environmentally benign conditions

Simple and green conditions for copper-catalysed ATRA reactions in water have been developed. Firstly, [Cu(ADPA)(H2O)(ClO4)2] (1b, ADPA = 9-[(2,2'-dipicolylamino)methyl]anthracene) was demonstrated to be capable of selectively catalysing the ATRA of CCl4 to styrene using L-ascorbic acid (AsH2) as a reducing agent in organic solvent mixtures under ambient atmosphere. Mechanistic investigation suggested that our ATRA reaction proceeded via a single-electron transfer (SET) mechanism through an inner-sphere complex, which is consistent with the widely accepted mechanism for copper-catalysed ATRA. To perform the reaction in water as a sole solvent, a biocompatible surfactant (2 wt% Tween 20 or Tween 80) was added to improve solubility and increase the local concentration of organic reagents and the copper catalyst. Without the need for a complicated oxygen-free set-up, the ATRA reaction catalysed by this simple aqueous-dispersed system can be performed at a mild temperature (60 °C) and a relatively short reaction time (6 h) using 1 mol% of the catalyst. Furthermore, this facile protocol is also applicable for other alkene substrates demonstrated in this work, resulting in satisfactory to excellent substrate conversion and product yields.

Catalytic Halogen Exchange in Miniemulsion ARGET ATRP: A Pathway to Well-Controlled Block Copolymers

Halogen exchange in atom transfer radical polymerization (ATRP) is an efficient way to chain-extend from a less active macroinitiator (MI) to a more active monomer. This has been previously achieved by using CuCl/L in the equimolar amount to P_n -Br MI in the chain extension step. However, this approach cannot be effectively applied in systems based on regeneration of activators (ARGET ATRP), since they operate with ppm amounts of catalysts. Herein, a catalytic halogen exchange procedure is reported using a catalytic amount of Cu in miniemulsion ARGET ATRP to chain-extend from a less active poly(n-butyl acrylate) (PBA) MI to a more active methyl methacrylate (MMA) monomer. Influence of different reagents on the initiation efficiency and dispersity is studied. Addition of 0.1 m NaCl or tetraethylammonium chloride to ATRP of MMA initiated by methyl 2-bromopropionate leads to high initiation efficiency and polymers with low dispersity. The optimized conditions are then employed in chain extension of PBA MI with MMA to prepare diblock and triblock copolymers.

Low Ppm Atom Transfer Radical Polymerization in (Mini)Emulsion Systems

In the last decade, unceasing interest in atom transfer radical polymerization (ATRP) has been noted, especially in aqueous dispersion systems. Emulsion or miniemulsion is a preferred environment for industrial polymerization due to easier heat dissipation and lower production costs associated with the use of water as a dispersant. The main purpose of this review is to summarize ATRP methods used in emulsion media with different variants of initiating systems. A comparison of a dual over single catalytic approache by interfacial and ion pair catalysis is presented. In addition, future development directions for these methods are suggested for better use in biomedical and electronics industries.

Photoinduced Miniemulsion Atom Transfer Radical Polymerization

Photomediated atom transfer radical polymerization (photoATRP) of (meth)acrylic monomers was conducted in miniemulsion media. The polymerization procedures took advantage of an ion-pair catalyst formed by interaction of Cu/TPMA² (TPMA = tris(2-pyridylmethyl)amine) and an anionic surfactant, sodium dodecyl sulfate (SDS). The ion-pair catalyst was efficient in controlling ATRP reactions with catalyst loadings as low as 100 ppm. The effect of different polymerization parameters, such as the size of the reaction vial, amount of surfactant, and solids content influencing the photoATRP in miniemulsion, was studied. The polymerization was conducted with solids content ranging from 5 to 50 vol % under a moderate surfactant loading (<5 wt % relative to monomer). Excellent temporal control was achieved upon switching the UV light on and off multiple times, and the polymer was successfully chain extended, indicating high retention of chain-end fidelity.

Ab Initio Emulsion Atom-Transfer Radical Polymerization

Stable latexes of poly(meth)acrylates with predetermined molecular weights, narrow molecular-weight distributions, and controlled architecture were prepared by true ab initio emulsion atom-transfer radical polymerization. Water-soluble (macro)initiators in combination with a hydrophilic catalyst, Cu/tris(2-pyridylmethyl)amine, initiated the polymerization in the aqueous phase. The catalyst strongly interacted with the surfactant sodium dodecyl sulfate (SDS), thereby tuning the polymerization within nucleated hydrophobic polymer particles. Long-term stable latexes were obtained, even with SDS loading below 3 wt % relative to monomer. Block and gradient copolymers were prepared in situ. The reaction volume and solid content were successfully increased to 100 mL and 40 vol %, respectively, thus suggesting facile scale-up of this technique. The proposed setup could be integrated in existing industrial plants used for emulsion polymerization.

