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Macromol. Symp. 2011, 302, 110120 111
Figure 1.
Heat flow (HF) time curves of styrene emulsion polymerization at 70 8C (A) and 60 8C (B) illustrating the huge
influence of the polymerization temperature on the reproducibility for the particular polymerization recipe (83 g
of water, 6.77 g of styrene, 0.237 g of SDS, 0.058 g of borax buffer, 0.045 g of KPS).
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
112 Macromol. Symp. 2011, 302, 110120
Figure 2.
Average properties of final latexes (A) and net duration and lag time of the polymerization (B) in dependence on
the temperature of styrene emulsion polymerization; recipe: 83 g of water, 6.77 g of styrene, 0.237 g of SDS,
0.058 g of borax buffer, 0.045 g of KPS, the number of repeats varies between 4 and 18.
Figure 3.
Averaged heat flow time curves and average overall heat of reaction for styrene emulsion polymerization in
dependence on polymerization temperature; recipe: 83 g of water, 6.77 g of styrene, 0.237 g of SDS, 0.058 g of
borax buffer, 0.045 g of KPS, the number of repeats varies between 4 and 18.
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
Macromol. Symp. 2011, 302, 110120 113
60 and 70 8C. Both the monomer conver- Thus, the nucleation step is particularly
sion (X) and the average particle size (Di) sensitive to even tiny changes of the
of the final latexes show a weak dependence interfacial tension, temperature, supersa-
on the polymerization temperature turation, and chain length of the nucleating
(Figure 2A). X increases with T species. Moreover, dissolved gas (either
whereas Di decreases. Figure 2B reveals oxygen or nitrogen) that generate bubbles
that the lag time strongly depends on the has a strong influence on the nucleation
polymerization temperature with a steep process as experimentally proven[10] and, in
transition between 64 and 68 8C. The net general, any interface influences nucleation
duration of the polymerization, that is the as the activation free energy is drastically
overall time minus the lag time, decreases affected.[13,14]
with increasing T and is almost constant
for T > 67 8C. Moreover, the experimental In-Situ Formation of Stabilizer
scatter of the lag time is much larger than The adoption of thermal styrene polymer-
that of the net duration. Also, the shape of ization,[15] that is filling a reactor with water
the averaged reaction rate profiles and hydrophobic monomer, sealing, and
(Figure 3A) depends on T showing more heating up is the simplest way to perform
or less clearly the appearance of a gel effect heterophase polymerization. In fact, doing
at low T and a significant shape transition so in the presence of stabilizer was the
between 66 and 67 8C. The heat of the technology of the first heterophase poly-
reaction (DRH) is, except one outlier, merization ever.[16] The drawbacks of this
apparently constant and the average value procedure might be compensated by the
of 70.07 kJ/mol is the expected one for chance to get polymer dispersions contain-
styrene.[9] ing less foreign material, provided stability
Another explanation of these results is can be achieved by the proper choice of
possible assuming an energy barrier that monomers. So, hydrophobic and hydro-
must be surmounted during the initial stage philic monomer combination such as styr-
before emulsion polymerization can com- ene and styrene sulfonate might be good
mence. If the internal energy of the reaction candidates. Indeed, this particular combi-
mixture or the driving force (F) is high the nation works fine and stable latexes are
lag time is short and no delay is observed. accessible.[17] Another, not that straightfor-
By visual inspection of the reaction it is ward monomer is tBuA either alone or in
clear that the heat flow increases when the combination with styrene. The use of tBuA
reaction system has changed from whitish is feasible due to the easiness of tert-
emulsion to bluish latex. This observation butylester hydrolysis leading to stabilizing
strongly suggests that the energy barrier carboxylate groups. As the rate of hydro-
is connected with the event of particle lysis is finite, thermal tBuA homopolymer-
nucleation. Indeed, non-micellar nuclea- ization in water results in latexes (cf.
tion theory, such as classical nucleation Figure 4A). Adding styrene at definite time
theory, that can also be applied for intervals, thus, mimicking a semibatch
emulsion polymerization[1012] predicts that procedure, leads to the formation of stable
the rate of nucleation (rnuc) is an expo- copolymer latexes (cf. Figure 4B). Con-
nential function (Equation 2) of the cube of trary, the outcome of the batch copolymer-
the interfacial tension nucleus water (s), ization where the same amount of styrene is
the molar volume of the nucleating species added from the beginning of the reaction is
squared, the cube of the thermal energy almost only coagulum (cf. Figure 4C).
