Miniemulsion Polymerization-A Comparative Study Preparative Variables
Miniemulsion Polymerization-A Comparative Study Preparative Variables
Miniemulsion Polymerization-A Comparative Study Preparative Variables
of Preparative Variables
SYNOPSIS
sion and high resistance to droplet ~oalescence.~-~ weeks before use. Potassium persulfate (FMC) was
In conventional emulsion polymerization, the recrystallized from distilled deionized water and then
principal locus of particle nucleation is the aqueous dried a t room temperature under vacuum. Sodium
phase or the monomer swollen micelles depending lauryl sulfate (BDH Chemicals), hexadecane (Ald-
on the degree of water solubility of the monomers rich), cetyl alcohol (Aldrich) , and sodium bicar-
and the amount of surfactant used; lower water sol- bonate (Fisher) were used as received. The water
ubility monomer and higher amounts of surfactant was distilled and deionized (DDI) .
would favor particle nucleation in monomer swollen
micelles.' Monomer droplets are considered only to
The Polymerization Process
act as monomer reservoirs supplying monomer to
the growing polymer particles. However, in the The recipe used in this study consists of 80 wt %
miniemulsion polymerization, the small size of the DDI water, 20 wt % styrene, with 2.66 m M sodium
monomer droplets enables them to become the bicarbonate, 2.66 m M potassium persulfate, 5 or 10
principal locus of particle nucleation. Thus, different m M sodium lauryl sulfate, and 15-40 m M (all based
conditions used in their preparation produce mini- on water) cosurfactant (cetyl alcohol or hexadec-
emulsions with different average droplet sizes and ane) . The reaction temperature was 70°C.
size distributions, which, in turn, exhibit different There are some differences in the procedures for
polymerization kinetics and final particle size dis- preparing styrene miniemulsions with hexadecane
tributions. versus cetyl alcohol (Fig. 1) . In the preparation of
Since the introduction of miniemulsion polymer- miniemulsions with hexadecane, sodium lauryl sul-
ization in the early 1970s,' many investigators have
studied the subject and have used many different
methods to prepare mini emulsion^.^-'^ The impor- PREPARATION OF MINIEMULSIONS WITH HEXADECANE
tant parameters in preparing miniemulsions are the
type and amount of cosurfactant (usually hexade-
cane or cetyl alcohol) and the means of carrying out
Fl Dissolve
EXPERIMENTAL
Add
styrene
1
Materials
,j
(Miniemulsion
I
+
+ + +
RESULTS AND DISCUSSION Figure 4 Conversion versus time curves for runs C2
( Microfluidizer, 10 mM SLS) , C8 (Microfluidizer, 5 mM
The conditions for all experiments are described in SLS), M6 ( Microfluidizer, 10 mM SLS/30 mM CA) , and
M10 (Microfluidizer, 5 mM SLS/ 15 mM CA) .
Table I. The variables in these experiments are the
concentration of sodium lauryl sulfate, the type and
40
I
without cooling the gel phase. The styrene was added rene followed by homogenization. The kinetics of
to the gel solution (sodium lauryl sulfate, cetyl al- run M10 is significantly faster than that of run M11.
cohol, and water) at 65°C before being homogenized This indicates that the emulsion droplets of run M10
with the Microfluidizer, whereas in run M11, the gel are smaller than those of run M11. This is probably
solution was cooled to room temperature and soni- because the viscosity of the emulsion prepared at
fied to break up the gel phase before adding the sty- higher temperature (M10) is lower than that at room
temperature (M11), allowing more effective ho-
mogenization. The final particle numbers are con-
I
0.8
M10:
__--
,_-- ,A11
sistent with the kinetic results (Table 11). The cor-
responding particle size distributions (Fig. 8) exhibit
similar shapes and show a significant number of
small particles. This indicates that some particle
nucleation occurs continuously throughout the
polymerizations.
Another study was carried out to evaluate the ef-
fect of the type of homogenization on the polymer-
ization kinetics and final particle size distribution.
The results are shown in Figure 9 in which the only
difference is that the emulsion in run M12 was ho-
mogenized using the Microfluidizer,and in run M13,
by the sonifier ;both contained 20 m M hexadecane.
The polymerization rate in run M12 was much faster
than that of run M13, which agrees with the final
,;:'
,;.' particle numbers (Table 11). Figure 10 shows that
0 ' . , . , . , . , . , . , . the particle size distribution of run M12 is much
0 30 80 00 120 IS0 180 210
Reaction Time (Minutes) narrower than that of run M13 (which has a con-
Figure 7 Conversion versus time curves for runs M10 siderable number of large particles), which is con-
( Microfluidizer,5 mM SLS/ 15 mM CA, styrene added to sistent with the claim that the Microfluidizer pro-
the gel phase at 65°C) and M11 (Microfluidizer, 5 mM vides a greater and more uniform shear than does
SLS/15 mMCA, styrene added to the gel phase at 25"C), the sonifier.
MINIEMULSION POLYMERIZATION 1065
Figure 9 Conversion versus time curve for runs M12, Figure 11 Conversion versus time curves for runs C6,
homogenized with the Microfluidizer and M13, homoge- C7, and C8, “conventional” cases; M10 and M11, mini-
nized with the sonifier. emulsions with cetyl alcohol; and M12, miniemulsion with
hexadecane.
A comparison of the various methods of preparing slower than those prepared with hexadecane (M12)
miniemulsions can be made from the combined re- and those without cosurfactant (C6, C7, and C 8 ) .
sults illustrated in Figure 11.At conversions higher However, the rate in run M10 increases faster and
than about 30%, all runs exhibit similar kinetics, surpasses those of the “conventional” cases. This
but a t lower conversions, some differences can be may indicate that particle nucleation is slowed by
noted. This region is magnified in Figure 12. The the presence of cetyl alcohol on the surface of the
initial polymerization rates of the miniemulsions monomer droplets. This is the subject of further in-
prepared with cetyl alcohol (M10 and M11) are vestigations.
0.004 . , . I . I . I ’ I
0 10 20 30 4u 50
Reaction Time (Minutes)
Diameter (nm)
Figure 12 Conversion versus time curves magnified for
Figure 10 Particle size distributions for runs M12, ho- runs C6, C7, and C8, “conventional” cases; M10 and M11,
mogenized with the Microfluidizer and M13, homogenized miniemulsions with cetyl alcohol; and M12, miniemulsion
with the sonifier. with hexadecane.
1066 TANG ET AL.