Miniemulsion ARGET ATRP via Interfacial and Ion-Pair Catalysis: From ppm to ppb of Residual Copper

It was recently reported that copper catalysts used in atom transfer radical polymerization (ATRP) can combine with anionic surfactants used in emulsion polymerization to form ion pairs. The ion pairs predominately reside at the surface of the monomer droplets, but they can also migrate inside the droplets and induce a controlled polymerization. This concept was applied to activator regenerated by electron transfer (ARGET) ATRP, with ascorbic acid as reducing agent. ATRP of n-butyl acrylate (BA) and n-butyl methacrylate (BMA) was carried out in miniemulsion using CuII/tris(2-pyridylmethyl)amine (TPMA) as catalyst, with several anionic surfactants forming the reactive ion-pair complexes. The amount and structure of surfactant controlled both the polymerization rate and the final particle size. Well-controlled polymers were prepared with catalyst loadings as low as 50 ppm, leaving only 300 ppb of Cu in the precipitated polymer. Efficient chain extension of a poly(BMA)-Br macroinitiator confirmed high retention of chain-end functionality. This procedure was exploited to prepare polymers with complex architectures such as block copolymers, star polymers, and molecular brushes.

Harnessing the interaction between surfactant and hydrophilic catalyst to control eATRP in miniemulsion

In contrast with previous accounts, it is reported that a single, strongly hydrophilic Cu complex can control an electrochemically mediated atom transfer radical polymerization (eATRP) in oil-in-water miniemulsion in the presence of anionic surfactants, such as sodium dodecyl sulfate (SDS). The anionic surfactant interacted strongly with cationic copper complexes, enabling controlled polymerization by a combination of "interfacial" and "ion-pair" catalysis, whereby ion pairs transport the catalyst to the monomer droplets. The ion-pair system was assembled in situ by mixing commercially available reagents (NaBr, SDS, and traditional hydrophilic copper complexes). Polymer purification was very facile because after reaction >99% of the hydrophilic copper complexes spontaneously left the hydrophobic polymer particles.

Electrochemical Atom Transfer Radical Polymerization in Miniemulsion with a Dual Catalytic System

An electrochemical approach was used to control atom transfer radical polymerization (ATRP) of n-butyl acrylate (BA) in miniemulsion. Electropolymerization required a dual catalytic system, composed of an aqueous phase catalyst and an organic phase catalyst. This allowed shuttling the electrochemical stimulus from the working electrode (WE) to the continuous aqueous phase and to the dispersed monomer droplets. As aqueous phase catalysts, the hydrophilic Cu complexes with the ligands N,N-bis( 2-pyridylmethyl)-2-hydroxyethylamine (BPMEA), 2,2'-bipyridine (bpy), and tris(2-pyridylmethyl)amine (TPMA) were tested. As organic phase catalysts, the hydrophobic complexes with the ligands bis(2-pyridylmethyl)-octadecylamine (BPMODA) and bis[2-(4-methoxy-3,5-dimethyl)-pyridylmethyl]octadecylamine (BPMODA*) were evaluated. Highest rates and best control of BA electropolymerization were obtained with the water-soluble Cu/BPMEA used in combination with the oil-soluble Cu/BPMODA*. The polymerization rate could be further enhanced by changing the potential applied at the WE. Differently from traditional ATRP systems, reactivity of the dual catalytic system did not depend on the redox potential of the catalysts but instead depended on the hydrophobicity and partition coefficient of the aqueous phase catalyst.

Versatile procedure for site-specific grafting of polymer brushes on patchy particles via atom transfer radical polymerization (ATRP)

Combining chemically anisotropic colloids with Surface-Initiated ATRP enables for site-specific grafting of p(NIPAM) brushes. The resulting, partially grafted particles are employed as colloidal building blocks for finite-sized clusters.

Electrochemically mediated atom transfer radical polymerization of n-butyl acrylate on non-platinum cathodes

Inexpensive metals and metal alloys were used as cathodes in well-controlled, electrochemically mediated ATRP ofn-butyl acrylate in DMF with the ppm level of catalysts.

An ATRP-based approach towards water-borne anisotropic polymer–Gibbsite nanocomposites

This paper describes the synthesis of anisotropic polymer–Gibbsite nanocomposites with “muffin-like” morphology via a starved-feed ATRP emulsion polymerisation.

Recent Progress on Transition Metal Catalyst Separation and Recycling in ATRP

Atom transfer radical polymerization (ATRP) is a versatile and robust tool to synthesize a wide spectrum of monomers with various designable structures. However, it usually needs large amounts of transition metal as the catalyst to mediate the equilibrium between the dormant and propagating species. Unfortunately, the catalyst residue may contaminate or color the resultant polymers, which limits its application, especially in biomedical and electronic materials. How to efficiently and economically remove or reduce the catalyst residue from its products is a challenging and encouraging task. Herein, recent advances in catalyst separation and recycling are highlighted with a focus on (1) highly active ppm level transition metal or metal free catalyzed ATRP; (2) post-purification method; (3) various soluble, insoluble, immobilized/soluble, and reversible supported catalyst systems; and (4) liquid-liquid biphasic catalyzed systems, especially thermo-regulated catalysis systems.