(kBT), and the supersaturation (S) squared. Interestingly, the external look of the final
reaction mixture of repeated batch copo-
! lymerizations as shown in Figure 4C differs
s 3 v2
rnuc /exp (2) quite greatly pointing already to scattering
kB T3 ln2 S reaction conditions.
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
114 Macromol. Symp. 2011, 302, 110120
Figure 4.
Appearance of the final reaction mixtures of polymerizations in the rotation thermostat; A thermal tBuA
homopolymerization, B thermal tBuA polymerization with three subsequent styrene additions after every 4
hours started after 41 hours, C batch copolymerization of tBuA and styrene.
The TEM images depicted in Figure 5 styrene in the rotation thermostat exhibit
reveal for tBuA homopolymerization quite a strong stochastic nature of this
(image A) particles with varying density particular process. Again, despite all efforts
(core shell type morphology). Contrary, maintaining as good as possible identical
the particles after subsequent styrene experimental conditions, the results of
additions in the course of the polymeriza- repeated polymerizations scatter consider-
tion appear solid like (image B). On the ably.
other side, the TEM images of the particles
of the runs C1 C4 (repeated batch Swelling of Latex Particles
copolymerization) reveal rather erratic Within the molecular reflection of a
particle structures than a single uniform colloidal polymer particle its surface is
morphology. not homogeneous but patchy as it is
The results for the batch thermally- attractive for functional groups with quite
initiated copolymerization of tBuA and different properties. Interfaces are places
Figure 5.
TEM images of the particles observed in the dialyzed dispersions shown in Figure 4.
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
Macromol. Symp. 2011, 302, 110120 115
where, compared with homogeneous sites, together in Figure 6. These images were
additional forces act.[18] Interfacial effects obtained from polystyrene gel particles
are crucial for heterophase polymerizations with different chemical composition dis-
as mass transfer of monomer and radicals persed in either water or ethyl benzene.
are essential for the kinetics. The chemical The particles differ regarding the concen-
composition of the contact area at the tration of sulfonate groups. The original
interface may canalize, induce, or support polystyrene gel particles (PS-gel) have a
particular reaction pathways. sulfur content of 0.24% stemming from the
In textbooks and many articles on styrene sulfonate comonomer and initiator
emulsion polymerization the swelling of end groups. These particles (image A)
latex particles is considered as being contain no further stabilizer and the quite
perfectly understood on the basis of hydrophobic solid can be redispersed easily
equilibrium thermodynamics as developed in ethyl benzene and with some more
during the 1950ies.[19] This equilibrium efforts also in water (TEM images C and
monomer volume fraction in polystyrene B). After sulfonation (sulfur content of
latex particles of an unswollen size of 10.3%, image B) the redispersion is now
100 nm is about 0.5 depending at given very easily possible in water but practically
temperature and molecular weight on the impossible in ethyl benzene (TEM images
monomer polymer interaction and the E and F of Figure 6).
interfacial tension.[20] For both samples, the TEM images of
It is practically impossible to get direct the particles redispersed in water (B, E)
experimental proof how the decoration of reveal nothing special as they look like
the particles surface influences mass trans- ordinary latex particles except some devia-
fer. Yet it is possible to demonstrate the tion from sphericity due to crosslinking. In
basics of the idea by the TEM images put contrast, in ethyl benzene (image C, F) both
Figure 6.
SEM and TEM images illustrating the redispersion behavior of original and sulfonated polystyrene gel particles; A
dry original particles, B original particles in water, C original particles in ethyl benzene, D dry sulfonated
particles, E sulfonated particles in water, F sulfonated particles in ethyl benzene; the bars indicate 200 nm.
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
116 Macromol. Symp. 2011, 302, 110120
sorts of particles look differently. The agent the overall turbidity of the latex
swollen state of the original, more hydro- increases. As result of swelling, the size of
phobic particles can be imagined as they the particles and their scattering intensity is
appear in the TEM quite fluffy with less expected to grow by a factor of about 1.26
dense edges. Moreover, during drying the and 4, respectively. However, the light
particles do aggregate and, compared with microscopy images C and D reveal that
the aqueous system, their contact areas are beside the swollen latex particles with a size
larger. This is due to fact that the electro- of 50 nm, which are only visible as back-
static repulsion is less effective and that in ground haze under oblique transmission
the interstitial volume the concentration of (image D), much larger objects of up to
dangling chains is quite high so that an 25 mm in diameter with a broad size
additional attractive force is operating.[21] distribution freely move in the dispersion.
The sulfonated, more hydrophilic particles This means, the monomer is during any
show only weak interaction with ethyl stage of the emulsion polymerization not
benzene. Quite large lumps of aggregated only present either molecularly dissolved or
particles are detectable by visual inspec- in micrometer sized droplets, formed by
tion, yet after sonication. The degree of mechanical comminution, but molecules
swelling of the particles is so low that they coexist with aggregates and drops of
are even unable to relax to the spherical various sizes. The smaller monomer dro-
shape. The high concentration of hydro- plets are generated via spontaneous emul-
philic sulfonate groups prevents effectively sification,[24] which is facilitated by the
the penetration of ethyl benzene. presence of surfactant in the dispersion.
There are other experimental facts and From a molecular perspective all these
theoretical arguments supporting the monomer species can interact with particles
necessity of changing the view on swel- and contribute to swelling.
ling.[22] It turned out that the knowledge of
the physical state of the monomer in the
reaction system is extremely helpful, not Molecular Versus Deterministic
only for swelling but for better under- Modeling
standing of emulsion polymerization in
general.[2224] The images of Figure 7 give The experiments presented above eluci-
a glimpse about the real situation and dated some of the challenges in predicting
illustrate essential features. emulsion polymerization kinetics. Many
In comparison to image A, image B different chemical and physical processes
shows that upon contact with the swelling take place simultaneously and sometimes
Figure 7.
Light microscopy images of a polystyrene latex with an unswollen size of 40 nm exposed quiescently for about
60 hours time (in the absence of any external shear forces) to ethyl benzene as swelling agent; A pure latex, B
swollen latex with ethyl benzene on top, C image of swollen latex with perpendicularly transmitted light, D
image of swollen latex with oblique transmission; the bars indicates 50 mm.
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
Macromol. Symp. 2011, 302, 110120 117
competitively in the different phases. where L is the average chain length of the
Because some of these processes cannot polymer formed inside the particles, and
be investigated independently, the conven- tentry is the time between two consecutive
tional approach to determine the kinetics of entry events (tentry 1/ra). Using the values
emulsion polymerization relies on many of the example, it is found that the average
kinetic model assumptions followed by the chain length of the polymer formed is 12.
identification of the model parameters from With this simple deterministic approach it is
experimental data.[25] One the other hand, not possible to determine the chain length
the development of powerful and reliable distribution, so the result is a perfectly
techniques for the simulation of the beha- monodisperse distribution of chain lengths.
vior of atoms and molecules has allowed the It is possible to improve the deterministic
determination of the kinetics of individual, model by considering a full set of popula-
completely independent processes in emul- tion balance equations, that is, solving mass
sion polymerization.[22,26,27] The main balance equations for the living and dead
advantage of this new approach is the chains of all chain lengths.[29] Now it is
precise control of the experimental possible to obtain polydisperse chain length
conditions, which allows the identification distributions but the complexity of the
of the true effect of individual phenomena model is enormously increased since the
on the reaction kinetics. One step forward size of the system is of the order of
in the development of a complete as magnitude of the largest chain length. This
possible model of emulsion polymerization value is usually unknown a priori but
consists in the consideration of various typically quite large for emulsion polymer-
phenomena at different time and/or space ization. It is possible to reduce the compu-
scales by means of multiscale integration tational load by using approximation
techniques.[28] functions for describing the chain length
The following example is thought just to distribution, which is the basis of the
illustrate the differences between both Galerkin method[30] used by the commer-
modeling strategies. Let us consider poly- cial software PREDICI. Clearly, these
merization inside particles with CM being 5 methods do not consider random fluctua-
mol/L and constant during the time of the tions at a molecular scale and therefore
simulation as a result of the replenishment they always predict the same results for the
of monomer from the continuous phase. same recipe and process conditions. Such
The rate coefficient of propagation (kp) behavior is, however, according to the
and the molecular weight (wM) of the experimental results presented in the pre-
monomer be 240 L/(mol s) and 100 g/mol, vious sections, not always the case in
respectively. Thus, the propagation fre- emulsion polymerization.
quency is 1200 s-1 inside the particles. On the other hand, a molecular
Exemplarily, let us now assume that the stochastic simulation considers that all
radicals are generated in the continuous entry and all propagation events follow a
phase and they enter the particles at a rate Poisson distribution with a mean value
(ra) of 1 s-1. Finally, instantaneous termi- given by the reciprocal of the correspond-
nation is assumed when 2 radicals are ing rate. Running these simulations leads
present in the same particle, that is, the for different particles typically to slightly
particles obey zero-one kinetics. Following different results scattering around an aver-
the conventional modeling approach, the age (cf. Figure 8). This is due to the random
chain length of the polymer formed inside nature of all the processes taking place at a
the particles is given by Equation (3) molecular scale, including for example
Brownian motion, temperature and velo-
Z tt entry
kp CM kp CM t entry city fluctuations, rotation of non-symme-
L dt (3) trical molecules, etc. Stochastic simulation
t wM wM
methods not only allow the prediction of
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
118 Macromol. Symp. 2011, 302, 110120
Figure 8.
Average chain length (A) and cumulative chain lengths distributions (B) after 1000 seconds obtained using the
conventional and the molecular approach for the emulsion polymerization of a single particle; kp 240 L/
(mol s), CM 5 mol/L, ra 1 s1, wM 100 g/mol; A line is the result of conventional, deterministic modeling
and the points are the results of four molecular modeling runs representing four different particles, the right
graph is a zoom of the first 2 minutes; B a1, a2 chain lengths distributions of two molecular modeling runs, b is
a monodisperse distribution (L 12) as the result of deterministic modeling (Equation 3).
the variability of a given process, but also rate of capture on particle size is observed,
result in a closer approximation to the real but for more concentrated systems
situation. (>0.1% volume fraction), a second or
The second example is related to the rate higher order dependence on particle size
of radical capture by or radical entry in the is evidenced.
particles. In the previous example, an Now, a big step forward is attained in the
arbitrary rate of radical entry was assumed. modeling of the first example if Brownian
However in practice, the determination of Dynamics simulation is used to determine
the kinetics of radical capture requires the the rate of radical capture and then, the
use of a model of the process. In this case, process is simulated using the molecular
we can also use a conventional or a approach. This is the basis of multiscale
molecular approach. The conventional integration. Multiscale modeling has been
approach consists in assuming a kinetic used to study secondary nucleation during
expression for the rate of radical capture, as seeded emulsion polymerization, and it was
a function of radical diffusion coefficient particularly possible to investigate the
and particle size (linear, squared, etc.), and effect of the locus of radical generation.
then testing the model against experimental This effect could hardly be evaluated using
data.[25] In the molecular approach, a conventional modeling, but it turned out to
technique called Brownian Dynamics simu- be relatively simple to investigate using the
lation is used for simulating the behavior of molecular approach.[31] Another interest-
the radical under the conditions of the ing example is the modeling of particle
process, and then, after a certain number of swelling during emulsion polymerization.
replicas, a distribution of capture times are Swelling is the net result of two opposite
obtained which can be used to determine processes, absorption and desorption of
the rate of radical capture.[26] The distribu- monomer molecules by and from the
tion of capture times obtained is a Poisson- polymer particles, from and to the contin-
type distribution, so the rate can be easily uous phase. A multiscale modeling
determined from the reciprocal of the approach may consist in the determination
average capture time. Using Brownian of monomer absorption and desorption
Dynamics simulation it was found that rates by means of Brownian Dynamics
the rate of radical capture strongly depends simulation, followed by the simulation of
on the concentration of polymer particles the consumption of monomer by propaga-
in the system. Thus, for highly diluted tion either inside the particles or in the
systems an almost linear dependence of the continuous phase. As a result of this
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
Macromol. Symp. 2011, 302, 110120 119
Figure 9.
Illustration of scatter in chemical reactions by means of multiple (A) or single (B) reaction pathways in
dependence on the driving force for the conversion, in case A there are two paths whereas in B there is no path 2;
the driving force F is defined as overall energy difference between initial and final state.
Copyright 2011 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.ms-journal.de
120 Macromol. Symp. 2011, 302, 110120
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